QCS - 2014.pdf

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QCS 2014

Contents

Page 1

CONTENTS

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SECTION 2 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14 Part 15

GENERAL Introduction Use and Maintenance of the Site Site Access and Entry onto the Site Protection Interference Project Meetings Submittals Building Demolition Materials Occupational Health and Safety Engineer’s Site Facilities Contractor’s Site Facilities Setting Out of the Works Temporary Works and Equipment Temporary Controls Traffic Diversions Project Co-ordination Other Contractors Regulatory Requirements Clearance of the Site Final Inspection and Handover Procedures New Technologies and Innovations Design and Supervision Consultant Quality Requirement Construction Dewatering

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SECTION 1 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Part 19 Part 20 Part 21 Part 22 Part 23 Part 24

QUALITY ASSURANCE AND QUALITY CONTROL General Submittals Contractor’s Quality Personnel Document and Data Control Quality Records Quality Audits Inspection And Test Materials Nonconformance Monitoring Laboratories Site Meetings And Reports Failure By The Contractor To Meet Acceptable Quality Performance Suspension of Work APPENDIX A – Sampling and Testing Frequencies APPENDIX B – Templates (Contractors Project Quality Plan Template, Contractors Inspection And Test Plan Template, and Quality Non-conformance Template)

Contents

Page 2

GROUND INVESTIGATION General Boreholes Pits and Trenches Soil Sampling in-Situ Testing, Instrumentation and Monitoring Laboratory Testing

SECTION 4 Part 1 Part 2 Part 3 Part 4 Part 5

Foundations and Retaining Structures General Requirements for Piling Work Concrete Works for Piling Shadow Foundations Deep Foundations Retaining Structures

SECTION 5 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Part 19 Part 20

CONCRETE General Aggregates Cementitious Materials Water Admixtures Property Requirements Concrete Plants Transportation and Placing Of Concrete Formwork Curing Reinforcement Joints Inspection and Testing Of Hardened Concrete Protective Treatments for Concrete Hot Weather Concreting Miscellaneous Structural Precast Concrete Prestressed Concrete Testing of Water Retaining Structures Personnel Qualifications and Certification

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SECTION 3 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6

SECTION 6 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9

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QCS 2014

ROADWORKS General Site Clearance Earthworks Unbound Pavement Materials Asphalt Works Concrete Road Pavements Asphalt Plants Recycled and Stabilised Road Materials Recycled Aggregate for Roadworks

Contents

Page 3

Vehicle Crash Barriers Kerbs, Footways and Paved Areas Fencing Traffic Signs, Markings and Studs Works in Relation To Services Road Lighting Traffic Signals Road Drainage Geosynthetics Miscellaneous

SECTION 7 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6

GREEN CONSTRUCTIONS Introduction Global Sustainability Assessment System - GSAS Energy Water [W] Indoor Environment Cultural and Economic Value

SECTION 8 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12

DRAINAGE WORKS General Earthworks Pipes and Fittings Materials Pipeline Installation Valves, Penstocks and Appurtenances Miscellaneous Metal Works Miscellaneous GRP Works Protective Coatings and Painting Trenchless Pipeline Construction Pipelines Cleaning and Inspection Survey Sewer Rehabilitation Vacuum Sewerage System

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Part 10 Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Part 19

SECTION 9 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14

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QCS 2014

MECHANICAL AND ELECTRICAL EQUIPMENT General Submersible Pumps Centrifugal Pumps (Dry Well) Centrifugal Pumps (Split Casing) Archimedian Screw Pumps Surge Control System Lifting Equipment Electric and Pneumatic Actuators Odour Control Equipment-Carbon Type Odour Control Equipment-Scrubber Type Screening Equipment Grit Removal Equipment Aeration Equipment Air Blowers and Compressors

QCS 2014

Contents

Page 4

Settlement Tank Equipment Tertiary Treatment Granular Filters Sludge Thickening and Dewatering Equipment Mixers and Stirrers Chlorination Plant Equipment Washwater Systems Miscellaneous Equipment Ventilation Systems

SECTION 10 Part 1 Part 2 Part 3 Part 4 Part 5

INSTRUMENTATION, CONTROL AND AUTOMATION General Telemetry/SCADA Primary Elements Panel Mounted and Miscellaneous Instruments Control Panels and Control Room Hardware

SECTION 11 Part 1 Part 2

HEALTH & SAFETY Regulatory Document Safety and Accident Prevention Management / Administration System (SAMAS)

SECTION 12 Part 1 Part 2 Part 3 Part 4 Part 5

EARTHWORKS RELATED TO BUILDINGS General Excavations Filling Utility Trenches Installation of Protective Membranes

SECTION 13 Part 1 Part 2 Part 3 Part 4 Part 5

MASONRY General Mortar and Grout Accessories Unit Masonry Masonry Laying

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Part 15 Part 16 Part 17 Part 18 Part 19 Part 20 Part 21 Part 22

SECTION 14 Part 1 Part 2 Part 3 Part 4 Part 5

ROOFING General Membrane Roofing Metal and Plastic Roofing Roof and Deck Insulation Roofing Tiles

SECTION 15 Part 1 Part 2 Part 3

SECTION 15 INSULATION OF BUILDINGS General Building Insulation Cold Stores

Contents

Page 5

STRUCTURAL STEELWORKS General Materials Drawings Fabrication Welding Bolting Accuracy of Fabrication Erection Accuracy of Erected Steelwork Protective Treatment

SECTION 17 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6

METALWORK General Materials Classification Metal Doors and Windows Architectural Metal Work Light Metal Support and Cladding Support Workmanship

SECTION 18 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7

CARPENTRY, JOINERY AND IRONMONGERY General Wood Treatment Structural Timber (Rough Carpentry) Architectural Timber (Finished Carpentry, Millwork) Joinery Fasteners and Adhesives Ironmongery (Hardware)

SECTION 19 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7

PLUMBING WORK General Water Distribution Plumbing Pipework in Trenches Cold Water Storage Hot Water Storage Commissioning of Systems Plumbing for Gases

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SECTION 16 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10

SECTION 20 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7

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QCS 2014

DRAINAGE WORKS FOR BUILDINGS General Internal Drainage Works External Drainage Works Drainage Pipes in Trenches Structures Related To Drainage Work Surface Water Drainage Commissioning Of Systems

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ELECTRICAL WORKS General Provisions for Electrical Installation MV Factory Built Assemblies (FBA’s) Protective Devices Motor Starters Low Voltage Variable Speed Controllers Cables and Small Wiring Conduits and Conduit Boxes Trunking Cable Trays Wiring Accessories and General Power Light Fittings Emergency Lighting Telephone Installations Structured Cabling Systems Electric Motors Power Factor Correction Capacitors Standby Diesel Generator Set Uninterruptible Power Supply Systems Sound and Call Systems Elevators/Escalators Lightning Protection Earthing and Bonding Inspection and Testing Documentation Format Electrical Identification Electromagnetic Compatibility Battery and Battery Charger Small Enclosures Underfloor Ducts Duct Bank and Manholes Power Distribution Transformers 11 kv Switchgear Actuators HV Variable Frequency Drive

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SECTION 21 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Part 19 Part 20 Part 21 Part 22 Part 23 Part 24 Part 25 Part 26 Part 27 Part 28 Part 29 Part 30 Part 31 Part 32 Part 33 Part 34

Contents

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QCS 2014

SECTION 22 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9

AIR CONDITIONING, REFRIGERATION AND VENTILATION General Central Refrigeration and Air Conditioning Equipment Unitary Equipment Air Handling Equipment Chilled Water Pipework Ductwork and Air-Side Equipment Thermal Insulation Exhaust Fans Accessories

SECTION 23 Part 1 Part 2

FIRE FIGHTING AND FIRE ALARM SYSTEMS General Fire Alarm and Detection Systems

QCS 2014

Contents

Page 7

Analogue Addressable Fire Alarm Systems Fire Fighting System Testing and Commissioning

SECTION 24 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14

FINISHES TO BUILDINGS General Lath and Plaster Dry Lining (Wall Board) Special Wall Surfaces Tiles Terrazzo Stone Flooring Unit Masonry Flooring Floor Screeds and Treatments Joints, Caulking and Sealants Recessed Duct Covers Carpeting Other Floor Coverings Ceilings

SECTION 25 Part 1 Part 2 Part 3 Part 4

GLASS AND GLAZING General Glass Workmanship Glazed Curtain Walling System

SECTION 26 Part 1 Part 2 Part 3 Part 4

PAINTING AND DECORATING General Surface Preparation for Painting Primers, Paints and Coatings Wall Coverings of Decorative Papers/Fabrics

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SECTION 27 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9

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Part 3 Part 4 Part 5

SECTION 28 Part 1 Part 2 Part 3

EXTERNAL WORKS General Block Paved Areas Fences and Gates Fountains and Aquatic Features Site Furniture Flag Poles Protective or Shade Cover Systems Play Field and Park Equipment Miscellaneous Other External Works LANDSCAPING Landscape Planting Landscape Irrigation System Play Equipment General Specification

QCS 2014

Contents RAILWAYS Design Related Issues Aspects Site Clearance Geotechnical Specifications Tunnel Cut and cover Structure Earthworks and Roadworks Concrete Structures Steel Structures Drainage Railway Track Monitoring and Instrumentation Survey and Setting Out

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SECTION 29 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12

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QCS 2014

Introduction

Page 1

INTRODUCTION The purpose of the technical regulation QS 27/2014 [Qatar Construction Specifications 2014 (QCS2014)] is to provide technical guidance in connection with the execution of constructions in the State of Qatar. Such guidance includes the establishment of the minimum acceptable material quality and workmanship for those kinds of work which commonly occur in engineered projects in the State of Qatar. Qatar Construction Specifications 2014 (QCS 2014) supersedes Qatar National Construction Standards 2010 (QCS 2010) in all respects.

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While working earnestly to benefit from new engineering developments, Laboratories and Standardisation Affairs in the Ministry of Environment requests that all those undertaking works projects in the State of Qatar to implement the specifications contained herein.

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We welcome any observations, suggestions or additions for future issues.

QCS 2014

Document History

Page 1

DOCUMENT HISTORY The purpose of the Document History is to record changes to Qatar Construction Specifications. In the event of a revision to the technical regulation, Laboratories and Standardisation Affairs in the Ministry of Environment will issue the amended pages and re-issue the Document History. The Document History pages should contain a description of the change, the issue reference and the date of issue as noted below. The updated Document History should replace the superseded history and the revised pages of the technical regulation should be placed in the appropriate position in the technical regulation. The technical regulation QS 27/2007 [Qatar National Construction Standards 2007 (QCS 2007)] replaces Qatar Construction Specification 2002 (QCS 2002) and it supersedes in all respects.



The technical regulation QS 27/2010 [Qatar Construction Specifications 2010 (QCS 2010)] replaces the technical regulation QS 27/2007 [Qatar National Construction Standards 2007 (QCS 2007)] and it supersedes in all respects.



Further, the technical regulation QS 27/2014 [Qatar Construction Specifications 2014 (QCS 2014)] replaces the technical regulation QS 27/2010 [Qatar Construction Specifications 2010 (QCS 2010)] and it supersedes in all respects.

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Description

Date

Original Issue

April 2000

Qatar Construction Specification 2002

Revision I

November 2002

Qatar National Construction Standards 2007

Revision II

July 2007

Qatar Construction Specifications 2010

Revision III

March 2011

Qatar Construction Specifications 2014

Revision IV

October 2014

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Qatar Construction Specification

Issue

QCS 2014

Acknowledgements

Page 1

ACKNOWLEDGEMENTS

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The Qatar Construction Specifications (QCS 2014) has been drawn upon the technical knowledge and experience of a number of Governmental Ministries, Departments and Authorities in the State of Qatar. The QCS technical committee and associated subcommittees whose members are acknowledged below spearheaded the current revision of QCS 2014.

Eng. Khalid Al-Emadi Chairman of QCS Manager of Q&S Dept. Ashghal

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Dr. Mohammed Saif Al-Kuwari Assistant Undersecretary Ministry of Environment

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Abdul Hameed M. Al-Yahri Sec. of the committee Ministry of Environment

Yousef Mahmoud Ahmed Nooh Asst. Sec. of the committee H/ of the Documents Editing Quality Supervisor -Ashghal

Meshal Saoud Al Mesallam Ministry Of Energy & Trade

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Nasser Al- Naimi Deputy Chairman of QCS Ministry of Environment

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Technical Committee for Preparing and Development of QCS

Dr. Noureddin Daas

Moaaz Hashim

Dr. Khaled Hassan

Osman Elhussien

Chairperson of Concrete Committee Ministry of Environment

Chairperson of Road Committee Member of: Rail committee Quality Expert - Ashghal

Member of Concrete Committee TRL

Chairperson of Rail Committee Member of Road committee Quality Researcher - Ashghal

Sharif Mohamed Chairperson of Drainage Committee Member of Rail Sub-committee Design Engineer- Ashghal

Gareth Thomas Chairperson of: Quality Committee Quality Assurance & Quality Control Expert - Ashghal

Ehab G Saleh Chairperson of: Safety Committee Safety Specialist - Ashghal

QCS 2014

Acknowledgements

Page 2

Sub Committees Members

Adel M. Quraan Reviewers CH2M HILL

Adrian Black Safety Committee MWH

Ahmed Mohd. Sayd Concrete Committee Ministry of Environment

Allan McEwan Quality Committee KBR

Ahmed Sami Roads Committee Ashghal

Amr Elmotasem Concrete Committee AEB

Arthur Hannah Roads Committee (TRL) London

David Matyus Concrete Committee QPMC

David Lewis Roads Committee AMEY

Dick Steer Drainage Committee Ashghal

Dr.Hany Mohamed Reviewers Ashghal

Effrosyni Plexousaki Quality Committee ANAS

Elie Khairallah Concrete Committee ACTS

Essam El Sarag Green Building GORD

Fatih Türk Concrete&RailCommittee Mace / EC Harris

Fraser McCaskill Quality Committee Mace / EC Harris

Gary Cook Roads Committee ANAS

Ghaleb Al Zubi Reviewers ACES

Gireesh Babu Concrete Committee QDC

Hazem Abdel Rahman Roads Committee Ashghal

Huw Woodyatt Roads Committee Exova

Issam A. Sarhan Website Developer MOE

Jaafar. Al-Aloosi Concrete Committee Ashghal

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Abdulrahim Sukik Concrete Committee ACES

Jaafer Mohammed Roads Committee MOE

Jose Vellattukudy Drainage Committee Ashghal

Karunarathna T A Drainage Committee Ashghal

Karen O’Sullivan Roads Committee FUGRO

Kim Catrambone Roads Committee Parsons Brinckerhoff

Konstantinos k Roads Committee Ashghal

Martin Cahalan Quality Committee AMEY

Mathhar Mustafa Concrete Committee Hilti Qatar

Markus Kretschmer Concrete&RailCommittee Qatar Rail

Melina Davies Roads Committee Parsons Brinckerhoff

Mohammed Adil Document Controller Ashghal

Mohammed Al-Yahri Drainage Committee Ashghal

QCS 2014

Acknowledgements

Page 3

Mohanasundaram Concrete Committee QDC

Michael De Roos Safety Committee Ashghal

Michelle Magbojos Roads Committee Ashghal

Neil Courtman Quality Committee Mace

Neil Kirkpatrick Green Building Parsons Brinckerhoff

Nicholas Ray Quality Committee CH2MHill

Packiaraj Drainage Committee Ashgha

Petru Ghicu Drainage Committee Ashghal

Peter E. Sebaaly Roads Committee ANAS

Peter Latham Concrete Committee ReadyMix

Peter Sutton Safety Committee AMEY

Rabih Boukaidbey Concrete Committee ACTS

Rania Hashim Abadi Roads Committee Ashghal

Rawshan Haniffa Document Controller Ashghal

Rabih Fakih Concrete Committee GREY MATTERS

Rolando Matias Quality Committee Parsons Brinckerhoff

Roy Cupples Roads Committee Ashghal

Salah Mousa Safety Committee Ministry of Labor

Richard James Ellis Roads Committee Gulf Laboratories

Robert Overett Roads Committee Parsons Brinckerhoff

Saleem Purayil Purayil Document Controller Ashghal

Shyam Sundar Concrete Committee QDC

Sheik Pahary Safety Committee QPM

Subrato Mukherjee Concrete Committee QDC

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Srinivasan Samiappan Concrete Committee QDC l

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Mohamed El sherbiny Green Building Ashghal

Tom Baines Safety Committee EC Harris

Yasser Berzan Safety Committee Ashghal

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Acknowledgements

Page 4

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QCS 2014

Ministry of Environment Dr Mohamed Saif Al-Kuwari Undersecretary Assistant of MoE

Preparing and Development of Qatar Building Code Committee Technical Committee for Preparing and Development of QCS

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ORGANIZATIONAL CHART

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Eng. Khalid Al-Emadi Chairman of QCS

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Nasser Al-Naimi Deputy Chairman of QCS

Abdul Hameed M. Al-Yahri, Yousef Mahmoud Ahmed Nooh, Gareth H. Thomas, Noureddin Daas, Moaaz Hashim, Osman Elhussien, Sharif Mohamed, Ehab Saleh

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Sub Committees

QUALITY

Gareth H. Thomas Effrosyni Plexousaki Neil Courtman Allan McEwan Martin Cahalan Nicholas Ray Rolando Matias Fraser McCaskill

CONCRETE Noureddin Daas Khaled Hassan Jaafar Isam S. Al-Aloosi Rabih Fakih David Matyus Peter Latham Gireesh Babu.K.M Srinivasan Samiappan Shyam Sundar Rajaram Mohanasundaram Rangasamy Ahmed Mohamed El Sayd Amr Elmotasem Elkady Abdulrahim Mohammed Mathhar Ghazi Mustafa Sabet Hajem Ibrahi Elie Khairallah Subrato Mukherjee Rabih Bahij Boukaidbey Fatih Türk

ROADS

GREEN BUILDING

DRAINAGE

SAFETY

RAIL

Moaaz Hashim Osman Elhussien Jaafer Mohammed Al Saidi Gary Cook Huw Woodyatt Richard James Ellis Arthur Hannah Khaled Hassan Michelle Magbojos

Khalid Al- Emadi Noureddin Daas Mohamed El sherbiny Essam El Sarag Neil Kirkpatrick

Sharif Mohamed Dick Steer Mohammed Homoud Al-Yahri Petru Ghicu Jose Vellattukudy Packiaraj Thangaswamy Karunarathna T A. Kithsiri

Ehab Saleh Yasser Berzan Peter Sutton Tom Baines Salah Mousa Michael De Roos Adrian Black Sheik Pahary

Osman Elhussien Moaaz Hashim Sharif Mohamed Markus Kretschmer Fatih Turk

Contributors to Road Section Peter E. Sebaaly Karen O’Sullivan Konstantinos Kanellaidis Recycling Robert Overett Moaaz Hashim Osman Elhussien Gary Cook Ahmed Sami Sayed Abbas

Road Lighting Work Group

Website Developer

Kim Catrambone Melina Davies Hazem Abdel Rahman David Lewis Roy Cupples Rania Hashim Al-Abadi

Issam A. Sarhan

Reviewers

Document Controllers

Dr.Hany Mohamed Ghaleb Al Zubi Adel M. Quraan

Yousef Mahmoud Nooh Saleem Puthiya Purayil Mohammed Adil Rawshan Haniffa

QCS 2014

Feedback

Page 1

FEEDBACK It is intended that the technical regulation, Qatar Construction Specifications (QCS), will be amended periodically. Any suggestions for amendments to Qatar Construction Specifications should be sent to Laboratories and Standardisation Affairs in the Ministry of Environment. By post:

The Coordinator Qatar Construction Specifications 2014 Laboratories & Standardisation Affairs Ministry of Environment PO Box 23277 Doha, Qatar

By e-mail:

[email protected]

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Section number and title Part number and title Clause and paragraph number Page Your name and contact details

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Please ensure that the following information are included in all correspondences:

Please use the following feedback form where possible and applicable.

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QCS 2014 Feedback

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Section name and title

Clause and paragraph number

Comments / Suggestions / Technical Justifications

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Name and contact details

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Part name and title

QCS 2014

Section 01: General Part 01: Introduction

Page1

1

INTRODUCTION ........................................................................................... 2

1.1

GENERAL ...................................................................................................... 2

1.1.1 1.1.2 1.1.3 1.1.4

Scope of this Section Scope of the Qatar Construction Specification References Precedence of Specification and Documents

1.2

COMPLIANCE ............................................................................................... 3

1.2.1 1.2.2

Compliance with the Qatar Construction Specification Compliance with the General Conditions of Contract

1.3

STANDARDS ................................................................................................. 3

1.3.1 1.3.2 1.3.3

References to Standards 3 Government Published Specifications, Regulations, Notices and Circulars 3 Survey Marks 5

1.4

TERMS AND DEFINITIONS .......................................................................... 5

1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.4.10 1.4.11 1.4.12 1.4.13 1.4.14 1.4.15 1.4.16 1.4.17 1.4.18 1.4.19 1.4.20 1.4.21 1.4.22

General Approved Contract Contract Documents Contractor Drawings Engineer Engineer’s Representative Government Government Departments and Utility Services Guarantee Independent Agency Owner Permanent Works Plant Project Documentation Singular and Plural Site Specifications Specified Temporary Works Works

1.5

ABBREVIATIONS AND SYMBOLS ............................................................... 7

1.5.1 1.5.2

General Site Conditions

1.6

LANGUAGE ................................................................................................. 10

1.6.1

Contract Language

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5 5 5 5 5 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7 7 9 10

QCS 2014

Section 01: General Part 01: Introduction

Page2

INTRODUCTION

1.1

GENERAL

1.1.1

Scope of this Section

1

This Section specifies the general clauses applicable to Works being carried out in accordance with this Specification.

1.1.2

Scope of the Qatar Construction Specification

1

The clauses in this Specification are applicable to each and every part of the Works. Their function is to bring together all those statements which are normally common to most types of work.

2

The Qatar Construction Specification applies to the entire Works, whether on the Site or in yards, workshops and factories employed elsewhere in connection with the Works.

1.1.3

References

1

The following standards are referred to in this Part:

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BS 6100......................Building and civil engineering: Vocabulary

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BS ISO 80000 ............Quantities and Units

BS EN 1991-1-4 .........Eurocode 1. Actions on structures. General actions. Wind actions

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BS EN 1992-1-1 .........Eurocode 2. Design of concrete structures. General rules and rules for buildings

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ASCE/SEI 7-05...........Minimum Design Loads for Buildings and other Structures Guide to the Design of Concrete Structures in the Arabian Peninsula, 2008

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Seismic hazard and seismic design requirements for the Arabian Peninsula region. The 14th World Conference on Earthquake Engineering October 2008

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Civil Aviation Authority wind records. Ministry of Communication & Transport, Department of Civil Aviation & Meterology. 1.1.4

Precedence of Specification and Documents

1

The precedence of documents shall be: (a)

Particular Conditions of Contract.

(b)

General Conditions of Contract.

(c)

Project Specific Specification.

(d)

Project Specific and General Drawings.

(e)

Qatar Construction Specification.

QCS 2014

Section 01: General Part 01: Introduction

Page3

COMPLIANCE

1.2.1

Compliance with the Qatar Construction Specification

1

Unless otherwise stated in the Project Documentation, the Contractor shall comply with every requirement of the Qatar Construction Specification that is relevant to the type of work forming any part of the Contract and shall adopt whichever permissible option or alternative that is best suited to the needs of the construction work being undertaken.

2

Any information in the Contract documents as to the whereabouts of existing services and mains is approximate and for the guidance of the Contractor who shall not be relieved of his obligations under of the General Conditions of Contract .

1.2.2

Compliance with the General Conditions of Contract

1

The Qatar Construction Specification is intended for use with the General Conditions of Contract.

2

The Contractor shall comply with the provisions of the General Conditions of Contract in the course of construction of the Works.

1.3

STANDARDS

1.3.1

References to Standards

1

Any standard referred to in this Specification shall be deemed to be the version and/or standard(s), that was current forty-two days prior to the date of return of Tenders.

2

Any standard referred to in this Specification shall be taken as a reference to an equivalent Specification.

3

The Contractor shall have copies of all referenced standards applicable to the work being undertaken. Translations of standards not written in English shall be provided where necessary.

1.3.2

Government Published Specifications, Regulations, Notices and Circulars

1

The works shall be executed in accordance with the following Government specifications, regulations, notices and circulars:

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1.2

(a)

The General Conditions of Contract.

(b)

The Qatar Construction Specification (QCS) issued by the Qatar Standards, Laboratories and Standardisation Affairs, Ministry of Environment, 2014 and all revisions and addenda issued by the same ministry prior to the date of the announcement inviting tenderer.

(c)

The Code of Practice and Specification for Road Openings in the Highway prepared by the Ministry of Industry & Public Works, January 1992.

(d)

The Guide for Civil Users of Explosives in Qatar prepared by the former Ministry of Public Works.

(e)

The Qatar Survey Manual prepared by the Survey Section of the former Ministry of Industry & Public Works.

QCS 2014

Section 01: General Part 01: Introduction

Page4

The Qatar Traffic Manual prepared by the former Ministry of Public Works and the Qatar Highway Design Manual prepared by MMAA, 1997.

(g)

The Traffic Control at Road Works Manual issued by the former Ministry of Industry & Public Works.

(h)

Rules, Regulations and Code of Practice for Design and Installation of Air Conditioning, Heating, Ventilation & Refrigeration (ACHVR) Systems for Government Buildings, 2nd Edition, 1989, prepared by Qatar General Electricity and Water Corporation (QGEWC).

(i)

Regulations for the Installation of Electrical Wiring by the former Qatar National Telephone Services.

(j)

The Regulations for the Installation of Electrical Wiring, Electrical Equipment and Air Conditioning Equipment, Feb 2006 Edition prepared by the Qatar General Electricity and Water Corporation (QGEWC).

(k)

Rules and Regulations for Plumbing Works prepared by the Qatar General Electricity and Water Corporation (QGEWC).

(l)

Any current and relevant regulations, notices or circulars issued by the Public Works Authority, Ministry of Municipal Affairs & Agriculture (including the previous Ministry of Public Works and the previous Ministry of Industry and Public Works), Qatar General Electricity and Water Corporation (QGEWC) (including the previous Ministry of Electricity and Water), Qatar Telecom (Q-TEL), the Qatar Standards, the Supreme Council for the Environment and Natural Reserves or the appropriate local Municipality prior to the date of the announcement inviting tenderer.

(m)

State of Qatar Law No. 30 of 2002 and all subsequent amendments concerning “The Environment and Natural Resources Protection” – Articles 6, 17, 19 & 35.

(n)

State of Qatar Law No. (6) of 1987 and all subsequent amendments concerning Materials and Equipment from Qatar or other CCASG countries.

(o)

The Method of Measurement for Road and Bridgeworks published by the Ministry of Industry and Public Works, Civil Engineering Department , 1987.

(p)

Standard Method of Measurement of Building Works published by the Ministry of Public Works, Engineering Services Department, 1973.

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Safety Rules issued by the Electricity Networks Department of the former Ministry of Electricity and Water.

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(f)

2

(r)

The Jointing Manual prepared by the Electricity Networks Department of the former Ministry of Electricity and Water.

(s)

The Labour Law, No. (14) of The Year 2004 Published by Labour Department of Ministry of Civil Service Affairs & Housing, 2005.

(t)

Developer’s Drainage Guide prepared by the Public Works Authority, 2007.

(u)

Qatar Traffic Law No. 19 of the Year 2007.

(v)

CDD (Civil Defence Department) – Fire Safety Handbook.

(w)

Civil Defence Law No. 9 of the Year 2012.

(x)

Worker Rights Booklet 2009 (National Human Rights Committee).

The Contractor shall be deemed to have his own copy of the Government specifications, regulations, notices and circulars given at (a) to (t) above.

QCS 2014

Section 01: General Part 01: Introduction

Page5

Where any standard publication, specification, regulation, notice, etc or any correspondence refers to a Government Ministry, department, division, section, etc it will be deemed to be the same as any successor Ministry, department, division, section, etc which has or may subsequently be officially promulgated by the Government of the State of Qatar.

1.3.3

Survey Marks

1

The Contractor shall consult the Engineer prior to any earth or other works to determine if the work is likely to disturb survey marks. If the Engineer requires a survey mark to be moved the Contractor will be responsible for recreating the survey mark to an approved design and specification, and for resurveying the point using survey companies approved by the Engineer authority.

2

The Contractor shall be responsible for the protection of the survey marks within the boundaries of the site for the duration of the contract period, and shall be liable for all costs of any remedial work required by the Engineer.

3

On the practical completion of the Works the Engineer will issue a certificate stating that all survey marks, whether disturbed or otherwise by the Contractor, have been reinstated or protected to the satisfaction of the Engineer.

4

In the event of failure to comply with the requirements of this Clause the Engineer, without prejudice to any other method of recovery, may deduct the costs of any remedial work after the practical completion date carried out by the Engineer, from any monies in its hands or which may become due to the Contractor.

1.4

TERMS AND DEFINITIONS

1.4.1

General

1

The following terms and conditions shall apply when used within, or in association with, the Qatar Construction Specification. Terms, which are restricted in their application to certain types of material or workmanship, are dealt with in the appropriate Section.

2

The definitions given in the General Conditions of Contract shall apply to this specification.

1.4.2

Approved

1

means terms such as “approved’, “approved by”, “to the approval”, “as directed” and the like refer always to approval or directions given by the Engineer in writing.

1.4.3

Contract

1

means the binding agreement entered into between the parties and the Contractor for the construction of the Works.

1.4.4

Contract Documents

1

means documents which together form the Contract

1.4.5

Contractor

1

means the party responsible for the construction of the Works.

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Section 01: General Part 01: Introduction

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Drawings

1

The drawings included in the Project Documentation.

1.4.7

Engineer

1

means the party appointed by the Owner to administer the Contract

1.4.8

Engineer’s Representative

1

means the party appointed from time to time by the Engineer to perform duties on behalf of the Engineer whose authority and delegated powers shall be notified in writing to the Contractor by the Engineer.

1.4.9

Government

1

means the Government of the State of Qatar, including its ministries and offices

1.4.10

Government Departments and Utility Services

1

means any governmental, semi-governmental, administrative, fiscal or judicial ministry, department, commission, authority, tribunal, agency, municipality or body, and shall include the provider of electricity, gas, water, wastewater and other public services, and any party with a regulatory function under the laws of the State of Qatar.

1.4.11

Guarantee

1

A Guarantee is a written assurance that a material, product, component, item of equipment, finishing or any other part of the Works meets certain defined standards or quality criteria and/or lasts for a certain length of time.

2

A warranty is the same as a Guarantee as defined in Clause 1.4.17.1.

1.4.12

Independent Agency

1

means a party where specified in the Contract Documents or as instructed by the Engineer as an Approved agency who is responsible for specific tasks assigned to that party by the Contract Documents

1.4.13

Owner

1

means the party for whom the Project is being undertaken and to whom the handover of the final product will be made.

1.4.14

Permanent Works

1

means the permanent works, forming part of the Works, to be designed and / or executed and completed by the Contractor under the Contract.

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1.4.6

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Plant

1

means, irrespective of ownership, all plant, facilities, temporary structures and accommodation, equipment, tools, appliances, apparatus, machinery, vehicles and other things required for the design, execution and completion of the Works and the remedying of defects, whether imported or locally supplied, but excluding Temporary Works and any other things intended to form or forming part of the Permanent Works

1.4.16

Project Documentation

1

All documents associated with and applicable to the Project Contract.

1.4.17

Singular and Plural

1

Words importing the singular only also include the plural vice versa where the context requires.

1.4.18

Site

1

Means the places provided by the Owner where the permanent works are to be executed and to which Plant and Materials are to be delivered, any other places that may be specified in the Contract Documents or by an instruction of the Engineer as forming part of the Site

1.4.19

Specifications

1

All specifications contained in the Contract including any modifications or additions thereto as may from time to time be issued or approved in writing by the Engineer.

1.4.20

Specified

1

Specified in the Project Documentation.

1.4.21

Temporary Works

1

means temporary works of every kind (other than Plant) required on the Site for the execution and completion of the Permanent Works and the remedying of Defects.

1.4.22

Works

1

means all works, supplies and services of any kind, including Permanent Works and Temporary Works, required for the project and to satisfy the requirements of the Contract Documents.

1.5

ABBREVIATIONS AND SYMBOLS

1.5.1

General

1

Units shall generally be in accordance with the Systèm International d’Unités and the relevant provisions of BS ISO 80000

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1.4.15

QCS 2014

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microns ampere Celsius centi day diameter gram (me) hour hectare joule kilo litre mega metre milli Newton number number Pascal radius second tonne volt Watt

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µ A C c d dia g h ha J k l M m m N No. nr Pa r sec t V W

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American Association of State Highway and Transportation Officials American Concrete Institute American National Standards Institute American Society of Mechanical Engineers American Society for Testing & Materials American Welding Society American Water Works Association British Standard British Standard Institution Cement and Concrete Association Commission of approval of Electrical Equipment Chartered Institution of Building Services Engineers Concrete Industry Research and Information Association Concrete Reinforcing Steel Institute Concrete Society Deutsches Institute fur Normung (German Institute for Standardization) Electronic Industries Association European Standards (Euro-Norm) Federal Highway Authority Factory Mutual Engineering Division Gulf Standards Institution of Civil Engineers International Electrotechnical Commission Institution of Electrical Engineers

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AASHTO ACI ANSI ASME ASTM AWS AWWA BS BSI C & CA CEE CIBSE CIRIA CRSI CS DIN EIA EN FHWA FM GS ICE IEC IEE

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Reference to a technical society, institution, association or governmental authority is made in the Specifications in accordance with the following abbreviations:

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The following abbreviations are used in this Specification:

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Section 01: General Part 01: Introduction

IEEE ISO LPC LPCB MMAA NEMA NFPA PCI PWA QCS QGEWC QS

Page9

Institute of Electrical and Electronic Engineering International Organization for Standardization Loss Prevention Council Loss Prevention Certification Board Ministry of Municipal Affairs and Agriculture National Electrical Manufacturer’s Association National Fire Protection Agency Prestressed Concrete Institute Public Works Authority (Ashghal) Qatar Construction Specification Qatar General Electricity & Water Corporation Qatar Standards (Laboratories and Standardisation Affairs, Ministry of Environment) Qatar Telecom Provider Swedish Standards Institute United Kingdom Department of Transport Urban Planning and Development Authority Verband Deutscher Elektrotechniker (Association for Electrical, Electronic and Information Technologies)

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Ooredoo SIS UK DOT UPDA VDE

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QCS 2014

Site Conditions

1

The Site conditions shall be assumed to be as follows for tendering purposes:

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1.5.2

Maximum ambient temperature .......................... 50C

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Minimum ambient temperature ........................... 5C

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Design ambient temperature ............................... 50C Maximum metal temperature under the sun ....... 85C

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Maximum ambient humidity ................................ 100% Minimum ambient humidity ................................. 20%

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Design ambient humidity ..................................... 100% 50-year return period Wind Speed:

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(a) Nominal wind speed for 3 sec gust ……… 38 m/s (A per ASCE 7-05 / IBC 2012) (b) Mean hourly wind speed…………….…… 25 m/s (as per BS 6399-2)

(c) Mean 10 minutes wind speed…………… 27 m/s (as per BS EN 1991-1-4)

Yearly rainfall ....................................................... 80 - 150 mm 2

The wind is very directional and that the W-NNW sector predominates for velocities greater than 8m/s (30km/h). However, the wind in coastal areas tends to exhibit a diurnal pattern, with onshore winds during daylight hours changing to offshore at night.

3

The temperature is relatively mild from October to May and hot from June to September.

4

The relative ambient humidity is generally low from October to May and generally high from June to September.

5

Under certain climatic conditions, considerable condensation may take place.

6

A considerable amount of salt is contained in the atmosphere which together with the relatively high ambient humidity, can produce sever corrosion problems.

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Section 01: General Part 01: Introduction

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7

Distribution and occurrence of rainfall events are very erratic. Rainfall events are generally of a high intensity with a short duration and usually occur between December and March.

8

The prevailing wind directions are from the north and west.

9

The seismic design for all building structure shall be based upon local seismic accelerations recommended as per ASCE 7-10, IBC 2012 or BS EN 1998-1:2004. Local seismic spectral accelerations based upon uniform hazard response spectra for 475 year and 2475 year return period as below. Peak Ground Acceleration (PGA) 2475 year

475 year

2475 year

475 year

0.045

0.10

0.090

0.147

0.045

2475 year

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0.065

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Wind tunnel test is recommended for buildings under below criteria Total building height exceeding 120m from ground.

(b)

Structure with irregular geometry or shape.

(c)

Unusual terrain or surrounding structure in the area.

(d)

Any other factor as per design requirements or designer recommendation.

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(a)

The ratio of the wind speed for any return period to the 50 year return period wind speed as per Peterka & Shahid Equation is

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1 second Spectral Acceleration (g) – S1

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0.2 second Spectral Acceleration (g) - Ss

Building structure design working life shall be minimum as specified below

10

Examples

Temporary structures (a)

10 to 25

Replaceable structural parts, eg. Gantry girders, bearings

3

15 to 30

Storage and similar structures

4

50 to 75

Building structures and other common structures

5

120

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Indicative design working life (years)

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Design working life category

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12

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VT / V50 = [0.36+0.1 ln (12T)]

(a)

Civil engineering structures like bridges, tunnel etc.

Structures or parts of structures that can be dismantled with intention of being reused, aren’t temporary structures.

1.6

LANGUAGE

1.6.1

Contract Language

1

All communications, meetings and documentation shall be in English. END OF PART

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Page 1

10

OCCUPATIONAL HEALTH AND SAFETY .................................................... 3

10.1

GENERAL ...................................................................................................... 3 3 3 4 5 6 6 7 7 7 8 8 10 10 11

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10.1.1 Scope 10.1.2 Responsibility 10.1.3 Organisation for Occupational Health and Safety 10.1.4 Reporting Accidents 10.1.5 General Sanitation 10.1.6 Safety Notice Board 10.1.7 Compensation for Damage 10.1.8 Occupational Health and Safety Performance 10.1.9 Occupational Health and Safety Leadership and Accountability 10.1.10 Safe-working Arrangements 10.1.11 Labour Rights, Benefits & Obligations 10.1.12 Language barriers and communications issues 10.1.13 Communications, Consultations and Participation 10.1.14 Management Review

CONTRACTOR OCCUPATIONAL HEALTH AND SAFETY PLAN ............. 11

10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6

General Occupational Health and Safety Policy Risk Assessment and Job Hazard Analysis Intervention Requirement for Training Method Statements

10.3

EMERGENCY RESPONSE PLAN (ERP) .................................................... 19

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10.3.1 General

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11 16 16 16 17 19 19

EARTHQUAKE EMERGENCY MANAGEMENT PLAN ............................... 20

10.4.1 10.4.2 10.4.3 10.4.4 10.4.5 10.4.6 10.4.7

Background Requirements Phase One: Gap Analysis (‘as is’) Phase Two: Implementation (‘to be’) Phase Three: Future Requirements What Should We Do During An Earth Quake? What Should We Do After An Earth Quake?

10.5

SPECIAL SAFETY REQUIREMENTS AND PRECAUTIONS ..................... 24

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10.5.1 Permits 10.5.2 Guarantee 10.5.3 Mechanical Plant, Machinery and Equipment 10.5.4 Existing Utilities 10.5.5 Excavations 10.5.6 Warning Signs 10.5.7 Confined Spaces 10.5.8 Lifting Operation 10.5.9 Lifting Gear 10.5.10 Scaffolding

20 21 21 22 22 23 23 24 24 24 25 26 28 28 30 30 31

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10.5.11 Hot work and Welding 10.5.12 Compressed Gas Cylinders 10.5.13 Working at Height 10.5.14 Electrical 10.6

32 33 34 36

FIRST AID ................................................................................................... 37

10.6.1 First Aid and Clinic 10.7

37

FIRE PRECAUTION AND PREVENTION ................................................... 37

10.7.1 General 10.7.2 Emergency Equipment 10.7.3 Hazardous Substances

SAFETY OF THE PUBLIC ........................................................................... 41

.

10.8

37 39 40

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41

WELFARE, SAFETY AND PROTECTION OF WORKMEN ........................ 42

10.9.1 10.9.2 10.9.3 10.9.4 10.9.5 10.9.6 10.9.7

General Personal Protective Equipment (PPE) / Attire Safety Equipment Support Facilities for Contractors Staff and Labour Summer Working Conditions and fatigue Additional Environmental Protection and Pollution Control Plant and Equipment Test Certificates

10.10

LABOUR ACCOMODATION ....................................................................... 46

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10.9

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10.10.1 General 10.10.2 Quality of Labour Accommodation 10.10.3 Provision for Fire Safety 10.10.4 Provision for Health Care 10.10.5 Access to Transport 10.10.6 Access to Religious, Social and Domestic Facilities 10.10.7 Access to Communications 10.10.8 Number, Quality and Location of Sanitation Facilities 10.10.9 Food Preparation Areas 10.10.10 Pest and Vermin Control 10.10.11 Security at Labour Accommodation 10.10.12 Social Issues 10.10.13 Competence of Labour Accommodation Management 10.10.14 Environmental Conditions at Labour Accommodation 10.10.15 Health and Safety for Labour Accommodation Residents

42 42 42 43 45 45 46 46 46 47 47 48 48 49 49 49 50 50 50 51 51 52

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10

OCCUPATIONAL HEALTH AND SAFETY

10.1

GENERAL

10.1.1

Scope

1

This Part specifies the Health, Safety and Welfare requirements for construction and its associated practices.

2

Related Sections and Parts are as follows.

Section 11

Health and Safety

.

Protection Building Demolition Materials Engineer’s Site Facilities Setting-out of the Works

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This Section

Responsibility

1

It is the Contractors responsibility to implement an Occupational Health and Safety Management System meeting as a minimum the requirements of BS OHSAS 18001. It shall be the duty of the Contractor to provide the following:

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10.1.2

Safe plant and equipment;

(b)

Safe means of handling, transporting and storage of articles and substances;

(c)

Adequate training, instruction, information and supervision;

(d)

A safe place of work with safe access to and egress from the place of work;

(e)

A safe and healthy environment; and

(f)

Adequate welfare facilities.

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(a)

It is the Contractor’s responsibility to conduct his operations in such a manner as to prevent injury to persons or damage to property. The Contractor shall take precautions for protection against risks and shall inspect Occupational Health and Safety conditions where the Works are being executed.

3

The Contractor shall conform to all Acts, Orders and Regulations made by any official authority with respect to Occupational Health and Safety.

4

The Contractor shall note that Occupational Health and Safety (OHS) shall be treated with high importance at all stages of the Contract. Contractor shall understand that the Contract Price includes the Execution Programme for provision and implementation of an Occupational Health and Safety Policy and Plan to ensure the highest standards are enforced throughout Construction, Pre-commissioning and Commissioning.

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The Contractor’s attention is drawn to the requirements of latest revision of: Qatar Construction Specification – QCS,

(b)

Qatar Law No.14 of the Year 2004 – The Labour Law, and the ministerial decisions issued in implementation of the provisions of the Labour Law issued by Law No. 14 of 2004,

(c)

Qatar Traffic Law No. 19 of the Year 2007,

(d)

Environmental Protection Law No. 30 of the Year 2002 and Decision No. (4) for the year 2005 by issuing the executive regulations of Environmental Protection Law,

(e)

Civil Defence Law No. 9 of the Year 2012,

(f)

CDD (Department of Civil Defence) – Fire Safety Handbook; and

(g)

Worker Rights Booklet 2009 (National Human Rights Committee).

.

(a)

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The Contractor is required to fully comply with the stated requirements relating to Occupational Health and Safety. In the event that legislation is updated the latest version shall be followed. The Contractor shall ensure that Contractor Personnel and Subcontractor’s employees comply with all requirements of latest revision of QATAR legislation mention above (but not limited to). Compliance with the standards shall be considered as a minimum requirement and Contractor shall establish additional arrangements as circumstances may require. Any failure by Contractor to obtain copies of that mentioned laws applicable to the Contract shall in no way relieve the Contractor from any responsibilities or obligation under the Contract.

7

The Contractor’s Representative shall be responsible for all Occupational Health and Safety matters during the performance of the Work up to and including the Completion Date. The Contractor’s Representative shall ensure that an effective Occupational Health and Safety management organization is maintained at all times to undertake the duties to comply with this requirement.

10.1.3

Organisation for Occupational Health and Safety

1

The Contractor shall submit an Occupational Health and Safety Organisation Plan detailing planning and management considerations for construction at an organisational level for the Engineer’s approval within Thirty (30) days of the award of the Contract.

2

The Occupational Health and Safety Organisation Plan shall provide the names, qualifications, experience and skills of all the Safety Team and key support staff.

3

The Contractor shall submit the names of the following to the Engineer for approval:-

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(a)

The details of its proposed competent and experienced Occupational Health and Safety Manager. The minimum education for the proposed Occupational Health and Safety Manager are but not limited to Bachelor degree in Engineering / Science or equivalent with 10 years experiences in the same field as Safety Manager and the ability to communicate with all nationalities, plus Professional OHS Qualification by Examination (NEBOSH, IOSH Managing Safely, OSHA 30 hours, ... etc), Management Qualification prefer certified as BS OHSAS 18001 lead auditor, implementation and continues improvement Relevant Training Attendance. The Engineer shall review the details and if necessary interview the proposed individual to assess his/her suitability for the position prior to giving approval for appointment. The Contractor is not

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permitted to execute any form of Work on the Worksite until such time as an approved Occupational Health and Safety Manager has been deployed on a full time basis to the Worksite. The Contractor shall not remove the appointed Occupational Health and Safety Manager without prior approval from the Engineer. (b)

Deputy Occupational Health and Safety Manager who is capable of performing all of the duties of the Occupational Health and Safety Manager in the event of his absence. The requirements and procedure outlined in Clause (a) above applies equally to the appointment of the Deputy Occupational Health and Safety Manager.

The Contractor shall appoint Occupational Health and Safety Officers and support staff in sufficient numbers to ensure the effective function of the Occupational Health and Safety discipline within the Contractor’s organisation. The minimum education for the Occupational Health and Safety Officer are HND / HNC with 4 years experiences in the same field as Safety officer, certified from NEBOSH, IOSH or OSHA 30 hours, Professional in control and monitoring the site activity. The Contractor shall appoint and deploy full time on the Worksite one Occupational Health and Safety Officer for each and every 50 persons employed at the Worksite. For a less than 50 persons employed at the Worksite, a minimum of one (1) Safety Officer shall be present on site during all working hours each day throughout the Contract period. This is in addition to the Occupational Health and Safety Manager and his Deputy.

5

The Safety Officers shall have no other duties, either on-site or off-site, other than Occupational Health and Safety duties, and shall be exclusive to one site.

6

The Contractor shall ensure that each and every Subcontractor employed on the Worksite appoints suitably competent and experienced qualified Occupational Health and Safety staff to ensure the effective function of the Occupational Health and Safety discipline within the Subcontractor’s organisation. The requirements and procedure outlined above for contractor Occupational Health and Safety staff to be applies equally to the appointment of the Subcontractor Occupational Health and Safety Staff. The Subcontractor shall appoint and deploy full time on the Worksite one Occupational Health and Safety Officer for each and every 50 persons that they employ at the Worksite. Any Subcontractor that employs more than 100 persons will appoint an Occupational Health and Safety Manager. This is in addition to the Occupation Occupational Health and Safety Officers.

10.1.4

Reporting Accidents

1

The Contractor shall promptly report to the Engineer any accident whatsoever arising out of, or in connection with, the Works whether on or adjacent to the Site which caused death, personal injury or property damage, giving full details and enclosing statements of witnesses.

2

Promptly shall mean immediately by telephone where it impacts on the operation of the project and electronically in all cases never more than 24 hours.

3

The Contractor shall implement arrangements for effectively managing any emergency incident that may occur as a result of Work and/or on the Worksite.

4

The Contractor shall make all necessary arrangements for emergency preparedness including, but not limited to, medical equipment and facilities, trained personnel, communication systems, transportation, search and rescue equipment.

5

The Contractor shall produce and submit to the Engineer monthly performance reports and incident reports. Reports shall be in the format approved by the Engineer.

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6

The Contractor shall refer to, and in particular, QCS 2013 (Section 11, Part 2) for all incident classifications and definitions.

7

Incident Investigation final reports to be submitted for all lost time major / reportable Incidents within 10 days of the incident. All incidents that result in lost time from work, near miss, dangerous occurrence or damage to property (asset) shall be reported. The normal steps to be taken after an incident shall be; Submit incident notifications immediately;

(b)

Conduct the investigation;

(c)

Prepare the report with conclusions and recommendations;

(d)

Prepare appropriate plan of corrective action;

(e)

Include in monthly Health and Safety statistics report;

(f)

Submit to Engineer for review and re-submittal if required.

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General Sanitation

1

The Contractor shall maintain the Site and all working areas in a sanitary condition and in all matters of health and sanitation shall comply with the requirements of the Supreme Council of Health and the Public Works Authority.

2

The Contractor is responsible for all measures necessary to prevent the breeding of mosquitoes on the Site for the duration of the Contract.

3

The Contractor shall ensure that pests are not permitted to the Site facility by initiating a routine pest control program. Non-toxic pest control methods shall be used.

4

The disposal surplus water and the accompanying growth of trees and the proliferation of insects and rodents. Does the site cause an environmentally danger to the surrounding area?

10.1.6

Safety Notice Board

1

The Contractor shall set up and maintain (cleaned and legible) throughout the course of the Contract safety notice boards in prominent places on the Site. These notice boards shall be located in positions approved by the Engineer such that they are clearly visible to the Contractor’s employees. They shall be fully illustrated and provide details of key safety procedures to be followed.

2

The notice boards shall be in Arabic, English and;

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10.1.5

(a)

In all other languages which are the mother tongue of five or more of the Contractor’s employees, or

(b)

The preferred languages (can be understood) by the workers on the Worksite.

3

The Contractor’s employees shall be made fully aware of the notice boards prior to commencing duties on Site.

4

The Contractor shall maintain up to date copies of all industry codes and standards that apply to the Work.

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Compensation for Damage

1

Claims for compensation arising from damage or injury caused by the Contractor’s failure to provide adequate Occupational Health and Safety measures shall be the sole responsibility of the Contractor.

2

The Contractor shall notify the Engineer of any claim made against him which is in any way connected to the Contract.

3

The Contractor is required to copy to the Engineer any formal Occupational Health and Safety related communication between the Contractor and enforcing authorities or government organizations.

10.1.8

Occupational Health and Safety Performance

1

The Contractor shall ensure acceptable Occupational Health and Safety performance of all Subcontractors, visitors, vendors, public and other parties that may enter the Worksite or the amounts identified in the Bills of Quantities.

2

Should acceptable Occupational Health and Safety performance not be maintained by the Contractor then the Engineer may, in addition to any other amounts withheld under the Contract, withhold up to 10% of the amount of any interim invoice issued by the Contractor.

3

The Contractor shall develop and implement programmes which shall act as incentives for their teams at all levels, to make a positive contribution to good health and safety performance.

10.1.9

Occupational Health and Safety Leadership and Accountability

1

The Contractor shall be committed to Health and Safety leadership and this is to be achieved through working in partnership with the main project stakeholders including the Engineer and the Client.

2

The Contractor shall demonstrate commitment to the safety, health and welfare of all stakeholders and workers on projects and shall demonstrate leadership in achieving the following objectives:

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10.1.7

(a)

A safe, healthy workplace

(b)

Be consulted on their working conditions, to be heard, and to influence their working conditions

(c)

Return home from work unharmed at the end of each working day; to which everyone has a right to.

3

The Contractor shall provide opportunities through forums and meetings involving important project stakeholders, including the Client, The Engineer, sub-contractors and other relevant contractors to raise health and safety issues, assist in the development of leadership programmes, share good practice and be recognised for good performance.

4

The Contractor’s senior management shall visibly demonstrate support, commitment, Leadership and Accountability on all health and safety issues by the following actions: (a)

The Engineer’s Zero Harm Initiative;

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Section 01: General Part 10: Occupational Health and Safety

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Training employees to work safely;

(c)

Recognizing and rewarding employees;

(d)

Identify risks to health and safety and develop mitigation/control plans and communicate these to workers;

(e)

Reinforce safe work practices;

(f)

Place health and safety as the first item on the agenda at meetings.

(g)

Allocate adequate resources for health and safety management and implementation

(h)

Develop health and safety targets and objectives and measure and review performance;

(i)

Foster positive health and safety culture and behaviour through their own actions;

(j)

Treat health and safety as a core value equal in importance with productivity, quality and ethical standards;

(k)

Participate in health and safety meetings and safety walkabouts;

(l)

Develop efficient contingency plans and allocate adequate emergency resources;

(m)

Provide trained and competent workforce;

(n)

Promote personal health and well-being; and

(o)

Seek to exceed current legislation in relation to welfare and labour facilities.

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10.1.10 Safe-working Arrangements

The Contractor shall have arrangements to empower their staff to make sensible decisions about their own safety and the safety of others affected by what they do, and not put themselves or others at risk of harm.

2

Contractor to have safe-working arrangement that ensures:

Employees can stop work immediately where they believe they or others are at risk of harm

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That health and safety concerns can be raised and associated actions taken

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(c)

No disciplinary action is taken against those who use the worksafe arrangement to raise a genuine health and safety concern

(d)

That the process is cascaded to their subcontractors

3

All such arrangements shall be briefed to all staff, including any agency or sub contract staff before they start work.

4

Where safety concerns are raised or a stop work process has been invoked employers shall document them and the action taken to resolve them; and shall advise others working on the project were the issue is likely to impact on them or be similar to those faced by other organisation

10.1.11 Labour Rights, Benefits & Obligations 1

The Contractor shall document implementation of Labour Law, in particular with respect to the following:

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Recruitment – The Contractor shall maintain an up-to-date list of all agents/agencies used and should provide copies of licences for same to the Engineer. The Contractor shall, through their best endeavours, satisfy themselves, and the Engineer, that recruitment agents/agencies used do not charge recruits any fees inconsistent with those allowed for under the Labour Law (Qatar Law no.14 of the year 2004).

(b)

Contracts – The Contractor shall retain, for inspection by the Engineer, copies of written employment contracts for all employees working on the project. Such employment contracts shall be in accordance with the requirements of the Labour Law and no contract clause may contravene the Labour Law.

(c)

Wages – A Wage Register shall be retained in accordance with the requirements of the Labour Law. The Contractor shall update the Wage Register to ensure that employee wages, including relevant overtime payments, are paid in a timely fashion and in a manner consistent with the requirements of the Labour Law. These records shall be available for inspection by the Engineer and shall clearly identify overtime payments and rates.

(d)

Severance Pay – The Contractor shall retain records to demonstrate that payment of severance payments have been made, where appropriate, in accordance with Article 132 of the Labour Law.

(e)

Records & Files – These shall be retained in accordance with the Labour Law, and shall be made available to the Engineer for inspection.

(f)

Work Rules & Disciplinary Rules – These shall be in accordance with the Labour Law, shall be conspicuously displayed, and shall be provided to the Engineer.

(g)

Working Hours & Leave - The Contractor shall retain records to demonstrate that all employees’ working hours and leave allowances are consistent with the requirements of the Labour Law.

(h)

Collective Labour Disputes - Any/all collective labour disputes shall be dealt with in accordance with the requirements of the Labour Law. Complete records of all such disputes shall be retained by the Contractor for review by the Engineer. As a minimum, the Contractor shall inform the Engineer immediately, on receipt of complaint/claim from the employees. Subcontracts As such, obligations, relating to Recruitment, Contracts, Wages, Records & Files, Work Rules & Disciplinary Rules, Working Hours & Leave and Collective Labour Disputes shall be passed on to the subcontractor in the event that works are subcontracted by the Contractor. Similarly, subcontractor records shall be made available to the Engineer.

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2

The Contractor shall provide copies of Contracts, Work Rules, Disciplinary Rules, Pay Slips, etc. to employees in a range of appropriate languages, as widely understood by the workforce.

3

The Contractor shall submit a monthly declaration to the Engineer outlining compliance with Labour Law in relation to payment of wages and working hours for the preceding period.

4

The Contractor shall facilitate contact between project employees and relevant independent bodies such consulates, NGOs, or other relevant organisations offering social support. A list of such local contacts shall be provided to new employees during their induction process. An up-to-date list of contact details for these organisations shall also be displayed in public areas such as the canteen, recreational areas, etc.

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10.1.12 Language barriers and communications issues 1

The Contractors shall ensure that their workforce fully understand site health and safety requirements, including emergency arrangements and site rules in place. The language needs of personnel shall be addressed during induction and through training. Emphasis should be placed on ensuring proper supervision of all staff, but in particular those who may have difficulties in understanding verbal or written communications. Where practicable, signage shall make maximum use of pictograms.

2

Those who have responsibility for managing Contractor personnel on construction site shall be able to communicate in both written and oral English to a standard appropriate to the tasks being performed. Note that there may be personnel who are not competent in the English language, and this is permitted provided that the Contractor can demonstrate that:

(b)

Such team members shall receive the required health and safety training / briefing (including any emergency procedures) before commencing work in a form that they understand

(c)

Appropriate arrangements are made to ensure that instructions are effectively communicated to and understood by all team members

(d)

Particular attention has been given to the communication requirements of safety critical workers. ensuring a translator is available who is capable of instructing the nonEnglish speaking personnel in safety and other operational matters, and

(e)

Maintaining a reasonable ratio of non-English speaking personnel to each translator at all times.

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Such team members are able to give oral instructions and warnings to others

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Special provisions for safety critical instructions conveyed by the translator shall be recorded as being received and clearly understood by each non-English speaking person. Such records shall include those for safety induction, emergency procedures, safety method statements and safety awareness talks.

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10.1.13 Communications, Consultations and Participation The Contractor shall be required to disseminate and transfer information regarding Health and Safety issues. Typical information to be communicated should include but not be limited to; any new policies or procedures and general awareness.

2

The Contractor shall ensure communications arrangements are in place to inform of key health and safety issues. These will include lessons learnt from incidents, sharing of good practice, health and safety campaigns and initiatives. Contractors shall have processes in place to ensure an appropriate cascade to all site personnel.

3

The following methods of communication but not limited to shall be observed;

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(a)

Meetings; Health and safety meetings shall be conducted on a weekly basis separate from other meeting that have safety on the agenda

(b)

Safety Alerts; Safety alerts shall be produced by the Contractor after a Major Accident/Incident or when appropriate.

(c)

Notice Boards; Information that shall be included as a minimum on an office notice board is any relevant emergency procedures, policy statement, safety alerts or updates

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(d)

Campaigns; Health and safety campaigns must be initiated by the Contractor to implement throughout the year. At least 4 campaigns must be run annually on a prorata basis. One of the campaigns must detail heat stress before the summer months.

(e)

Posters/Signs; Must be focused on themes relevant to site specific work activities/hazards

(f)

Safety Awards; The Contractor shall initiate a scheme whereby he recognises and rewards for positive health and safety related performance by individuals. This shall be on a monthly basis and communicated throughout the project workforce.

10.1.14 Management Review The Contractor has to supply evidence that their senior management have carried out a management review, at least annually, of their OHSE systems to ensure continuous improvement.

2

The review shall include, but not limited to, where appropriate, an evaluation of and / or changes to:

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Health and safety policy;

(b)

Objectives and targets;

(c)

Action plans;

(d)

Follow-up action from previous meetings;

(e)

Health and safety system suitability;

(f)

Audit results;

(g)

Preventive and corrective actions;

(h)

Regulatory changes;

(i)

Continual improvement measures;

(j)

Performance measures;

(k)

Major procedure and risk review changes; and

(l)

Health and safety plans.

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CONTRACTOR OCCUPATIONAL HEALTH AND SAFETY PLAN

10.2.1

General

1

The Contractor shall prepare a Contract specific Occupational Health and Safety Plan (the “Safety Plan”) and submit a Safety Plan to the Engineer for review and approval within thirty (30) days of the award of the Contract. The Contractor is not permitted to Work on the Worksite until such time as the Plan has been approved by Engineer. It will be a condition precedent to starting the works that the Contractor will have an approved Health and Safety Plan, Traffic Management Plan, and an Emergency Response Plan.

2

The Safety Plan shall include the Contractor’s proposals for the maintenance of safety on the Site. These proposals shall address the safety measures applicable with respect to all tasks to be undertaken in the construction of the Works.

3

The Safety Plan shall include the Contractor’s proposals for accident prevention. Accident prevention shall include but not be limited to training, monitoring and review of safety related procedures, enforcement of safety related matters and promoting safety awareness.

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The Safety Plan shall include a safety organisation chart showing the names and responsibility of all safety personnel deployed both on and off the Worksite to maintain acceptable Occupational Health and Safety performance of the Contract and the Work at all times, even outside the normal working hours, in particular night-time and holiday working. (refer to 10.1.3)

5

The Contractor is required to work in areas where dangerous concentrations of gases may be present in manholes, trench excavations and the like. It is the Contractor’s responsibility to provide all necessary detection equipment and to ensure that, if toxic or explosive gases are found, adequate measures are taken to protect his staff, workmen and members of the public.

6

The Safety Plan shall be specific to one Contract.

7

The Contractor shall regularly review the suitability of the Safety Plan. The Contractor shall undertake a full formal review of the Safety Plan annually on the date of award of the Contract or when necessary but no less than 6 monthly intervals and submit the findings of the review to the Engineer within 14 days of that date along with an amended plan should any amendment be required.

8

The Safety Plan shall contain the Contractor’s Occupational Health and Safety Policy. (refer to 10.2.2)

9

The Plan for construction works shall support and supported by the Contractor’s systems for risk management in particular risk assessment and method statement (refer to the Regulatory Document Section 11 Part 1 in particular section 1.1.7: Risk Assessments and Method Statement and Guidance document Section 11 Part 2 Section 2.4: Guidance on Risk Assessment and Method Statement). The plan shall include a schedule of risk assessments for all work activities in relation to the project. The plan shall include a list or schedule of identified work activities for which method statement will be developed before their execution..

10

The Safety Plan shall include the contract risk assessment and detail the arrangements for ensuring that it is updated to reflect any changes throughout the duration of the Work.

11

The Safety Plan shall detail the arrangements for undertaking job hazard analysis and ensuring that such analysis is included in each and every method statement.

12

The Safety Plan shall detail the management arrangements and standards to be used for each of the following:

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(a)

Scaffolding

(b)

Suspended Working Platforms

(c)

Fall Prevention and Fall Arrest

(d)

Prevention of Falling Objects

(e)

Excavations

(f)

Electricity

(g)

Structural Steel Erection

(h)

Demolition and Dismantling

Section 01: General Part 10: Occupational Health and Safety False work and Formwork

(j)

Reinforcement and Concreting

(k)

Cladding and Roof work

(l)

Confined Spaces

(m)

Lifting Appliances and Lifting Gear

(n)

Mobile Plant and Vehicles

(o)

Mobile Elevating Working Platforms

(p)

Construction Lifts

(q)

Machinery and Equipment

(r)

Power Tools

(s)

Hazardous Substances

(t)

Hot Work and Welding

(u)

Fire Prevention and Protection

(v)

Access and Egress

(w)

Housekeeping

(x)

Warning Signs and Barricades

(y)

Material Handling, Transportation and Storage

(z)

Lock Out and Tag Out

(aa)

Temporary Works

(bb)

Temporary Facilities

(cc)

Underground and Overhead Utilities

(dd)

Working Over or Adjacent to Water

(ee)

Working Environment

(ff)

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Personal Protective Equipment Site Traffic Control (including setting and taking down of all temporary traffic devices)

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The Safety Plan shall detail the arrangements that the Contractor shall use to ensure acceptable Occupational Health and Safety performance of all Subcontractors that may enter the Worksite. It shall detail the arrangements for evaluating Subcontractors prior to them being contracted to undertake Work. It shall detail the methods that the Contractor shall use to monitor their work and the penalties that shall be imposed should acceptable standards not be maintained.

14

The Safety Plan shall detail the manner in which the Contractor shall review, approve and incorporate all Subcontractor Occupational Health and Safety plans, risk assessments and method statements and incorporate them into their Occupational Health and Safety management system.

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The Safety Plan shall detail the arrangements that the Contractor shall use to ensure acceptable Occupational Health and Safety performance of all persons on the Worksite. In particular it shall detail the arrangements for penalties and disciplinary action that shall be taken should Contractor Personnel, Subcontractor employees or any other person on the Worksite not comply with Occupational Health and Safety requirements.

16

The Safety Plan shall detail the arrangements that the Contractor shall use to control and ensure acceptable Occupational Health and Safety performance of visitors and delivery personnel that may enter the Worksite.

17

The Safety Plan shall detail the Contractor’s arrangements for effectively managing any emergency incident that may occur as a result of Work or on the Worksite. The detail shall include the facilities required for emergency preparedness.

18

The Safety Plan shall detail the arrangements for notification and investigation of any incident that may occur as a result of Work or on the Worksite.

19

The Safety Plan shall detail the arrangements for the Contractor’s monthly performance reporting and incident reporting.

20

The Contractor shall ensure that their project monthly health and safety statistics report is completed and submitted by the agreed date to the Engineer and Quality & Safety Department. The Engineer will provide the necessary format for this report. The information collected will be submitted to the Engineer and Quality & Safety Department.

21

The Safety Plan shall detail the arrangements for assessing the general Health of employees and any job specific Health checks that may be required.

22

The Safety Plan shall detail the arrangements for self-inspection and auditing that shall be used to monitor the Work.

23

The Safety Plan shall detail the arrangements for tracking and effectively closing any Occupational Health and Safety related nonconformity or deficiency that may be identified as a result of monitoring. Written records of inspection, auditing and tracking shall be maintained and made available to any representative of Client on request.

24

The Safety Plan shall detail the arrangements for ensuring that all Contractor Personnel and Subcontractor employees are trained and competent to undertake their work in accordance with the required standards. In particular the Safety plan shall detail the training and competence requirements for the following employees;

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(a)

Supervisors

(b)

Electricians

(c)

Mobile plant and vehicle operators

(d)

Crane and lifting appliance operators

(e)

Riggers

(f)

Excavation Supervisors

(g)

Machinery operators

(h)

Scaffolders

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(i)

Scaffolding Supervisors

(j)

Confined space workers

(k)

Confined space supervisors

(l)

All persons working at height

Page 15

The Safety Plan shall detail the training arrangements specify the type and nature of training to be given including but not limited to induction, pre-work briefings, tool box talks, general awareness training, skills training and formal training conducted by training professionals or agencies. Written records of the attendees, training given and assessment of competency shall be maintained by the Contractor and made available for inspection by any representative of Client upon request.

26

The Safety Plan shall detail the Contractor’s arrangements for promoting the awareness of Occupational Health and Safety issues through notices, posters, newsletters, booklets, Occupational Health and Safety alerts and any other means. All such information shall be provided in the languages preferred by the training recipients of the training.

27

The Safety Plan shall detail the arrangements that the Contractor shall make to reinforce good performance. Such arrangements shall include incentive schemes to reward Contractor Personnel, Subcontractor employees or areas of Work that demonstrate exemplary Occupational Health and Safety performance.

28

The Safety Plan shall include details of all meetings that are held to specifically deal with Occupational Health and Safety issues. In particular the Contractor shall hold a monthly meeting chaired by the Contractor’s Representative, which Client shall be invited to attend, with the following items on the agenda;

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Suitability of the Contractor’s Occupational Health and Safety organization for the ongoing and planned Work;

(b)

Effectiveness of the Contractor’s system;

(c)

Significant areas of planned activity and associated risk;

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(f)

Incident review;

(g)

Occupational Health and Safety promotion planning;

(h)

Training needs assessment;

(i)

Auditing and inspection planning;

The Occupational Health and Safety Plan shall describe the Contractor’s Safety Management System that will be used throughout and shall conform with all requirements defined within the Contract and related documentation The contents shall include but not be limited to the following: (a)

Front Cover

(b)

Table of Contents

(c)

Project Scope, Requirements and Occupational Health and Safety Objectives

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Occupational Health and Safety Policy and BS OHSAS 18001 Certificate (if applicable)

(e)

Control of Occupational Health and Safety Plan

(f)

Reference Documentation

(g)

Safety Organisation and Responsibilities

(h)

Subcontractor Occupational Health and Safety

(i)

Risk Assessments and Method Statement

(j)

Non-conformance, Corrective and Preventative Action

(k)

Incident Reporting

(l)

Audits

(m)

Training

(n)

Key Performance Indicators and Continual Improvement

(o)

Management Review

(p)

Safety Meetings

(q)

Monthly Safety Report

(r)

Appendices

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Occupational Health and Safety Policy

1

The Contractor shall comply with the Client vision, mission and strategic objectives.

2

The Contractor shall develop and implement its own written Occupational Health and Safety Policy which shall be Project specific and demonstrate the Contractor’s understanding of and commitment to maintaining standards of Occupational Health and Safety (OHS) that are consistent with and an integral part of the Contractor’s business strategy.

3

The Contractor must set objectives and targets that shall be applicable to SMART - Specific, Measurable, Achievable, and Realistic and to a Time scale.

10.2.3

Risk Assessment and Job Hazard Analysis

1

Refer to Section 11 Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in particular section 2.4

10.2.4

Intervention

1

A system of positive intervention shall be used throughout the Project and the Contractor shall adopt the system by authorizing and requiring all Contractor Personnel and Subcontractor employees to intervene in any unsafe act or condition and take immediate corrective action to prevent any incident occurring.

2

Work may be monitored by any representative of Client who may intervene in any unsafe act or condition and require the Contractor to take immediate corrective action to prevent any incident occurring.

3

The Contractor is required to acknowledge that the system of positive intervention in use on the Project is one that shall enhance the following;

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(a)

levels of understanding and awareness of Occupational Health and Safety issues throughout the Project;

(b)

levels of personal responsibility and accountability for Occupational Health and Safety issues;

(c)

levels of proactively towards Occupational Health and Safety issues;

(d)

levels of compliance with contractual requirements and Project Occupational Health and Safety standards;

(e)

incident and injury prevention

The Contractor may be the focus of Occupational Health and Safety audits conducted by any representative of Client. The Contractor is required to cooperate with such audits and to acknowledge all audit findings. The Contractor shall take all corrective and preventive actions that may be required to address any nonconformity identified during such auditing.

5

The Contractor may be the focus of Occupational Health and Safety inspections conducted by any representative of Client. The Contractor is required to cooperate with and acknowledge such inspections and take all corrective and preventive actions that may arise as the result of such inspections.

6

The Contractor shall undertake routine Occupational Health and Safety inspections and audits for the on-going Work. Written records of inspections and audits shall be maintained and made available to any representative of Client upon request.

7

The Contractor may be issued with stop work instructions from the Engineer for any observed cases of serious or imminent danger associated with the Work. On receipt of a stop work instruction the Contractor shall refrain from work until such time as remedial action has been taken to alleviate the serious or imminent danger and to prevent it reoccurring.

8

The Contractor shall stop work if any unknown or unplanned conditions occur that give rise to serious or imminent danger. In such circumstances the Contractor shall assess the risks associated with any remedial work required and revise the method statements and job hazard analysis. The revised method statement shall be reviewed and approved by the Contractor’s Occupational Health and Safety Manager. Revised method statements shall be approved by the Engineer before recommencing Work.

10.2.5

Requirement for Training

1

The Contractor shall conduct training including contract specific induction, pre-work briefings, tool box talks, general awareness training, skills training and formal training conducted by training professionals or agencies. The contract specific induction will be at least 2 hours duration, approved by the Engineer and provided for all persons that enter the Worksite. Such induction training will be reviewed, revised and repeated for all persons that enter the Worksite at periods not exceeding 6 months throughout the duration of the Work. All training shall be provided in the languages preferred by the recipients of the training.

2

The Contractor is required to provide employees of Client with Occupational Health and Safety training relating to Work undertaken by the Contractor. Training is an integral part of job performance.

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The Contractor shall provide all Contractor Personnel and Subcontractor’s employees with individually unique Contract specific photo identity cards. Such cards shall be made available to any representative of Client on request. The Contractor shall not permit any Contractor Personnel or Subcontractor’s employees to access the Worksite unless they have been issued with their individually unique photo identity card. Such cards will not be issued prior to the Contractor Personnel or Subcontractor’s employee attending the Contractor’s induction training course.

4

The Contractor shall appoint a competent supervisor for each and every area of the following Work activities Temporary & permanent electrical installation

(b)

Crane and lifting appliance operations

(c)

Scaffolding erection, alteration and dismantling

(d)

Confined space entry

(e)

Excavation

(f)

Working at height

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The Contractor shall produce a health and Safety Training Matrix based on training needs analysis of all personnel working on the project. The matrix must detail positions against the training courses required from the analysis. All training courses provided to employees shall be free of charge, i.e. the cost will be borne by the Contractor.

6

The training topics will be based on a number of factors, such as but not limited to;

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(b)

Objectives that have been set;

(c)

Recurring issues on site; and

(d)

Accident/incidents on site.

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Courses designed to meet the needs of specific operatives involved in specialized trades including their roles and responsibilities must be provided through training. The following training could be consider as specialist, but not limited to: Safe entry into confined spaces;

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(b)

Crane operation;

(c)

Slingers/banks men;

(d)

Scaffolding/ false work/temporary works;

(e)

Abrasive wheels;

(f)

Woodworking machinery;

(g)

Excavation support equipment;

(h)

First aid;

(i)

Fire Marshall;

(j)

Accident Investigation;

Note – any external training must be delivered by a competent organisation (i.e. 3th Party).

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The Contractor shall provide training and instruction to their employees in relation to the performance of their work. This training shall be provided during working hours and immediately after an employee commences employment. It shall include: (a)

Occupational hygiene.

(b)

Essential elements of local laws and regulations.

(c)

Policies and procedures concerning aspects of human rights those are relevant to operations.

The Contractor shall actively encourage the following for their workforce: Creating employment opportunities.

(b)

Facilitating training opportunities for employees with a view to improving skill levels.

(c)

Ensuring non-discrimination in hiring and promotion practices.

(d)

Promoting life-long learning and on-the-job training.

(e)

All training shall be provided in appropriate languages, based on the demographics of the labour accommodation facility.

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The Contractor shall retain records of all training provided to labour accommodation residents. Such records shall include, as a minimum, the name, age and nationality of those attending the training course/session and the type of training provided. These records shall be available for inspection by the Engineer.

11

The Contractors shall conduct Emergency Drills to thoroughly test its emergency preparedness and response within 6 months of the date of award of the Contract and thereafter at periods not exceeding 6 months throughout the duration of the Work.

12

The Contractor shall hold a Contract Specific Occupational Health and Safety Meeting chaired by the Contractor’s representative on a monthly basis throughout the duration of the WORK. Additionally the Contractor shall include Occupational Health and Safety as an item on the agenda for each and every meeting held and ensure that the subject is actively discussed.

13

The Contractor shall provide contract specific Safe Practice Booklets for each and every person employed on the Worksite and provide training on the content of the booklet.

10.2.6

Method Statements

1

Refer to Section 11 Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in particular section 2.4

10.3

EMERGENCY RESPONSE PLAN (ERP)

10.3.1

General

1

The Contractor shall prepare an emergency response plans for the project and the following but not limited to shall be addressed;

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(a)

Responsibilities;

(b)

Risk assessment and hazard identification and controls for potential emergencies;

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Hazard identifications and controls;

(d)

Coordination with outside emergency response organizations;

(e)

Arrival of outside emergency response groups;

(f)

Emergency response equipment;

(g)

Emergency drills;

(h)

Tests of emergency preparedness and response program;

(i)

Crisis management plan - major events emergency response plan;

(j)

Evacuation procedure;

(k)

Medical facilities;

(l)

Site fire prevention and response reporting;

(m)

Environmental spills and releases;

(n)

Security including (bomb threat);

(o)

Malicious threats; and

(p)

Severe weather conditions.

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(c)

It shall be mandatory that all personnel are aware and understand what actions to take and when to take them in the event of an emergency situation. The Contractor shall provide such information, instruction and training as may be required to assist the personnel to respond appropriately, in the event of an emergency.

3

The Contractor shall develop ERPs for review by the Engineer in order to verify the suitability and capability of arrangements. The Contractor shall ensure a schedule is produced to conduct drills and exercises on a regular basis at the sites under its control.

4

Records of drills and exercises conducted shall to be kept together with details of follow up actions and performance assessments for audit purpose.

5

The first emergency drill shall be conducted within first the 30 calendar days following commencement of operations; afterwards emergency drills shall be conducted on a 6 monthly basis as a minimum.

6

All ERPs’ shall be reviewed and whenever necessary revised and updated every 6 months, periodic auditing must be carried out to ensure compliance.

10.4

EARTHQUAKE EMERGENCY MANAGEMENT PLAN

10.4.1

Background

1

During the month of April 2013 earthquakes occurred in Iran with varying degrees of tremors felt in the State of Qatar and the wider Middle East Region.

2

April 16th 2013 was by far the larger earthquake measuring 7.8 on the Richter scale with the tremors physically being felt in numerous locations and buildings across the region. Whilst events of this type are rare, the impacts could be serious both from a human and business scale.

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Following these events it is clear that should have an earthquake evacuation procedure. This emergency management plan has been developed; however it requires integration into the existing emergency and evacuation plans.

4

It is to be advised that the earthquake procedure whilst very important is one element of a much larger requirement for Emergency Management Planning to ensure that all scenario’s and eventualities are addressed inclusive of crisis management and business continuity.

10.4.2

Requirements

1

Outlined below is a suggested approach that could be taken to take into account those other elements of emergency planning starting with a review of the current arrangements for buildings, towers and associated structures inclusive of car parks.

2

The suggested overall approach would be a three phase priority approach. The first phase identifying the ‘as is’ situation to the desired outcome of ‘to be’ and the ‘future’ requirements, but this is not limited and may require additional elements as recommended by other experts.

10.4.3

Phase One: Gap Analysis (‘as is’)

1

Engage the relevant technical experts for the various aspects of the review, inclusive of but not limited to Fire Design Engineer, Health and Safety Consultant, training providers etc.

2

Review all existing emergency process, procedures, plans and protocols within the organisation and engage with other stakeholders such as Civil Defence to understand any wider requirements, etc.

3

Review of all buildings physical emergency evacuation systems to ensure they meet relevant codes and legislative requirements.

4

Review all evacuation assembly points and engage other building owners nearby the organisation building.

5

Develop work assignments for the organisation personnel and Safety Wardens during earthquakes.

6

Review the organisation buildings maintenance department records.

7

Identify relevant codes, legislative requirements and specific procedures needed for forward planning.

8

Identify salient issues for consideration namely high rise building, crowded indoor public places, indoor safety, outdoor safety, automobiles etc.

9

Identify non-structural hazards such as file cabinets, rack storage units, book shelves, HVAC ...etc.

10

Involve other stakeholders such as the organisation Health and Safety Section, Civil Defence, Ministry of Environment, other building owners in the immediate district etc to ensure their views, requirements, interests and responsibilities are established.

11

Review existing business resiliency and continuity plans, process and procedure.

12

Review existing crisis management plans, process and procedure.

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Indicate future planning and requirements inclusive of the proposed new and existing car park.

14

Include training and awareness plan for the wider organisation based upon the identified training needs.

15

Undertake training and awareness for any developed process and procedures.

16

Produce gap analysis report detailing all required changes, upgrades to process, procedures, plans, training requirements, emergency systems etc.

17

Present outcomes of gap analysis.

18

Develop an initial implementation plan, methodology and programme for Phase 2 and 3 based upon the outcomes of the Gap Analysis.

19

Review plans to backup computer records and equipment of vital records.

10.4.4

Phase Two: Implementation (‘to be’)

1

Implement agreed gap analysis outputs/approach inclusive of all manuals, procedures, technical information required.

2

Develop administrative processes and procedures to support the plan.

3

Communicate the plan to all those affected at different level of the business.

4

Include for planning of any associated drills and lessons learnt.

5

Implement lessons learnt into plan, processes and procedures.

6

Establish periodic review of emergency systems.

10.4.5

Phase Three: Future Requirements

1

Advise if engagement of further consultants/engineers to undertake seismic survey of existing buildings.

2

Development of business continuity plans.

3

Development of post-earthquake assessment procedures.

4

Development of crisis management plans.

5

Undertake training and awareness for any developed process and procedures.

6

Include for planning of any associated drills and lessons learnt.

7

Development of all related support materials.

8

Development of coordination procedures with Civil Defence and other authorities during earthquakes.

9

Periodic review of emergency planning systems.

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What Should We Do During An Earth Quake?

1

Stay calm!

2

If you're indoors, stay inside and if you're outside, stay outside.

3

If you're indoors, stand against a wall near the centre of the building, stand in a doorway, or crawl under heavy furniture (a desk or table i.e. cover your head and neck).

4

Drop down onto your hands and knees.

5

Stay away from windows and outside doors.

6

If you're outdoors, stay in the open away from power lines or anything that might fall. Stay away from buildings.

7

Don't use matches, candles, or any flame.

8

Broken gas lines and fire don't mix.

9

If you're in a car, stop the car and stay inside the car until the earthquake stops.

10

Don't use elevators or put yourself at risk.

11

For impaired mobility, if you cannot drop to the ground, try to sit or remain seated so you are not knocked down. If you are in a wheelchair lock your wheels. Protect your head and neck with a large book, a pillow, or your arms.

10.4.7

What Should We Do After An Earth Quake?

1

Check yourself and others for injuries. Provide first aid for anyone who needs it.

2

Check the building, water, and electric lines for damage. If any are damaged, isolate if possible and report to relevant authorities.

3

Turn on the radio. Don't use mobile phones unless it's an emergency.

4

Stay out of damaged buildings.

5

Stay inside buildings unless directed to do otherwise.

6

Evaluate and critique once a crisis situation is stabilised.

7

Expect further aftershocks.

8

Stay away from beaches. Tsunamis sometimes hit after the ground has stopped shaking.

9

If you're at work follow the emergency arrangements and instructions for the particular building after the earthquake.

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10.4.6

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SPECIAL SAFETY REQUIREMENTS AND PRECAUTIONS

10.5.1

Permits

1

A permit-to-work system (Hot work, Excavation, Scaffolding & Electric work) shall be observed (correctly issued, Signed & Client requirement enforced) when undertaking any work on an existing utility, service, item of equipment or structure.

2

A permit-to-enter system shall be observed (correctly issued, Signed & Client requirement enforced) when undertaking any work in a confined space.

10.5.2

Guarantee

1

Where the Contract requires work to be carried out within or adjacent to any pipeline or at a sewage treatment plant, the Contractor shall comply with any requirement of the Public Works Authority.

10.5.3

Mechanical Plant, Machinery and Equipment

1

Sufficient suitable standby plant shall be immediately available in cases where the safety of the Works or of personnel depends upon mechanical plant.

2

Test and thorough examination by a competent person of all equipment that is capable of storing energy, such as air receivers and pressure vessels, is required at periods not exceeding 12 months. Reports of such test and examination will be held on the Worksite and made available to the employer on request.

3

The Contractor will make arrangements for all mobile plant and vehicles that enter the Worksite to be checked by 3rd party certification to ensure the following are provided and in good working order: Braking systems

(b)

Steering systems

(c)

Gauges and warning lights Operating controls

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(e)

Windscreens and wipers

(f)

Reversing alarms

(g)

Rear view mirrors

(h)

Roll over protection devices

(i)

Wheels, tyres, track

(j)

Pneumatic and hydraulic hoses

(k)

Seat belts and anchors

(l)

Fuel lines and tanks

(m)

Electrical control systems

(n)

Suspension and stabilization systems

(o)

Bodywork, covers and panels

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Mobile plant and vehicles that are defective will be removed from use in work areas and taken to a repair facility on the Worksite or removed from the Worksite.

5

Repair work will only be carried out by trained and authorised mobile plant and vehicle repair technicians.

6

Whenever maintenance work is ongoing the machinery or equipment will be isolated and deenergized.

7

All mobile plant and vehicle operators will hold relevant Qatari driving licenses for the category of plant or vehicle that they operate. In addition operators of mobile plant will be in possession of a 3rd party training certificate to verify that they have the skills necessary for safe use of the plant.

8

Operators will use mobile plant and vehicles only in accordance with their operating manuals.

9

The Contractor will conduct a job hazard analysis for each item of machinery and equipment that will be used.

10

The following site rules will be observed by all mobile plant and vehicle operators:

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Mobile plant and delivery vehicles will not be reversed without a banks man in attendance.

(b)

No passengers will be carried on mobile plant or vehicles other that in seats that are specifically designed for carrying passengers.

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The Contractor shall prevent oil / fuel leak causing environmentally pollution.

12

The Contractor will eliminate or reduce the associated hazards for construction lift such as, construction lift failure, falling persons and falling objects by meeting or bettering these specifications. And: All construction lifts will have flat base plates without holes or openings, enclosed sides and roof that are designed to prevent from falling objects. All construction lifts will have overload protection devices that prevent movement of the platform if it is overloaded.

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10.5.4

Existing Utilities

1

Prior to excavating in any area, the location of existing utilities shall be confirmed from asbuilt drawings, contact with utility authorities and trial holes.

2

Excavation in the vicinity of any utility shall be carried out to the requirements of the utility owner.

3

Protection for utilities is the least effective means of controlling any associated risk. Where Contractors use this method the following will be provided: (a)

Marker posts or blocks that clearly indicate the nature, depth and path of all underground utilities.

(b)

Where traffic routes pass over underground utilities temporary protection will be provided. Warning signs stating the maximum vehicle weight that may safely cross the utility will be positioned on the access route at each side of the utility.

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(c)

Temporary barriers or fences that run parallel to the route of any overhead utilities. Warning signs detailing the nature of any overhead utilities on the barriers or fences.

(d)

Where traffic routes pass below overhead utilities warning signs stating the maximum vehicle height and height restrictors will be positioned on the access route at each side of the overhead utility.

Where any construction activity adjacent to a utility is undertaken the minimum clearance distances will be clearly established and communicated to each and every person involved with the construction activity.

5

Traffic routes and material stockpile areas will be clearly identified and established prior to excavation work commencing. All excavation areas, traffic routes and stockpile areas are to be surveyed for overhead services. Any services identified are to be removed or clearly marked with height restrictors and warning information.

10.5.5

Excavations

1

During the planning stage all materials and equipment required for the safe excavation work must be clearly identified. Such equipment and materials may include the following:

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Shoring

(b)

Solid Barriers

(c)

Vehicle stop blocks

(d)

Access ladders or scaffolding

(e)

Ventilation

(f)

Lighting

(g)

Signage

(h)

Pumps

(i)

Generators

(j)

Air Monitoring Devices

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Rescue Equipment

2

For all excavation work a competent excavation supervisor will be appointed. The level of training and experience required to determine competence will vary depending on the complexity of the excavation. He will have previous experience of the type of excavation work to be undertaken and formal Occupational Health and Safety training relating to the safety of excavation work.

3

Temporary safety barriers should be used to protect workers and the travelling public from excavations that are more than 300mm deep in accordance with the Qatar Work Zone Traffic Management Guide.

4

Once the design requirements are known a job hazard analysis of the excavation work will be completed by the excavation supervisor with the assistance of Occupational Health and Safety staff and engineers as required. The Job Hazard Analysis will clearly identify the job specific risks and control measures for the excavation work.

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5

Prior to commencement of any excavation work all persons involved will be given a pre-work briefing based on the Job Hazard Analysis relating to the risks and required control measures for the excavation work. The appointed excavation supervisor will be responsible for presenting and recording the briefing.

6

Prior to commencement of work all materials, plant and equipment will be checked to ensure that they are in good condition. In particular the condition of all mechanical excavators will be checked to ensure that: All windows in the drivers cab are clean, unbroken and unobstructed.

(b)

Rear view mirrors are securely attached, unbroken and clean.

(c)

All track plates and connectors are in good condition and secured with proprietary locking pins.

(d)

All dipper arm joints and attachments are secured with proprietary pins and locking pins.

(e)

All task and indicator lighting is in working order.

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Trucks will only be operated by persons with valid Qatari driving licenses. Plant such as excavators, loading shovels etc shall only be operated by trained and competent operators that hold valid 3rd Party certification for the type of plant being operated. This certification is required in addition to Qatari driving license requirements.

8

When the reversing of trucks is necessary for the collection or delivery of materials a banks man will be in attendance. All banks men will be provided with high visibility clothing and be trained in the safety aspects of reversing vehicles. Where vehicles are reversing up to an excavation or travelling alongside an excavation vehicle stop blocks or vehicle barriers will be provided to prevent them falling into the excavation.

9

Continuous adequate solid barriers will be placed around all excavations over 1.2m deep at a distance at least of 1.2m. Where night time pedestrian or vehicle access is adjacent to excavation then all solid barriers will be fitted with warning lights.

10

Pedestrian access to and from all excavations will be by means of ladder or adequately constructed staircases. The possibility of a person falling from a height of more than 2m from the access will be prevented. The horizontal distance between access points will not exceed 15m.

11

All ladders used on the Project will be manufactured in accordance with an internationally recognised standard. Any ladder that is found to be defective will be removed from use immediately.

12

All straight ladders will be positioned at an angle to minimize the risk of slipping or falling backwards. The distance between the base of the vertical plane and the base of the ladder will be 1 unit out for each 4 units in height of the vertical plane.

13

Ladders that are used to gain access from one level to another will extend at least 1m above the upper level surface. Where a general access ladder run extends a distance of more than 6m a landing point with a firm level platform and fall prevention measures will be provided at each and every 6m.

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Excavations shall be kept clean and tidy at all times. Accumulated waste and unused materials will be removed from excavations on a daily basis. All excavations will be thoroughly cleaned prior to any backfilling operations commencing.

15

To prevent the risk associated with falling objects excavated materials, other materials and equipment shall not be stored at the edge of any excavation. A clear distance of 2m shall be maintained around all excavations.

10.5.6

Warning Signs

1

The Contractor shall set up and maintain (cleaned and legible) throughout the course of the Contract enough traffic diversion signs in accordance with the Qatar Work Zone Traffic Management Guide and additional warning signs & guides.

2

Additional areas that require warnings signs and barriers are: Excavations over 1.2m deep

(b)

Any edge, opening or platform from where a person may fall more than 2m

(c)

Electrical transformers and substations

(d)

Confined space entry points

(e)

Areas below and around working at height and heavy lifting operations

(f)

Areas of open water more than 1m deep

(g)

Areas where flammable goods are stored

(h)

Areas where radiation sources are used or stored

(i)

Areas within Worksites that are classed as non-construction areas

(j)

Areas within non construction areas where construction activity is on-going

(k)

Areas below overhead utilities

(l)

Areas above underground services

(m)

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Areas where test and commissioning activities are on-going

Warning signs will clearly state the nature of the hazard and instruct people of the correct actions to take. Warning signs will be manufactures in accordance with internationally recognised standards. All signs will be in English, Arabic and the languages preferred (can be understand) by the workers on the Worksite.

4

All safety barriers and barricades are to comply with the Qatar Work Zone Traffic Management Guide..

10.5.7

Confined Spaces

1

Entry into a confined space will only be permitted where a competent person is appointed to directly supervise the work. The competent person will hold a certificate of training or license that is issued by a 3rd party. The competent person will be appointed in writing by the Contractor and the appointment will be copied to the employer.

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Any person that enters into a confined space will have received formal training in the safe methods of entry and working in a confined space. Such training will include the arrangements for emergency communication and response. In addition every person that enters into a confined space will be given a briefing by the appointed competent person relating to the specific hazards of the work and the control measures that have been detailed in the job hazard analysis.

3

Any person that acts as an attendant for confined space work will have received formal training in the safe methods of rescue from a confined space and the arrangements for emergency communications with external emergency services.

4

The contractor will only permit trained workers, under the direct supervision of an authorised competent person, with confined space attendants present, to enter a confined space.

5

Internal combustion engines will not be taken into a confined space or operated in a position where their exhaust gasses may be drawn into the confined space.

6

Persons entering into a confined space will wear a full body rescue harness that is attached to a rescue line anchored outside the confined space

7

The contractor will implement a safe working procedure for confined space entry that includes the following: Preparation of a confined space entry permit

(b)

Provision of all equipment necessary for entering into and working in the confined space including access, lighting, mechanical ventilation, gas detectors, communication, personal protective equipment and emergency rescue equipment. All such equipment will be manufactured in accordance with internationally recognised standards

(c)

Provision of warning signs and barriers around the confined space entry point

(d)

Setting up emergency communication and rescue equipment

(e)

Issue of a permit to enter the confined space

(f)

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Checking of the atmosphere inside the confined space and installation of ventilation equipment

(g)

Installation of lighting

(h)

Entry into and work in the confined space.

(i)

Monitoring of conditions in the confined space.

(j)

Continuous checking and recording of all persons entering into and exiting from the confined space by the confined space attendant

(k)

Completion of work and removal of all equipment from the confined space

(l)

Accounting for all persons and equipment that entered the confined space

(m)

Securing the entry point to the confined space

(n)

Closing the confined space entry permit

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Lifting Operation

1

The Contractor will appoint a competent lifting operations supervisor for the Worksite. The lifting operation supervisor will ensure that the requirements of this specification are met at all times.

2

Rigging of loads and signalling of cranes will be undertaken only by trained and competent persons. All riggers will be required to wear a blue construction safety helmet and a red high visibility vest for the purpose of easy identification on the Worksite.

3

Cranes will only be operated by trained and competent operators who are in possession of an operator’s license issued by a 3rd party. In addition appropriate Qatari driving licenses are required for all mobile equipment’s.

4

A thorough examination of each lifting appliance will be made by a 3rd party inspector at periods not exceeding 12 months and after substantial re-erection, alteration or repair. Load capacity to be displayed.

5

All lifting appliances on the Worksite will have a copy of the manufacturers operating manual and load rating charts available for use and kept with the operator cabinet or machine.

6

Before a mobile crane is positioned for a lift, attention will be paid to the condition of the ground upon which the crane will stand, as this will be subjected to high point-loadings from outriggers or tyres. Dependent upon the nature of the ground and/or the size of the crane to be used, a special hard standing may have to be prepared.

7

The maximum safe working wind speeds for all construction activity and in particular lifting operations and Working at height activity is 25 Knots. The construction will monitor the weather conditions and suspend work when wind speeds in excess of the maximum safe working speeds are anticipated.

8

Outriggers will be properly set and locked if a locking device is provided. When controlled remotely from the cab, the operator will make a physical check to ensure that each pad has an adequate bearing before a load is lifted. Sound timber packing or metal plates will be used under each outrigger pad to distribute the load. It is essential that outriggers are supported at the jacking points and not under the outrigger beams. Also, lifting location to be barrier off.

9

A method statement and job hazard analysis will be provided to the Engineer for all structural steel erection activity. No structural steelwork erection will commence prior to approval of the method statement and job hazard analysis by the Engineer. All structural steel erectors will be fully conversant with the construction method, sequence and hazard control measures prior to any work activity commencing.

10.5.9

Lifting Gear

1

Lifting gear means any chain sling, rope sling, or similar gear, and any ring, link, hook, plate clamp, shackle, swivel or eye bolt, used on the Worksite.

2

All lifting gear will be subjected to a thorough examination by a competent person from 3rd party at intervals not exceeding 6 months. Identity number and SWL to be check.

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10.5.8

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3

A wire rope used in raising, lowering or suspension of a load, will not be used if it is kinked, significantly rusted, the core is visible or the rope has visible broken wires, exceeding 5% of the total or in any length equal to 10 times the diameter of the rope.

4

Riggers will check the condition of lifting gear prior to each and every lift.

5

Any lifting gear that is found to be defective will be removed from service and sprayed with red paint to indicate that it is not to be used. All defective equipment will be removed from the Worksite.

6

A system will be established on the Worksite for storage of all lifting equipment not regularly in use. Such equipment will not be left in the work areas.

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10.5.10 Scaffolding For all scaffolding construction activity and dismantling activity a competent scaffolding supervisor will be appointed. The level of training and experience required to determine competence will vary depending on the complexity of the scaffolding structure to be erected or dismantling. Industry standards and codes detail competency requirements.

2

All employees involved in scaffolding construction activities and dismantling activity will be trained in the safe methods of working and in particular the manner in which fall prevention or arrest is to be achieved. Contractors will maintain detailed information of the training provided and the methods that they have used for assessment of competency and suitability for all employees undertaking scaffolding construction activities.

3

All scaffolding erection areas and dismantling areas will be provided with barriers and warning signs to exclude all personnel that are not specifically involved with the scaffolding construction and dismantling activity. Where such areas are adjacent to roadways barriers with a capability to prevent vehicles entering the area will be erected or dismantling. Where such areas are adjacent to members of the public or 3rd parties then screening and falling object protection will be provided. The appointed scaffolding supervisor is to be made responsible for ensuring that exclusion zones are in place and maintained at all times whilst scaffolding construction and dismantling activity is on-going.

4

All materials being used for scaffolding construction will be checked prior to them being used to ensure they are in good condition. Any materials found to be defective will be clearly marked as defective and discarded or removed from the construction area to ensure that they are not used.

5

Scaffolding that has been constructed in accordance with the design will be inspected for use by displaying green scaff tag at all access points of the scaffolding detailing the following information:

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(a)

the unique identification and location of the scaffolding inspected

(b)

the name of the person making the inspection

(c)

the date that the inspection was completed

(d)

the intended use and capacity of the scaffolding

(e)

the required re-inspection frequency for the scaffolding

The person making the scaffold inspection will maintain written details of the inspection that they have conducted to enable them to verify their scaff tag system.

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All scaffolding that does not display green scaff tag for use will be fitted with red scaff tag states that the scaffolding is not fit for use and the access points will be removed or made unusable.

8

Users of scaffolding will at all times conduct their work in a manner that eliminates the possibility of falling objects.

9

Users of scaffolding are to be prohibited from altering or dismantling any part of scaffolding.

10

Users of scaffolding are required to maintain unobstructed access and egress at all times. All debris and materials no longer required will be removed from scaffolding on a daily basis. All materials and equipment used on scaffolding will be stored in a manner that does not obstruct the free movement of the people using the scaffolding.

11

The frequency of re-inspection of scaffolding – every 7(seven) days – will be displayed on the green scaff tag. Users of scaffolding are required to check that the period of re-inspection has not been exceeded before using the scaffolding. In any case where the re-inspection date has been exceeded the user will request the appointed scaffolding supervisor to make the re-inspection and to re-sign the green scaff tag for use. The user will not access the scaffolding until such time as the re-inspection has been made.

12

Before any dismantling activity is undertaken on scaffolding it will be removed from use. All green scaff tag will be removed and replaced with red scaff tag which is not fit for use and all scaffolding access points will be removed or made unusable.

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The contractor will only use electric welding equipment in accordance with the following requirements: Welding cables and equipment will be properly maintained and inspected before use. Defective equipment will be removed from use and arrangement for repair will be made.

(b)

Electric welding cables are to be kept as short as possible and routed away from pedestrian walkway areas.

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(d)

All connections between welding equipment and welding cables will be securely bolted.

(e)

Pipelines containing flammable liquids or gases, or electrical cables will not be used as a ground.

(f)

When electrode holders are to be left unattended, the electrodes will be removed and the holder placed where it is protected from unintentional contact.

(g)

A fire resistant container will be provided for spent electrode stubs.

(h)

Welding machines will be turned off when being moved or when the equipment is not in use.

Electric welding operations will only be undertaken with earth return electrodes connected to the work piece.

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10.5.11 Hot work and Welding

2

Tanks, vessels and drums that have contained flammable or toxic liquids will be filled with water or thoroughly cleaned before hot work or welding is undertaken on them.

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3

Where coatings are present on materials to be heated the coating will be removed to prevent the coating being heated.

4

Suitable portable fire extinguishing equipment will be located within 6 meters of any hot work location.

10.5.12 Compressed Gas Cylinders The Contractor will only use compressed fuel gasses in accordance with the following requirements; Cylinders will not be transported with regulators, gauges and hoses attached.

(b)

Cylinders will be transported in an upright position and will not be hauled in equipment beds or truck beds on their side.

(c)

Cylinders lifted from one elevation to another will be lifted only in racks or containers designed for that purpose. Cylinders will not be hoisted by the valve cap or by means of magnets or slings.

(d)

Cylinders will not be used as, or placed where they may become part of, an electrical circuit.

(e)

Cylinders will be protected from extreme heat and from being struck by moving equipment and falling objects.

(f)

Cylinders will not be taken into a confined space.

(g)

Cylinders will not be used as rollers; will be transport on appropriate trolley.

(h)

Damaged or defective cylinders will not be used or be permitted to remain on the Worksite.

(i)

Type of gas clearly marked on cylinders and segregation of incompatible gases is required.

(j)

Oxygen cylinders will be kept free of oil and grease.

(k)

Cylinders will be secured in place during use and storage. Securing shall be around the body of the cylinder, securing around the cylinder neck or cap will be prohibited.

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Cylinder valves will be closed at all times when cylinders are not in use.

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A key wrench is required to be in place on the valve of acetylene cylinders at all times during use.

(n)

Fuel gas and oxygen hoses will be of different colours and will not be interchanged.

(o)

All hose, valve and regulator assemblies will incorporate a flashback arrestor.

(p)

Hoses are to be kept as short as possible and routed away from walkway areas.

(q)

Under no circumstances are damaged hoses or torches to be used.

(r)

Torches will be ignited by friction lighters or other approved devices only.

(s)

Fuel gases will only be used for the purposes of cutting or heating. They will never be used for pressure testing or ventilation.

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10.5.13 Working at Height Contractors are required to reduce the risk of persons falling from height by providing a means of fall prevention or arrest for every person on the Worksite that is exposed to a risk of falling a distance of 2m or more.

2

Supervisors of persons using fall arrest systems will be trained in the correct installation, use and maintenance of fall arrest systems. Training will be provided by a 3rd party. All persons required to use fall arrest systems will receive formal training in safe working at height prior to using such systems.

3

The use of safety belts as part of a fall arrest system is prohibited.

4

Safe access to the point at which a person will attach themselves to a fall arrest system will be provided. In cases where a person using a safety harness has to detach the lanyard from the anchor point and reattach it to a different anchor point, whilst being in a position where the risk of falling exists, double lanyards will be used with one of the lanyards remaining attached to the anchor point at all times.

5

Where any form of fall arrest system is used the contractor will put in place arrangements to rescue any person that is caught by the fall arrest system. The rescue system and equipment will be capable of rescuing any person that may be unconscious whilst suspended and or suffering from suspension trauma. The system will be capable of rescuing the suspended person within 3 minutes of the fall being arrested.

6

All edges of working platforms and work areas that objects may fall from will be provided with securely fixed continuous toe boards that are at least 200mm high.

7

All holes and openings in floor areas will be fitted with temporary covers to prevent objects falling to lower levels of the structure.

8

Where work is on-going on the exterior faces of structures the working platforms that are used to gain access will be fitted with lightweight mesh or netting to prevent objects falling from them.

9

Materials and equipment will not be stored or located within 2m of edges of working areas or platforms.

10

All materials and waste that may be blown by the wind from raised structures will be secured and stored in a manner that prevents them from being blown from the structure.

11

Where designated pedestrian walkways, entrances or exits are located beneath edges or openings where work is on-going steel framed and sheeted canopies will be erected to protect pedestrians from falling objects.

12

The contractor will produce a method statement and job hazard analysis for all roof and canopy work activity. For work on new structures safety information will be obtained from the designers and incorporated into the method statement and job hazard analysis. For work on existing structures where design information is not available then a survey of the existing structure will be made to identify hazards such as:

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Fragile coverings

(b)

Holes and openings

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(c)

Exposed edges

(d)

Lack of safe access

(e)

Damage or disrepair of the existing structure

(f)

Adjacent structures, facilities or services

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A method statement and job hazard analysis will be provided to the Engineer for all roof and canopy work activity. No work will commence prior to approval of the method statement and job hazard analysis by the Engineer. All roof and canopy installation workers will be fully conversant with the construction method, sequence and hazard control measures prior to any work activity commencing.

14

The contractor will meet the following roof and canopy work specific Occupational Health and Safety requirements:

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The storage of materials on roof surfaces will be minimized at all times

(b)

Storage of materials on roof surfaces is not permitted within 2m of any edge or eave

(c)

All openings and non-walkable areas will be protected by barriers and signage to prevent pedestrian access

(d)

All waste will be removed from the work areas on a daily basis and prior to any areas being left unattended

(e)

All areas of roof or canopy covering will be fully fixed at the time of positioning. The practice of laying large areas of unfixed coverings is prohibited

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The structure that the suspended working platform is attached to or mounted on will be surveyed and assessed to ensure that it is capable of supporting the loads that the equipment will impose on it.

16

The installation, maintenance, use and dismantling of suspended working platforms will be under the control of a competent person that is appointed by the Contractor. The competent person will be fully familiar with each and every type of suspended working platform in use on the Worksite. Persons who work from suspended working platforms will have received formal training to ensure the safety of themselves and of other persons that may be affected by the operation with particular emphasis on the correct use of the equipment, working at height and falling object prevention.

17

The following requirements will be met for all use of suspended working platforms;

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(a)

Users will not alter or interfere with any part of the suspended working platform, control or safety devices.

(b)

The work area below the suspended working platform will be clearly marked a pedestrian exclusion zone will be created.

(c)

The user will check all controls and safety devices on a daily basis to ensure that they are functioning correctly.

(d)

Use will cease whenever wind speed in excess of the maximum permissible is anticipated.

(e)

The suspended working platform will be maintained in a horizontal position whilst it is in use.

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(f)

The practice of transferring people or materials from the suspended working platform is prohibited other than at the designated access points.

(g)

Every person working from a suspended working platform shall wear a full body safety harness that is attached to an independent lifeline.

(h)

The platform will be kept free of loose materials or articles liable to endanger or interfere with the worker’s hand hold or foot hold

(i)

The power supply will be disabled whenever the suspended working platform is left unattended.

10.5.14 Electrical This specification applies to all temporary electrical systems on the Worksite and all electrical equipment used for construction, commissioning and testing purposes. The requirements given are minimum requirements and Contractors are required to equal or better them.

2

A competent electrician or electrical engineer will be appointed or employed on every contract. The competency requirements will be determined by the nature of the temporary electrical system that will be installed on the Worksite

3

The Contractor will reduce risk by using cordless tools or electrical equipment that is operated at reduced voltages. Only intrinsically safe electrical equipment will be permitted for use at any location where flammable atmospheres may exist or confined space.

4

All electrical equipment used on the Worksite will be manufactured in accordance with an internationally recognised standard.

5

Portable Power Tools will be of a double insulated type.

6

Jointing of all electrical cables and wires shall be by means of proprietary terminations or connectors. The practice of twisting and taping electrical components together to create a connection is prohibited.

7

Temporary power supplies for the Worksite may be provided from generators or via a Worksite specific transformer connected to the national power network. All generators and transformers on the Worksite shall be located in areas that are fenced and secured to prevent any unauthorized entry. Each such location will be provided with portable fire extinguishers. All electrical systems shall be bonded to the earth.

8

All electrical circuits that are created will be protected by earth leakage circuit breakers (ELCB). All metal components of an electrical system shall be earthed. Distribution of electrical power shall be provided through distribution panels and switches that are enclosed or housed in securely closed and locked boxes or cabinets.

9

Warning signs that clearly indicate electrical hazards shall be fixed to all electrical switch boxes and distribution panels. Similar signs shall be displayed at all transformers, generators and overhead power line locations.

10

All signs and notices shall be in English and Arabic and the language preferred (can be understand) by the workers employed on the Worksite.

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All electricity supply cables shall be buried or properly supported and protected and shall be armoured. Flexible cable shall only be allowed for hand lamps and hand held tools and shall not exceed 6 metres in length. Industrial type plugs and sockets shall be used. All electrical installations shall be in charge of a competent person who shall accept full responsibility for its use and any alterations or additions thereto. The name, designation and telephone number of such person shall be prominently displayed close to the main switch or circuit breaker of the installation, and also in the Contractor’s site office.

10.6

FIRST AID

10.6.1

First Aid and Clinic

1

The Contractor shall provide and maintain first aid Boxes / Clinic (according to number of workers as per Qatar Law No.14 of the Year 2004 – The Labour Law) complete with all first aid kits and equipment (as a minimum but not limited to Clean room with potable water supply, Stretcher, Ambulance, Standby Vehicle, ... etc) necessary for the initial care of any of the Contractor’s or Engineer’s personnel who may be injured.

2

The box shall be kept in a conspicuous place in the establishment and shall be available to the workers.

3

The use of the box shall be entrusted to a worker trained in providing first-aid medical services.

4

As a minimum, there should be a first aid box with Medical record book in all areas where work is in progress.

5

The Contractor shall ensure that the first aid Kits and equipment at each first aid box / clinic is complete and within expiration date in all respects at all times.

6

At each first aid box / clinic the names and contact Telephone numbers of the Contractor’s staff who are trained to render first aid shall be displayed.

7

The Contractor shall provide and maintain Periodic medical examinations for workers and follow up (maximum every year from employment date).

10.7

FIRE PRECAUTION AND PREVENTION

10.7.1

General

1

The Contractor shall take all necessary precautions against fire as required by the insurance company insuring the Works, the Department of Civil Defence and the Engineer.

2

Quantities of flammable materials on site shall be kept to an absolute minimum and shall be properly handled and stored. Any handling and storage recommendations made by Material Safety Data Sheet (MSDS) and the manufacturers of flammable materials shall be strictly adhered to.

3

All flammable materials storage areas will be located at least 20m away from other structures, areas where combustible materials are stored and areas where sources of ignition are found. Storage areas will be freely ventilated to eliminate any possible build up of flammable vapour or gas. Flammable material storage facilities will not be constructed of combustible materials.

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Except as otherwise provided herein, the Contractor shall not permit fires to be built or open type heating devices to be used in any part of the Site.

5

The Contractor shall provide, regularly checked and maintain approved by Department of Civil Defence fire fighting equipment in the site offices, the stores and about the Works where applicable. The type, amount and location of fire fighting equipment shall be to the requirements of the Department of Civil Defence. The Contractor shall confirm to the Engineer in writing that the requirements of the Department of Civil Defence have been met.

6

The Contractor shall make arrangements with the Department of Civil Defence to inspect the Works and promptly carry out their recommendations at his own expense if requested to do so by the Engineer.

7

Combustible fuel oils shall be stored in designated storage areas. Fuel oil shall only be contained in tanks or containers that are in good condition. Tanks and containers will be located in bounded areas capable of containing any spillage or leak. Bounded areas will be kept free of water and debris. All pump equipment and fuel oil lines or hoses will be maintained regularly to ensure that there no leaking parts. Fuel oil lines and hoses will be terminated with filler nozzles or valves that stop the flow of fuel oil when the device is not held. Any electrical equipment such as lighting and pumps that is located in fuel oil storage areas shall have an operating voltage of 110V or less.

8

Hot work and welding operations at height require particular controls to prevent people or materials below being exposed to the risks of the work activity, the following controls will be put in place;

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All work activity will be coordinated with other activities in areas below

(b)

Areas below will be cleared of all combustible and flammable materials.

(c)

Fire blanket / Fire retardant material will be used to cover any combustible materials that cannot be cleared.

(d)

Fire blanket / Fire retardant material must be removed after hot work and welding activities are completed.

(e)

A fire watchman will remain at the site of hot work activity for 30 minutes after work is finished.

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The Contractor will provide training in the correct selection and use of portable fire extinguishers for every person employed at the Worksite.

10

Portable fire extinguishers will be provided at the following locations:

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(a)

Every electrical generator, transformer and main distribution panel

(b)

Every piece of mobile plant and equipment

(c)

Every area of flammable materials storage and use

(d)

Every area of hot work activity

(e)

Every temporary structure

(f)

Every work area where combustible materials are present.

Smoking will be prohibited in any areas where flammable or combustible materials are stored. It will also be prohibited in any temporary structure other than in clearly designated and defined smoking areas. Smoking areas will be cleaned on a daily basis, a means of extinguishing cigarettes will be provided.

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Fire escape routes, exits and assembly areas will be provided for all enclosed temporary structures and permanent structures under construction. All such areas will be kept free from obstructions at all times. Wherever possible in permanent structures under construction the fire escape routes, exits and assembly areas used will be those designed for use in the occupied structure.

13

Information and warning signs will be provided at the following locations or areas: Flammable materials stores

(b)

Combustible materials stores

(c)

Temporary fire systems

(d)

Portable fire extinguishers

(e)

Fire escape routes, exits and assembly areas.

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The Contractor shall make all arrangements to keep access for Fire Brigade cleared and Emergency Alarms audible in all areas.

10.7.2

Emergency Equipment

1

Temporary fire protection equipment for the Worksite will be provided by the Contractor for the duration of the contract. Such equipment may include but is not be limited to: Portable fire extinguishers

(b)

Fire sand buckets

(c)

Fire water storage and distribution systems

(d)

Fire suppression systems

(e)

Fire / Smoke / Gas detection systems

(f)

Fire warning / Alarm / Emergency Evacuation systems

(g)

Procedures

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(j)

Torches

(k)

Loud Hailer

(l)

Emergency lighting

(m)

Adequate and safe Emergency Exit / Doors are provided

(n)

Assembly / Muster point

2

Escape routes, access ways to alarm points, extinguishers, hydrants and other fire fighting equipment and first aid kits kept clear of obstruction at all times

3

All structures that are normally occupied by five to twenty five people will be provided with the following: (a)

Portable fire extinguisher equipment.

(b)

First aid kit.

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(c)

Trained first aider.

(d)

Emergency contact information notices.

(e)

Telephone or radio communication equipment.

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All temporary facility structures that are normally occupied by twenty five to one hundred people will be provided with the above plus the following: (a)

Smoke detectors

(b)

One first aid kit for each 25 people.

(c)

Designated emergency evacuation routes.

(d)

An emergency preparedness and evacuation plan.

(e)

An emergency alarm system.

(f)

An emergency evacuation drill at periods not exceeding 6 months.

(g)

An area set aside for the heating and consumption of food.

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All temporary facilities structures that are normally occupied by more than 100 people will be provided with the above plus the following: A fire water system

(b)

An appointed nurse

(c)

Emergency lighting system

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All temporary fire protection equipment will be manufactured, inspected, tested and maintained in accordance with the Department of Civil Defence or internationally recognised standards.

10.7.3

Hazardous Substances

1

The Contractor will control the use, handling, transportation and storage of hazardous substances to reduce the associated health risks. These requirements below are the minimum that the Contractor will meet to comply with their contractual Occupational Health and Safety obligations.

2

Radioactive materials are hazardous substances and any use of such materials on Site will require a method statement and job hazard analysis to be submitted to the Engineer for approval prior to any radioactive material being delivered to the Worksite.

3

Where any spillage of liquid occurs the contractor will take action to immediately clean the spillage and remove any contaminated materials from the Worksite.

4

To effectively control the hazards associated with the use, storage, handling and transportation of hazardous substances the Contractor will:

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(a)

Maintain a register of all hazardous substances on the Worksite

(b)

Obtain Material Safety Data Sheets for all hazardous substances

(c)

Make an assessment of the health risks associated with the intended use of each hazardous substance

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(d)

Provide the control measures required to reduce the risks identifies to acceptable levels. Acceptability will be based on internationally recognised best practices and standards

(e)

Train people that use, handle or transport hazardous substances in the associated risks and control measures

(f)

Provide routine health checks for employees that are exposed to hazardous substances

(g)

Provide appropriate spill containment and disposal Spill kit

(h)

Toxic/ hazardous substance correctly tagged/ labelled/ signage and secured

(i)

Adequate storage provided and Class B fire extinguisher near by

SAFETY OF THE PUBLIC

10.8.1

Working in Public Areas

1

The Contractor must ensure that control measures are in place to protect the public, workforce and assets by providing appropriate lighting, fencing, barricades, and lockable units. Adequate levels of security including the use of trained security guards will be required. The Contractor must also ensure appropriate warning signage is displayed and where appropriate safe pedestrian walkways are identified and maintained.

2

Safety and security procedures shall be implemented in accordance with the Qatar Work Zone Traffic Management Guide and as required by the Department of Civil Defence and the police. These shall be included, as a minimum, warning signs and lights, adequate barricades, railings, road hump for reduced & control speed and other safeguards as required by the nature and location of the work being undertaken.

3

Access to all properties shall be maintained by adequately sign posted diversions, temporary bridges or other facilities.

4

A night watchman shall be assigned to ensure that all barricades, lights and other protective apparatus are maintained during the hours of darkness.

5

Designated pedestrian routes will be clearly signed and with firm even surfaces that are free from distractions. Where such routes traverse level changes they will be slopped at gradients not exceeding 10% or cut with steps of even height and a tread width of at least 400mm. Slopes and steps will have anti-slip surfaces. Where the edges of pedestrian routes are raised more than 1.2m above the surrounding level solid barriers will be provided at each raised edge to prevent people from falling.

6

All such equipment shall be routed away from pedestrian access areas. Where such equipment crosses pedestrian areas it will be located under the pedestrian area or over it at a height of at least 2.5m above the surface. Where such equipment is routed over a pedestrian area it will be clearly marked with warning signs.

7

No electrical cables, hoses or pipes shall be routed along any staircase, ladder access or across any doorway. This applies to both temporary and permanent works.

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Contractor shall provide Client with photocopies of passports, police clearances and any similar personal security documentation necessary to obtain Client temporary identification cards and passes for Contractor Personnel to enter Client STP / PTP / premises. Contractor shall ensure that Contractor Personnel display such identification at all times when they are on Client STP / PTP / premises.

9

The Contractor will provide a method statement and job hazard analysis for all demolition and dismantling activities. Everyone involved in the work needs to know what measures are to be taken to control the risks and a pre work briefing based on the method statement and job hazard analysis will be given and recorded by the supervisor. Workers will be closely supervised to ensure that the control measures required are put into practice. An exclusion zone will be created around the demolition or dismantling area to prevent persons not directly involved with the work activity around the work area gaining access. The Contractor will not allow materials to fall into any area where people are working or passing through. Protection screens, fences or canopies may be needed to control falling objects.

10.9

WELFARE, SAFETY AND PROTECTION OF WORKMEN

10.9.1

General

1

The Contractor must make arrangements for suitable welfare facilities to be present from the start of the work. There are specific requirements for provision of welfare facilities in the (Section 11, Part 1 Regulatory Document, 1.1.8, Appendix 1)

10.9.2

Personal Protective Equipment (PPE) / Attire

1

All the Contractor’s personnel shall be provided with safety helmets, eye protection and foot protection. Safety helmets, eye protection and foot protection shall be worn at all times by all Contractor’s personnel on the Site except.

2

All the Contractor’s personnel shall be provided with gloves, hearing protection, safety reflecting vests, dust mask and other protective clothing suitable for the nature of work they are performing and their working environment (Shorts and sleeveless shirts are prohibited).

3

All the Contractor’s personnel shall wear high visibility clothing as the outer layer of clothing at all times when working on a road or within a road works zone in accordance with the Qatar Work Zone Traffic Management Guide.

4

The need for other types of PPE will be identified by the contractor as part of their job hazard analysis or risk assessment process.

5

The Contractor will display signage detailing the requirements for mandatory PPE throughout to Worksite. Signage shall be in a format that is easily recognisable to all persons on site regardless of their preferred language.

10.9.3

Safety Equipment

1

Construction equipment must only be used in the manner and limitations for which it is designed, inspected regularly with colour code sticker and Qatar license for driver / operators must be available.

2

Adequate hard barricading, temporary bridges, temporary footpaths, lighting, warning tape and sign posting shall be provided at all excavations.

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3

Adequate bracing and shoring shall be provided at all excavations. 2m spoils clearance from the excavated pit and sloping shall be maintained (if applicable).

4

Correctly made ladders must be provided for access into excavations and onto scaffolding and buildings. Contractor’s self-made ladders shall not be used.

5

Scaffolding shall be erected in accordance with the international recognize standard, best practises and manufacturer’s recommendations and shall be fitted with toe boards, guardrails (top & mid rail), proper access, fully boarded platforms, tagging system and hand railing (refer to 10.3.10).

6

The following basic safety equipment is required for any works in confined spaces and shall be supplied by the Contractor: gas detectors/monitors complete with carrying case, rechargeable batteries and battery charger, calibration kit, all to the approval of the Engineer; consumable items and sensors to be replaced in accordance with the manufacturer’s recommendations during the course of the Contract (2 No.)

(b)

full body rescue safety harness with lifelines and shackles (6 No.)

(c)

lifting frame complete with fall arrest device (1 No.)

(d)

constant flow escape breathing apparatus complete with storage cases (2 No.)

(e)

automatic positive pressure self-contained breathing apparatus complete with storage case (1 No.)

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The Contractor shall maintain all safety equipment in good working order with up to date calibration and test certificates where appropriate.

8

The Contractor shall ensure that any personnel working above 2 m using fall protection devices with valid 3rd party certificate and to provide them proper training in the selection and use of fall protection devices.

9

The Contractor shall provide and maintain in good working order one compressed air escape respirator set (Dräger “Saver Auto PP” or similar) in the Contractor’s site office.

10

One oxygen resuscitation unit shall be provided in the Contractor’s site office.

11

Truck or Trailer Mounted Attenuators (TMAs), or lorry mounted crash cushions must be used in accordance with the Qatar Work Zone Traffic Management Guide.

10.9.4

Support Facilities for Contractors Staff and Labour

1

The Contractor shall provide, regularly clean and maintain for the duration of the Contract potable water, washing facilities and sufficient Toilets (with steel exhaust fan) & sanitary facilities for use by workmen in accommodation areas, at messing facilities and in areas where work is in progress.

2

The Contractor shall provide and maintain for the duration of the Contract messing facilities and a separate designated area for the consumption of food for his staff and labourers.

3

Cooking and dining facilities that are provided will be operated and maintained in a clean and hygienic condition. Food preparation and storage areas will be separated from eating areas.

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(a)

No person with any communicable disease will be permitted to work in any kitchen or dining room

(b)

Kitchen workers who have cuts or skin conditions on their hands will not be permitted to work in any kitchen or dining area

(c)

Kitchen workers that handle or serve food will wear latex gloves, hairnets and clean clothing.

When allowed for in the Project Documentation, the Contractor may provide accommodation facilities for his staff and labourers at the Site. Such facilities shall be maintained in a proper manner and to the satisfaction of the appropriate government departments and the Engineer.

5

The Contractor shall provide transportation between staff accommodation and areas of work for his staff and labourers.

6

The Contractor shall provide sufficient bins for waste and scrap regularly collected, segregated and removed from site.

7

Arrangements for the temporary storage of waste on site shall be made in clearly designated and defined areas that have fences and signs to clearly indicate the nature of the waste where combustible wastes are stored portable fire extinguishers will be provided.

8

Waste collection points will be provided throughout the work areas and will be clearly marked with signage to indicate the nature of the waste that is to be collected. Waste will be separated and collected in the following categories: Metals

(b)

Oils

(c)

Concrete & Stone

(d)

Tyre & rubber

(e)

Glass

(f)

General

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Where temporary facilities are created for the storage of materials and equipment such areas shall be clearly defined and fenced. Notices will be displayed to indicate the nature of the storage area. (a)

Any hazardous substances that are stored shall only be kept in accordance with the supplier’s recommendations and the requirements of the Hazardous Substances Specifications.

(b)

Flammable materials and fuel oil storage areas must be separated from other temporary structures or works under construction by a distance of 30m.

(c)

Where materials are stored in stacks they will not be stacked to a height of more than 1.5 m where the materials are to be manually handled. Materials for mechanical handling that are on pallets or contained in bins will not be stacked more that 3 units high with the base bin or pallet being on firm level ground.

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Circular materials such as pipes and tubes will be stored in a manner that prevents item from rolling. They will be placed in a container or frame, or have timber wedges of an adequate size inserted between the materials and the ground to prevent rolling.

The Contractors will make arrangements to maintain an adequate working environment and take into account the requirements of this specification to fulfil their contractual obligations relating to Occupational Health and Safety. Adequate arrangements will be based on internationally recognised standards. Ergonomics and proper layout of work area.

(b)

Darkness or poor visibility increases the risk of persons on the Worksite slipping, tripping or falling. It also increased the risk of operator error for plant, vehicle, machinery and equipment operations. To reduce such risks the Contractor will provide the following:

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(a)

Temporary lighting for all Worksite access areas and roads that will be used during the hours of darkness.

(ii)

Task lighting for all work activity at night or in areas with poor visibility.

(iii)

Emergency lighting for pedestrian access routes in areas of poor visibility and those used during night time working.

(iv)

Ensure the absence of glare.

(v)

Proper lighting in corridors.

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Summer Working Conditions and fatigue

1

During the period from June 15th until August 31st, work under direct sun rays is prohibited from 11:30 am to 3:00 pm unless special arrangement is taken by the Contractor to control and ease effect of the direct sun on the workers. This arrangement should be approved by the Engineer’s Representative and should be agreed upon before implementation.

2

High outdoor temperatures expose persons on the Worksite to the risk of dehydration. The Contractor will provide shaded rest areas, rest periods and drinking water supplies for all persons on the Worksite.

3

Sunlight exposes persons on the Worksite to the risk of skin disorders. Employers will provide work wear that covers the skin for employees working in direct sunlight. Sunlight may also cause glare for operators of mobile plant, vehicles, machinery and equipment which increases the risk of operator errors. The Contractor will provide shaded operating positions to reduce such risks.

4

Contractor shall develop suitable management arrangements to control working hours and/ or shift patterns in order to address and manage the risk of fatigue.

10.9.6

Additional Environmental Protection and Pollution Control

1

The Contractor shall comply with all conditions of Environmental Clearance issued for the Contract by the Ministry of Environment (MoE), and also where relevant, the predecessor to the MoE, the Supreme Council for the Environment and Natural Reserves.

2

The Contractor shall comply with all rules and regulations regarding environmental protection and pollution control issued by the MoE, and also where relevant, the predecessor to the MoE, the Supreme Council for the Environment and Natural Reserves.

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Plant and Equipment Test Certificates

1

Cranes, whether used to construct the Works or provided as part of the permanent Works, must have a current test certificate.

2

Each sling, shackle or other item of loose lifting tackle, whether used to construct the Works of provided as part of the permanent Works, must have either a current manufacturer’s test certificate or a current test certificate.

3

Test certificates must be issued by a competent testing authority approved by the Engineer.

4

The Contractor must have a copy of each test certificate on site available for inspection by the Engineer.

5

The following British Standards and Code of Practice shall be complied with:

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Mobile and Tower Cranes: BS 1757, BS 2799 and CP 3010

(b)

Overhead Cranes: BS 466 and BS 5744

(c)

Slings: BS 1290

(d)

Chain Blocks: BS 3243

(e)

Shackles: Alloy : BS 3551, High Tensile Steel : BS 3032

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10.10.1 General

These specifications for workers' accommodation can be accepted for implementation as long as in the interest of the worker provided they do not disturb the labour accommodation requirements of the decision of the Minister of Labour No. (17) for the year 2005 or any other matters developed in this context.

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10.9.7

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10.10.2 Quality of Labour Accommodation The Contractor shall provide space per person that meets or exceeds what is required by local legislation or 4.5 m2 per person within each room/accommodation unit.

2

The residential density shall not exceed (the lower of): that specified by appropriate local regulation or 4 persons per room/accommodation unit.

3

The Contractor shall provide personal storage space for residents’ belongings including secure storage for valuables.

4

The Contractor shall provide allowances for open spaces and pedestrian movement (e.g. hard surface walkways with minimum 0.75 m width) and shaded communal areas.

5

Where permissible under local planning guidelines, the Contractor shall provide air conditioned communal areas such as television/games rooms.

6

The Contractor shall designate pick up and drop off points (for buses) in such a way as to minimize walking distances for residents and to minimize noise and air quality impacts on residential buildings.

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The Contractor shall configure buildings/units in such a way as to create a sense of place and community.

8

The Contractor shall provide tea and coffee making facilities in kitchen and mess areas.

9

The Contractor shall provide physical barriers (e.g. fencing or landscaping) to visually screen the camp from adjacent worksites, etc.

10

The Contractor shall provide written evidence that all local planning guidelines have been adhered to when designing large scale, project related, labour accommodation facilities. Local planning guidelines indicate the numbers and type of community facilities which should be provided for a given population. Consideration shall be given at planning stage to the availability and capacity of communal facilities and spaces in the surrounding area. Where such facilities are not readily accessible, provision of public transport to access such facilities shall be considered.

11

The Contractor shall be aware of any changes in law relating to the provision of temporary labour accommodation.

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10.10.3 Provision for Fire Safety

The Contractor shall provide for adequate fire-fighting equipment in the labour accommodation (notwithstanding other local laws and regulations requiring same).

2

All relevant signage, notices, documentation and training relating to fire safety at labour accommodation shall be provided in appropriate languages, based on the demographics of the facility.

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10.10.4 Provision for Health Care

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The Contractor shall retain detailed records of all medical treatment carried out on-site. Records shall be retained for all instances of residents being transported for off-site medical attention. Such records shall include, as a minimum, the name, age and nationality of the treated party, and the nature of the complaint. These records shall be used to identify medical trends and implement proactive treatment to reduce absenteeism.

2

The Contractor shall provide all labour accommodation residents with access to a level of healthcare beyond basic first aid. Such facilities shall be readily accessible by residents, staffed by professional medical staff and have appropriate provisions and equipment. The exact specification of the facility shall be determined on a case-by-case basis, depending on the location and population of the labour accommodation.

3

The Contractor shall provide a facility to transport those requiring medical attention from the labour accommodation to and from appropriate off-site medical facilities, free-of-charge and in a timely manner.

4

The Contractor shall provide medical insurance for all workers in accordance with Qatar Labour Law.

5

The Contractor shall include a Public Health Training module as part of induction training for all new labour accommodation residents. As a minimum, this shall address:

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(a)

Personal hygiene and the appropriate use of the sanitary facilities provided (flush toilets, showers, hand washing, waste disposal facilities etc.).

(b)

Awareness of communicable diseases (including Sexually Transmitted Diseases), their transmission and prevention.

(c)

Practical information regarding residents’ rights and means of access to on-site and off-site medical facilities.

(d)

Food safety.

(e)

Littering, safe disposal of waste and related community hygiene standards.

The Contractor shall promote public health awareness throughout all facets of the accommodation. This shall include: (a)

Signage in kitchens, bathrooms etc. promoting hygienic practices.

(b)

Educational videos and presentations.

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The Contractor shall provide access to transport, free-of-charge to/from: Worksites, including backup services from worksite to labour accommodation for those who failed to access scheduled services.

(b)

Availability nearby for community facilities, shops and recreation areas during leisure time.

(c)

Religious facilities at suitable times.

(d)

Off-site medical facilities, including emergency access at all times.

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10.10.5 Access to Transport

Transport services shall be scheduled in such a way as to minimise waiting times and maximise accessibility.

3

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10.10.6 Access to Religious, Social and Domestic Facilities 1

The size and number of religious, social and domestic facilities shall be relative to and appropriate to the population of the labour accommodation.

2

The Contractor shall facilitate access to religious facilities for those required to work on Fridays.

3

The Contractor shall provide an on-site hall to facilitate religious practices. Alternatively, transport may be provided to facilitate off-site worship.

4

The Contractor shall provide adequate shaded areas to facilitate social interaction. Similarly, an appropriately sized, air-conditioned communal area(s) shall be provided (e.g. television and games room). The size and number of these facilities shall be relative to and appropriate to the population of the labour accommodation.

5

The Contractor shall provide preferably on-site, open spaces (for sports and recreation). Where space constraints are such that this is impossible, readily accessible off-site spaces shall be provided.

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The Contractor shall provide access nearby to basic domestic amenities. include, as a minimum:

These shall

(a)

Access to banking/money transfer services, including transportation to banking/money transfer facilities.

(b)

Laundry facilities.

(c)

Retail outlet(s) selling, as a minimum, essential items (e.g. food items, clothing, toiletries, phone cards, stamps etc.).

(d)

Communications.

These services shall preferably be available on or within walking distance of the labour accommodation.

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10.10.7 Access to Communications The Contractor shall provide a telephone, available at all times, for calling the emergency services. This facility shall be centrally located, conspicuous and all residents shall be aware of this facility.

2

The Contractor shall provide access nearby to the following:

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Retail outlet selling mobile phone credit.

(b)

Postal service, both inward and outbound.

(c)

Facility for residents to receive emergency messages (e.g. in case of family emergency abroad).

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10.10.8 Number, Quality and Location of Sanitation Facilities The Contractor shall adhere to an appropriate standard for the provision of toilets and showers etc. These facilities shall be maintained in good working order and shall be cleaned regularly.

2

The Contractor shall develop and implement a Waste Management Plan for the labour accommodation. This plan shall address the collection, segregation, storage, transport (offsite) and disposal (recycling) of wastes.

3

The Contractor shall provide adequate sanitary means for the disposal of waste water (including sewerage) from labour accommodation. The Contractor shall provide adequate management of surface water runoff to prevent the accumulation of standing/stagnant water (and the associated health risks).

4

The Contractor shall provide laundry areas, separate from washrooms and food preparation areas. Such laundry areas shall be adequately drained.

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10.10.9 Food Preparation Areas 1

The Contractor shall adhere to relevant local regulations relating to food preparation facilities. In the absence of such local regulations, an appropriate regional standard shall be applied The Contractor shall provide adequate food preparation facilities to allow cultural sensitivities to be respected such as separate preparation areas for meat and vegetables, and appropriate labelling and handling of food products.

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Where meals are provided to residents, the food offered shall be culturally appropriate based on the demographics of residents.

10.10.10 Pest and Vermin Control 1

The Contractor shall engage a pest control company to service the labour accommodation site.

2

Self closing doors fitted with fine mesh shall be installed at the entrances to food premises, washrooms, living areas and any other enclosed spaces.

10.10.11 Security at Labour Accommodation The Contractor shall provide adequate security personnel, based on the size, layout and population of labour accommodation.

2

The Contractor shall provide Protocols (Codes of Conduct) for the security personnel operating at labour accommodation. These Protocols shall clearly define the nature and permitted magnitude of response to security incidents. They shall also set out the circumstances under which security incidents should be handed over to Police control. Protocols will be developed in consultation with the Engineer

3

The Contractor shall ensure that all security personnel are adequately trained in the Protocols for security personnel.

4

The Contractor shall retain records of all security incidents arising at labour accommodation. Such records shall include, as a minimum, the name, age and nationality of all those involved (including security personnel), and the nature of the incident. These records shall be made available to the Engineer.

5

The Contractor shall provide labour accommodation residents with secure facilities for the storage of personal items and valuables.

6

The Contractor shall manage the movement of goods and personnel onto the accommodation facility.

7

The Contractor shall maintain adequate lighting on and around the labour accommodation at all times, therefore making it safer for residents to move around at all times.

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10.10.12 Social Issues 1

Any social issues arising at labour accommodation shall be addressed at regular project Quality, Health, Safety and Environment (QHSE) meetings.

2

The Contractor shall include an Intercultural Understanding module as part of induction training for all new labour accommodation residents. This shall include: (a)

Basic introduction to cultural norms and practices of other accommodation residents.

(b)

An explanation of native or local customs, festivals or religious rites.

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The Contractor shall enforce a ban on the sale, possession and consumption of solvents, alcohol and inhalants, for the purposes of intoxication, on labour accommodation sites. The Contractor shall use its best endeavours to prevent these substances from entering labour accommodation facilities.

4

The Contractor shall provide residents with contact details for relevant bodies such as consulates, NGOs, or other relevant organisations offering social support. A list of such local contacts shall be provided to new employees during their induction process. An up-to-date list of contact details for these organisations shall also be displayed in public areas such as the canteen, recreational areas, etc.

5

Any incidents of suicide or attempted suicide shall be investigated as a social issue to try to determine the root causes with a view to reducing the likelihood of a recurrence. This may include the engagement of qualified medical personnel to assist in this process (such as psychiatrists or psychologists).

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10.10.13 Competence of Labour Accommodation Management

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The Contractor shall provide Protocols (Codes of Conduct) for the labour accommodation management personnel. These Protocols shall clearly define the nature of issues and incidents which are considered within the remit of labour accommodation management. They shall also include guidelines outlining appropriate parties to whom incidents should be referred and at what stage. Protocols will be developed in consultation with the Engineer

2

The Contractor shall retain records of all issues and incidents, at labour accommodation, which are reported to or dealt with by labour accommodation management. Such records shall include, as a minimum, the name, age and nationality of all those involved (including members of the accommodation management team), and the nature of the issue or incident. These records shall be made available to the labour accommodation management company.

3

The Contractor shall ensure that no member of labour accommodation management accepts any form of payment by way of bribery or extortion or for any reason. Similarly the Contractor shall commit to permanently removing any member of labour accommodation management, from the accommodation, if they are found to have accepted or demanded such payments. In this event, the Contractor shall report any such offences to the appropriate local authorities to determine if a criminal offence has been committed.

4

The Contractor shall maintain labour accommodation facilities to a high standard and not allow them to fall into disrepair.

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10.10.14 Environmental Conditions at Labour Accommodation 1

The Contractor shall provide the Engineer with copies of the relevant environmental permits relating to the construction and operations of their labour accommodation facilities. The nature of the permitting requirements will be dependent on the jurisdiction of the facility.

2

Where labour accommodation is to be sited on or close to work sites/industrial sites, the accommodation facilities shall be located up-wind (based on prevailing wind) of the site and the distance between the camp and air discharge points around the site shall be maximised. Noise levels shall not exceed the requirements for night time hours – residential areas, as outlined in local laws and regulations.

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The accommodation area shall be separate from the work site and shall not be used for any operation activities (e.g. storage, workshops, etc.).

4

Where on site facilities such as a Sewage Treatment Plant (STP) are located on or close to the accommodation, planning requirements in relation to buffer zones, etc. shall be respected and integrated into site layout. Similarly, adequate buffer zones shall be included to ensure that sleeping accommodation is not immediately adjacent to main roads.

5

Appropriate waste management, storage and disposal facilities shall be provided on site. There shall be no burning of wastes on site. Similarly, there shall be no fires onsite.

6

Use of labour accommodation facilities shall be restricted to those normally resident in the accommodation. Where necessary, separate facilities, e.g. toilets, etc., shall be provided for adjacent work sites, etc.

7

Roads and parking areas shall be paved, or where this is impractical, dust suppression techniques shall be used to keep dust levels down within labour accommodation.

8

The Contractor shall appoint/engage a team of personnel dedicated to cleaning communal areas around the camp on a regular (daily) basis.

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10.10.15 Health and Safety for Labour Accommodation Residents The Contractor shall extend Workmen’s Compensation and Employer’s Liability Insurance to cover their staff while resident in labour accommodation.

2

The Contractor shall extend the accident reporting requirements, to include accidents occurring at off-site labour accommodation directly associated with the Project.

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END OF PART

QCS 2014

Section 01: General Part 11: Engineer’s Site Facilities

ENGINEER’S SITE FACILITIES .............................................................................. 2

11.1 11.1.1

GENERAL ............................................................................................................... 2 Scope 2

11.2 11.2.1 11.2.2 11.2.3 11.2.4

ENGINEER’S SITE OFFICES ................................................................................. 2 General 2 Type 1 Offices 2 Type 2 Offices 3 Car Parking Facilities 6

11.3 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5

UTILITY CONNECTIONS ........................................................................................ 6 General 6 Electricity 6 Water 6 Telephone 7 Internet 7

11.4 11.4.1 11.4.2 11.4.3 11.4.4 11.4.5 11.4.6 11.4.7

PROVISION OF EQUIPMENT AND SUPPLIES ...................................................... 7 General 7 Computers and Scanners/Printers 7 Photocopier 8 Measuring and Recording Equipment 9 Stationary Supplies 9 Safety Equipment and Clothing 10 Telephones and Facsimile Machines 10

11.5 11.5.1 11.5.2

ATTENDANCE ...................................................................................................... 11 Assistance to the Engineer 11 Contract Administration 11

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11

ENGINEER’S SITE FACILITIES

11.1

GENERAL

11.1.1

Scope

1

This Part specifies the requirements for the Engineer’s temporary site facilities and includes site offices, utility connections, provision of equipment and supplies and attendance.

2

Related Sections and Parts are as follows Part 10 Part 13

Occupational Health and Safety Setting Out of the Works

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ENGINEER’S SITE OFFICES

11.2.1

General

1

The Contractor shall provide site offices the type and number as stated in the Project Documentation. The position of the site offices shall be to the approval of the Engineer.

2

Upon removal of the site offices, the area occupied or otherwise affected by them shall be reinstated to its original condition.

11.2.2

Type 1 Offices

1

Unless described elsewhere in the Project Documentation the Contractor shall provide, maintain and remove on completion of the Works the Engineer’s site offices described in this Clause.

2

The Contractor shall proceed with the provision of a site office for the exclusive use of the Engineer immediately following the award of the Contract and shall provide temporary alternative accommodation to the Engineer’s approval until such time as the office is made available.

3

The office shall have a minimum area of 20 m and shall comply with the following:

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11.2

2

(a)

The structure shall be weatherproof.

(b)

The windows and doors shall be dust-proof and the windows shall be fitted with fly screens.

(c)

The office shall be air-conditioned to maintain a maximum steady dry bulb temperature of 25ºC at a relative humidity of 50% under the expected climatic conditions expected at the Site.

(d)

Adequate effective lighting and power outlets shall be installed in accordance with the latest requirements of the Qatar General Electricity & Water Corporation.

(e)

The walls and ceilings shall be painted with emulsion paint.

The office shall be provided with the following furniture to the approval of the Engineer: (a)

1 No. kneehole pattern desk with a total of six lockable drawers, approximately 1500 x 800 x 760 mm in size.

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Section 01: General Part 11: Engineer’s Site Facilities

(b)

1 No. swivel chair with armrests.

(c)

2 No. stacking or folding chairs.

(d)

1 No. hanging file or plan chest suitable for AO size prints.

(e)

1 No. wastepaper basket.

(f)

1 No. two drawer filing cabinet.

(g)

1 No. wall mounted pin board, 1000 x 2000 mm in size.

Sanitary and washing facilities shall be provided for the exclusive use of the Engineer and shall include a WC and a wash-hand basin an adequate supply of hot and cold water shall be provided at all times.

6

The Contractor shall insure the site offices against fire, burglary and other risks.

7

The Contractor shall keep on site at all times an adequate supply of clean, fresh, chilled drinking water for the consumption of the Engineer.

8

The Contractor shall maintain the offices in a clean and sanitary condition.

11.2.3

Type 2 Offices

1

The Engineer’s site offices described in this Clause shall be provided in lieu of Type 1 Offices only where it is a stated requirement of the Project Documentation.

2

The offices shall be portable units, mounted on skids or similar and where directed in the Project Documentation shall become the property of the Government on completion of the Contract. On completion of the Contract, the offices which are to become the property of the Government shall be repaired and redecorated to the satisfaction of the Engineer; they shall then delivered to a location designated by the Engineer within 50 km of the Site.

3

The buildings shall conform to the general configuration shown below. The number of each type of unit shall be as stated in the Project Documentation.

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The Contractor shall proceed with the provision of the portable offices, which shall be for the exclusive use of the Engineer immediately following the award of the Contract and shall provide temporary alternative accommodation to the Engineer’s approval until such time as the offices are made available.

5

The Contractor shall submit to the Engineer for approval a comprehensive specification and drawings showing the accommodation proposed complete with furnishings, equipment and fittings before placing any orders.

6

The units shall be mounted on adequate concrete foundations and shall be provided with concrete access steps where necessary.

7

The units may be constructed of composite timber framed panels with wood or metal cladding, any combination of these, or alternative forms or construction which comply with the following levels of performance:

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Walls

Thermal conductance Fire resistance -

0.60 w/m ºC ½ hour

Roof

Thermal conductance Roof resistance -

0.60 m ºC ½ hour

2

8

Roof coverings shall be selected for durability, freedom from excessive maintenance, and the ability to withstand extreme exposure to sun, heat and humidity.

9

The units shall be finished internally and externally with low maintenance materials.

QCS 2014

Section 01: General Part 11: Engineer’s Site Facilities

10

The offices shall be air-conditioned with wall mounted units to maintain each room at a maximum steady dry bulb temperature of 25ºC at a relative humidity of 50% under the expected climatic conditions expected at the Site. Extract fans capable of 10 air changes per hour shall be provided in the kitchen and toilets.

11

The installation and testing of wiring and electrical equipment in the units shall be in accordance with the latest requirements of the Qatar General Electricity & Water Corporation.

12

Each office shall be provided with the following furniture to the approval of the Engineer:

1 No. swivel chair with armrests.

(c)

No. stacking or folding chairs.

(d)

1 No. hanging file or plan chest suitable for AO size prints.

(e)

1 No. wastepaper basket.

(f)

1 No. two drawer filing cabinet.

(g)

1 No. wall mounted pin board, 1000 x 2000 mm in size.

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Each toilet shall be provided with the following sanitary fittings to the approval of the Engineer and an adequate supply of hot and cold water at all times: 1 No. low level WC suite.

(b)

1 No. Wash-hand basin.

(c)

1 No. shower tray, mixer fittings, rose and shower curtain.

(d)

1 No. toilet roll holder, towel rail, soap dish and mirror.

(e)

a suitable number of cups, saucers and drinking glasses.

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The samples and meeting room shall be provided with the following furniture to the approval of the Engineer: (a) (b)

No. folding or stacking chairs.

(c)

1 No. wall mounted blackboard, 1000 x 2000 mm in size.

(d)

1 No. wall mounted pin board, 1000 x 3000 mm in size.

(e)

1 No. shelf unit for approved samples with 5 tiers of shelves 400 mm wide x 2400 mm long overall.

2 No. tables, each approximately 1200 x 2000 mm in size.

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1 No. kneehole pattern desk with a total of six lockable drawers and approximately 1500 x 800 x 760 mm in size.

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(a)

15

All furniture and equipment shall remain the property of the Contractor and shall be removed following completion of the Works unless otherwise noted in the Project Documentation.

16

The Kitchen shall be provided with the following equipment to the approval of the Engineer (a)

1 No. stainless steel single bowl single drainer sink with hot and cold water and cupboards underneath

(b)

1 No. floor mounted two door cupboards to match sink.

QCS 2014

Section 01: General Part 11: Engineer’s Site Facilities

(c)

Cabinets and shelves to match sink, as required.

(d)

2 ring cooker and microwave.

(e)

1 No. Refrigerator/Freezer with a capacity no less than 500 litres.

(f)

1 No. three pint kettle and sufficient crockery and cutlery.

(g)

A suitable number of mugs, cups, saucers and drinking glasses.

(h)

Table coasters for use on desk tops.

(i)

Hand towels and drying up cloths, laundered regularly.

(j)

Dishwashing facilities, clothes, sponges and washing up liquid, all replaceable.

(k)

Cleaning brushes, mop, bucket and floor clothes.

The Contractor shall insure the site offices against fire, burglary and other risks.

18

The Contractor shall keep on site at all times an adequate supply of clean, fresh, chilled drinking water for the consumption of the Engineer.

19

The Contractor shall maintain the Offices in a clean and sanitary condition.

20

Each type of unit shall be provided with fire extinguishers and water cooler.

11.2.4

Car Parking Facilities

1

Parking areas shall be paved or have a finished surface as approved by the Engineer and shall be covered with a suitable canopy to provide shading.

2

The number of shaded car parking spaces required shall be 2 No. for Type 1 Offices and 6 No. for Type 2 Offices unless otherwise stated in the Project Documentation.

11.3

UTILITY CONNECTIONS

11.3.1

General

1

The Contractor shall make all arrangements and pay all charges in connection with the installation, maintenance, operation and removal of the service utilities described in this Clause.

11.3.2

Electricity

1

The Contractor shall arrange for the provision of an uninterrupted electrical power supply to the Engineer’s offices during all working hours and any at other time as requested by the Engineer for the duration of the Contract.

11.3.3

Water

1

The Contractor shall arranged for the provision of an uninterrupted water supply to the Engineer’s offices during all working hours and at any other time as requested by the Engineer for the duration of the Contract.

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QCS 2014

Section 01: General Part 11: Engineer’s Site Facilities

The Contractor shall provide inline filters on all water supplies into Employer and Engineer’s site Facilities. The Contractor shall maintain these at regular intervals as per manufacturer instruction throughout the duration of the Work order.

11.3.4

Telephone

1

The Contractor shall arrange for the provision of two (2) land lines for the sole use of the Engineer for Type 1 Offices and three (3) land lines for the sole use of the Engineer for Type 2 Offices.

2

The Contractor may recover the net cost of international calls made by the Engineer.

11.3.5

Internet

1

.The Contractor shall arrange for the provision of a dedicated and uninterrupted internet access to the Engineer’s offices during all working hours and at any other time as requested by the Engineer for the duration of the Contract. The internet connection should be provided with a bandwidth running at a minimum of 1 mbps upload capacity.

11.4

PROVISION OF EQUIPMENT AND SUPPLIES

11.4.1

General

1

The following items of equipment, supplies and associated level of service shall all be provided unless detailed elsewhere in the Contract Documentation.

11.4.2

Computers and Scanners/Printers

1

The Contractor shall provide new network/internet capable computers and scanners/printers for the sole use of the Engineer. The number of computers and scanners/printers required and their performance specification shall be as detailed in the Project Documentation. The Contractor shall also supply and install any computer software as detailed in the Project Documentation.

2

The Contractor shall maintain the computers and scanners/printer for the duration of the Contract and provide all consumables necessary for its operation.

3

The Contractor shall be responsible for installing legal copies of operating system and software, trouble shooting, supplying of required consumables and maintenance of the system.

4

Operating system and software requirements shall be as specified by the Engineer, with the following as a minimum:

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(a)

Latest version of Microsoft Windows Operating System

(b)

Latest version of Microsoft Office

5

All software must be of latest version and Arabic enabled, to the approval of the Engineer.

6

The Contractor shall ensure that all computers and scanners/printers provided for the Engineers use are networked within the Engineers facilities to the satisfaction of the Engineer.

QCS 2014

Section 01: General Part 11: Engineer’s Site Facilities

7

The Contactor shall provide new desktop computers and laptops as shown in the Schedule of Rates minimum 20-inch Flat Panel VGA/analogue colour monitors for use by the Engineer.

8

The Desktop and laptop computers shall comply with the following: Intel Core 2 Duo Processor (1.86GHz,1066MHz,2MB cache)

(b)

1000GB(7200rpm)Serial ATA Hard Drive

(c)

56k Modem

(d)

32X DVD+/-RW Drive

(e)

Wireless network adaptor (Wi-Fi)

(f)

Wireless Keyboard & Mouse

(g)

Card Reader

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(a)

The Desktop and laptop computers shall comply with the following: New licensed copies of MS Windows, MS Office Professional, MS Project and AUTOCAD, Primavera P6 and Primavera Contract Manager (PCM) SOFTWARE SHALL BE PROVIDED.

10

Colour printer shall be of the laser type suitable for A3 size paper and having scanning and copying facilities built in. It shall be quiet in operation (Hewlett Packard Desk Jet (latest model) or similar).

11

The Computer equipment shall be returned to the Contractor at the end of Maintenance Period. The Contractor shall be responsible for supply of all necessary cartridges and paper and for maintenance of the equipment by the manufacture’s agent throughout the period of the Work order.

12

The Contractor shall provide all necessary voltage stabilization equipment to ensure troublefree operation of the computer equipment.

13

All computers and printers shall be networked.

11.4.3

Photocopier

1

The Contractor shall provide a new photocopier for the sole use of the Engineer. The performance specification for the photocopier shall be as detailed in the Project Documentation.

2

The Contractor shall maintain the photocopier for the duration of the Contract and provide all consumables necessary for its operation.

3

Contractors shall provide a new floor standing, stationary platen, and plain paper colour photocopier for use and approved by the Engineer.

4

The photocopier shall be provided with an automatic document feeder capable of copying both sides.

5

The Range of copy sizes of the photocopier shall be from A3 size (297×420mm) to A4 size (210×297mm), portrait and landscape. Three paper storage trays shall be provided.

6

The photocopier shall be capable of reducing/enlarging originals by 50% to 200% in 1% increments.

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QCS 2014

Section 01: General Part 11: Engineer’s Site Facilities

The photocopier shall have an A4 size rotating paper cassette and automatic paper size/zoom ratio selection.

8

Throughput shall be not lesson than 40 A4 copies per minute.

9

The photocopier shall be able to scan and email documents.

10

The photocopier shall be returned to the contractor at the end of period of Maintenance. The contractor shall be responsible for supplying the necessary paper and maintenance of the equipment by the manufacture’s agent throughout the work order.

11.4.4

Measuring and Recording Equipment

1

The Contractor shall provide measuring and recording equipment for the sole use of the Engineer. The following items, which shall be to the approval of the Engineer, shall be provided for the duration of the Contract:

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1 No. Electronic Distance Measurement (EDM) station.

(b)

1 No. 1” Total Station theodolite (or equivalent) including all necessary tripods, prisms etc.

(c)

1 No. Automatic engineer’s level including tripod.

(d)

1 No. Metric levelling staff.

(e)

1 No. Calibrated steel survey band 50m long.

(f)

2 No. 30m nylon tapes.

(g)

2 No. 25 m metal tapes.

(h)

4 No. 5m pocket tapes.

(i)

6 No. Ranging rods.

(j)

1 No. Mason’s Spirit level.

(k)

1 No. Bitmac thermometer.

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1 No. digital camera. Level and field books as required.

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Other equipment such as pegs, tools, etc, which are necessary for the checking of the Works shall be provided as requested by the Engineer.

3

The Contractor shall maintain and replace as necessary the equipment for the duration of the Contract. Surveying instruments shall be new or in as good as new condition, of an approved make with a current certificate of adjustment.

11.4.5

Stationary Supplies

1

The Contractor shall supply stationary for the Engineer for the duration of the Contract. Stationary items shall include, but not necessarily be limited to, the following: (a)

Files and file dividers (A4 and A3 size).

(b)

Paper (A4 and A3 size).

(c)

Writing pens, marker pens, highlighter pens (various colours).

QCS 2014

Section 01: General Part 11: Engineer’s Site Facilities

(d)

Pencils (various colours).

(e)

Pencil sharpeners.

(f)

Erasers.

(g)

Staplers and staples.

(h)

Hole punches.

(i)

Paper chips and bull dog clips.

11.4.6

Safety Equipment and Clothing

1

The Contractor shall supply safety equipment and clothing for the Engineer and his staff. Safety equipment and clothing shall include, but not necessarily be limited to, the following: Safety helmets, boots, gloves, High visibility vests, safety glasses (Clear and tinted)

(b)

Safety belts and harnesses.

(c)

Boiler suits.

(d)

Any other PPE identified by the Contractors job hazard analysis or risk assessment process

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The Contractor shall also supply gas detection equipment and breathing apparatus in accordance with the relevant provisions of Part 10 of this Section, Occupational Health and Safety.

11.4.7

Telephones and Facsimile Machines

1

For Type 1 Offices, the Contractor shall supply and install a telephone and facsimile machine. The telephone and facsimile machine should conform to the relevant provisions of any Telecom Provider standard or requirement.

2

For Type 2 Offices, the Contractor shall supply and install a telephone in each office and the meeting room. Each telephone shall be connected to a private address box exchange (PABX) system. The Contractor shall also supply and install a facsimile machine. The telephones, PABX system and facsimile shall conform to the relevant provisions of any Telecom Provider standard or requirement.

3

The Contractor shall provide a new A4 size plain paper desktop facsimile machine complying with the following:

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(a)

2 Line × 24 character LCD Display

(b)

ITU compatible

(c)

Resolution horizontal scanning 8 pixel/mm

(d)

Vertical scanning Standard 3.85 lines/mm

(e)

Fine 7.7 lines/mm

(f)

150 sheet paper tray (80g/m2

The facsimile machine shall be returned to the contractor at the end of maintenance period. The Contractor shall be responsible for supply of all necessary toner or ink cartridges and plain white paper and for maintenance of the equipment by the manufactures’ s agent throughout the Work order.

QCS 2014

Section 01: General Part 11: Engineer’s Site Facilities

The Contractor shall provide six digital cameras and one digital video camera for the exclusive use of the Engineer or his designated representative and supply software, batteries, cables and USB flash drives or external hard drives as required. The Digital camera shall have a minimum specification of 35-105 zoom, with a minimum of 16.0 megapixels for prints up to 20”×30”, 8GB internal memory and video/audio facility. The cameras shall be returned to the contractor at the end of the contract period

11.5

ATTENDANCE

11.5.1

Assistance to the Engineer

1

The Contractor shall provide every assistance to the Engineer in carrying out his duties.

2

The Contractor shall provide for the use of the Engineer’s Representative and his staff, any chainman/assistants to carry out any duties whatsoever, as required by the Engineer’s Representative.

11.5.2

Contract Administration

1

The Contractor shall provide secretaries, cleaners and tea persons for the exclusive use of the Engineer for the duration of the Contract.

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QCS 2014

Section 01: General Part 12: Contractor’s Site Facilities

Page 1

12

CONTRACTOR’S SITE FACILITIES GENERAL ........................................... 2

12.1

GENERAL ...................................................................................................... 2

12.1.1 Scope 12.1.2 References

2 2

12.2

CONTRACTOR’S SITE FACILITIES ............................................................. 2

12.2.1 12.2.2 12.2.3 12.2.4 12.2.5

Buildings Site Fabrication Areas Materials Storage Area Power, Water, Lighting and Heating Miscellaneous

12.3

PROJECT SIGN BOARD............................................................................... 3

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12.3.1 Project Sign Board

ADVERTISING .............................................................................................. 4 4 4

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12.4.1 Photographs 12.4.2 Name Boards and Other Advertising

PROVISION OF HAMAD MEDICAL CORPORATION AMBULANCE SPOKE STATION ....................................................................................................... 4

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12

CONTRACTOR’S SITE FACILITIES GENERAL

12.1

GENERAL

12.1.1

Scope

1

This Part specifies the requirements for the Contractor’s temporary site facilities.

12.1.2

References

1

Related Sections and Parts are as follows: Part 9 Materials.

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CONTRACTOR’S SITE FACILITIES

12.2.1

Buildings

1

The Contractor shall provide all offices, sheds, stores and other buildings necessary for him to undertake all duties, obligations and activities associated with the construction of the Works.

2

All buildings shall be supplied and maintained in good condition and shall be of neat appearance.

3

The position of all the Contractor’s temporary site buildings shall be to the approval of the Engineer.

4

The Contractor shall maintain an office at the Site for the duration of the Contract. This office shall be open at all times during Site working hours.

5

Upon completion of the Contract, all temporary site buildings shall be removed and the area occupied or otherwise affected by them reinstated to its original condition.

6

The Government of Qatar will grant a right of access only within the road reservation. Should the Contractor need to use adjacent areas of land for camps, plant site etc, he shall arrange for the right to use the said land himself.

7

This clause in no way invalidates the obligations of the General Conditions of Contract.

12.2.2

Site Fabrication Areas

1

The Contractor shall provide an area suitable for assembly and fabrication purposes.

2

Fabrication areas shall simulate factory conditions if required in the Project Documentation.

12.2.3

Materials Storage Area

1

The Contractor shall provide sufficient and appropriate materials storage areas. The storage areas shall be suitable for the materials to be stored in them and shall offer necessary protection where required.

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Page 3

The Contractor shall ensure that the storage areas comply with the relevant provisions of Part 9 of this Section, Materials.

12.2.4

Power, Water, Lighting and Heating

1

The Contractor shall provide, maintain and subsequently remove temporary services for power supply, water supply, lighting and heating.

2

All electrical installations shall be in the charge of a competent person who shall accept full responsibility for its use and any alterations or additions thereto. The name, designation and telephone number of such person shall be prominently displayed close to the main switch or circuit breaker of the installation, and also in the Contractor’s site office.

3

Site work power tool supplies (except for operation of pumps) shall be of 110 volts (55 volts to earth). All electricity supply cables shall be buried or properly supported and protected and shall be armoured. Flexible cable shall only be allowed for hand lamps and hand held tools and shall not exceed 6 metres in length. Industrial type plugs and sockets shall be used.

4

All site electrical installations shall comply with the requirements of the current regulations of QGEWC.

12.2.5

Miscellaneous

1

The Contractor shall provide, maintain and subsequently remove temporary roads, paths, parking areas and refuse disposal areas. The area occupied by temporary roads, paths, parking areas and refuse disposal areas or otherwise affected by them shall be restored to their original condition on completion of the Contract.

12.3

PROJECT SIGN BOARD

12.3.1

Project Sign Board

1

Standard Signboard: The Contractor shall provide and erect a temporary signboard at the location of his approved site compound. In addition he shall provide signboards at the start and end of each ongoing work location for all works whether major or minor.

2

Project Identification Signboard: Information signboards shall be clearly displayed on approaches to works in the highway at each ongoing work location for all works whether major or minor. These shall be provided by the Contractor and shall be positioned so as not to cause hindrance to the movement of vehicular or pedestrian traffic. The signs shall be mounted on sturdy metal frames, be mobile and reusable, and shall be illuminated at night.

3

The Project sign boards shall comply with the standard details, as updated by the project drawings and specifications, and shall be to the approval of the Engineer. In addition, the Contractor shall obtain all necessary approvals from the relevant authorities prior to erection. The Contractor shall be responsible for the structural stability of the signboards but shall submit details of his proposals for support to the Engineer for approval.

4

The Contractor shall maintain, move and adapt the signboards as required during the progress of the Works and shall remove them upon completion.

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Section 01: General Part 12: Contractor’s Site Facilities

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ADVERTISING

12.4.1

Photographs

1

The Contractor shall not use photographs or any details of his work in connection with the Contract in any form of publicity or advertisement in any part of the world without having first obtained the Engineer’s approval to its content and context.

12.4.2

Name Boards and Other Advertising

1

Details of any further sign boards other than as designed in Clause 12.3.1 or advertisements that the Contractor may wish to erect on site shall be to the approval of the Engineer.

12.5

PROVISION OF HAMAD MEDICAL CORPORATION AMBULANCE SPOKE STATION

12.5.1

General

1

Ambulance Spoke Station is a temporary structure. This can be relocated quickly to any location in a rapidly changing infrastructure, which is a vital component of the design. It is designed to provide covered parking for up to two ambulances and accommodation for a small crew room for up to four paramedics. The crew need shelter from the summer heat in a safe environment in a prime response location to be ready for emergency calls. The stations are versatile and designed to be completely self-contained. It doesn't require to be connected to Electricity, Water or Sewerage or require any physical links to service providers. All of its power is provided by solar panels. The cabin can be dismantled and moved to another site within 48 hours, enabling Hamad Medical Corporation to relocate these small stations. The station does not require any form of building foundations, just level ground. Depending on the location, some stations may require minor works for access to and from the road.

2

The contractor will in no way be relieved of his responsibility under Qatari law to provide medical care, facilities, insurance, etc. to workers on site, and that Hamad Medical Corporations facility is mainly for the purpose of the general public (so that Hamad Medical Corporation can respond more quickly to emergency incidents in a rapidly changing infrastructure)

12.5.2

Requirements

1

If instructed by the Engineer, the Contractor shall make provision within or adjacent his site facilities for an Ambulance Spoke Station.

2

The Contractor is only required to provide an area for the for the facilities. The Ambulance Spoke Station and vehicles will be provided and installed by Hamad Medical Corporation or an entity on their behalf.

3

The area shall be a minimum of 10 metres by 17 metres.

4

The area must be levelled as the surrounding area of the Contractor facilities.

5

The areas shall be provided with clear access to the road network.

6

Access to the Ambulance Spoke Station is required 24hours/day 7 days/week.

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Section 01: General Part 12: Contractor’s Site Facilities

Page 5

7

Ambulance vehicle access is required to at least one long side.

8

Access for maintenance (water resupply, cleaning, removal of waste etc.) is required to one short side.

9

The allocated area shall be approved in writing by the Engineer after consultation with Hamad Medical Corporation.

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END OF PART

QCS 2014

13

Section 01: General Part 13: Setting Out of the Works

Page 1

SETTING OUT OF THE WORKS .................................................................. 2

13.1 GENERAL ...................................................................................................... 2 13.1.1 Scope 2 13.2 SITE INFORMATION AND INSPECTION ..................................................... 2 13.2.1 Site Information 2 13.2.2 Site Inspection 2 13.3 LEVELS AND REFERENCE GRID ................................................................ 2 13.3.1 Temporary Bench Marks 2 13.3.2 Site Grid 3

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13.4 SURVEYING .................................................................................................. 3 13.4.1 Site Survey 3

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13.5 SETTING OUT ............................................................................................... 3 13.5.1 Setting Out of the Works 3 13.5.2 Setting Out of Works Sited on Private Land 4

QCS 2014

Section 01: General Part 13: Setting Out of the Works

Page 2

13

SETTING OUT OF THE WORKS

13.1

GENERAL

13.1.1

Scope

1

This Part specifies the requirements for setting out of the Works and includes locating existing services, surveying the Site and establishment of temporary bench marks.

2

The Engineer reserves the right to order levels to be taken at any time considered necessary for the full and proper supervision and measurement of the Works.

3

Related Sections and Parts are as follows:

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Engineer’s Site facilities.

Part 11

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This Section

SITE INFORMATION AND INSPECTION

13.2.1

Site Information

1

Before commencing the setting out of the Works the Contractor shall ascertain the location of all existing underground services within the Site boundary. The Contractor shall prepare a plan detailing the location of the services.

2

Any conflict between existing services and any part of the proposed Works shall be brought to the attention to the Engineer without delay.

3

Any re-work resulting from the Contractor’s failure to locate and identify services shall be undertaken at the Contractor’s cost.

13.2.2

Site Inspection

1

Before commencing the setting out of the Works, the Contractor and the Engineer shall make an inspection of the Site.

2

Where appropriate, the Engineer shall require the Contractor to arrange for surveys to be undertaken, in conjunction with the owners or occupiers, of the condition of roads, properties, lands and crops which may be affected by the Works. Before any work affecting such roads, properties, lands or crops is commenced, the Contractor shall confirm in writing to the Engineer that the relevant survey is a true and accurate record of their condition.

13.3

LEVELS AND REFERENCE GRID

13.3.1

Temporary Bench Marks

1

. The Contractor shall establish accurate temporary bench marks on permanent blocks from which the levels to which the Works are to be constructed may be transferred. The location of temporary bench marks shall be agreed with the Engineer. The level of temporary bench marks shall be related to the Qatar National Height Datum.

2

The Contractor shall prepare a plan detailing the location of the bench marks and temporary bench marks and keep it up to date for the duration of the Contract.

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Section 01: General Part 13: Setting Out of the Works

Page 3

The Contractor shall protect and maintain the temporary bench marks until the Works are complete. Upon completion of the Works the Contractor shall clear away the temporary bench marks to the satisfaction of the Engineer.

4

The Contractor is responsible for checking the accuracy of temporary bench mark. Any rework resulting from incorrect or inaccurate temporary bench marks shall be undertaken at the Contractor’s cost.

13.3.2

Site Grid

1

When it is a requirement of the Project Documentation, or unless otherwise notified by the Engineer, the Contractor shall establish a Site Grid. The orientation of the Site Grid shall be determined by the layout of the proposed works and as agreed with by the Engineer. Grid spacing shall be 20m in each direction unless otherwise notified by the Engineer. Grid notation shall be numerical in one direction (y-axis) and alphabetic in the other (x-axis).

2

The grid shall be tied to the Qatar National Grid. An existing control station related to the Qatar National grid will be indicated by the Engineer for this purpose.

13.4

SURVEYING

13.4.1

Site Survey

1

The Contractor shall provide the Site survey and the correctness of that survey shall be entirely the Contractor’s responsibility.

2

The Site survey shall comply with the requirements of the Qatar Survey Manual as a minimum.

3

The Contractor shall, within 3 weeks of the date of commencement of the Works, carry out a check of the co-ordinates and levels of all permanent monuments, bench marks and survey markers used in the determination of the site survey model and proposed to be used for the setting out of the Works.

13.5

SETTING OUT

13.5.1

Setting Out of the Works

1

The Contractor shall carry out at his own cost the setting out of the Works.

2

The Contractor shall be responsible for:

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(a)

True and proper settings out of the Works in relation to reference data given in the Project Documentation.

(b)

Accurately setting out the positions, levels and dimensions of all parts of the Works.

Any delay or loss resulting from errors in the setting out of the Works shall be the responsibility of the Contractor. Setting out shall be reviewed by the Engineer before commencing the Works, but such approval shall in no way relieve the Contractor of his responsibility for the correct execution of the Work.

QCS 2014

Section 01: General Part 13: Setting Out of the Works

Page 4

The Contractor shall provide measuring and recording equipment for the Engineer in accordance with the relevant provisions of Part 11 of this Section, Engineer’s Site Facilities. The Contractor shall maintain all measuring and recording equipment in good working order at all times.

5

The Contractor shall provide all assistance which the Engineer may require for checking the setting out and taking measurements of the Works, including labour, equipment and transportation.

13.5.2

Setting Out of Works Sited on Private Land

1

The Contractor shall notify the Engineer in writing fourteen (14) days in advance of his intention to set out any of part of the Works that lies in private land.

2

The Contractor shall ensure that all requirements and instructions of private land owners are strictly adhered to.

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Section 01: General Part 14: Temporary Works and Equipment

Page 1

TEMPORARY WORKS AND EQUIPMENT ............................................................. 2

14.1 14.1.1

GENERAL ............................................................................................................... 2 Scope 2

14.2 14.2.1

TEMPORARY WORKS ........................................................................................... 2 General 2

14.3 14.3.1

TEMPORARY EQUIPMENT .................................................................................... 2 General 2

14.4 14.4.1

TEST CERTIFICATES FOR CRANES AND LIFTING TACKLE ............................... 3 General 3

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Section 01: General Part 14: Temporary Works and Equipment

Page 2

14

TEMPORARY WORKS AND EQUIPMENT

14.1

GENERAL

14.1.1

Scope

1

This Part specifies the requirements for Temporary Works required in connection with construction of the Works and temporary plant and equipment required in connection with aiding the construction of the Works. It does not include overpumping activities in respect of sewers and drains.

2

Related Parts and Sections are as follows: Quality Assurance and Quality Control

Section 11

Health and Safety

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Section 2

Occupational Health and Safety concerning temporary works and equipment is covered in Section 11 Health and Safety

4

Quality Controlling temporary works and equipment’s is covered in Assurance and Quality Control

14.2

TEMPORARY WORKS

14.2.1

General

1

Everything used for and in connection with the Temporary Works shall be fit for the purpose, in serviceable condition and in compliance with any relevant standard.

2

The Contractor shall design his Temporary Works to be of adequate strength, stability and suitability.

3

The Contractor shall submit details of any Temporary Works proposed to the Engineer for review before commencing the work. Such details shall include, but not be limited to design calculations and drawings. The submission to the Engineer of any such details shall not relieve the Contractor of his responsibility for sufficiency of the Temporary Works or of his other duties and responsibilities under the Contract.

4

The Contractor is responsible for ensuring that Temporary Works are not in any way detrimental to existing structures in any way. Particular care shall be taken with scaffolding to avoid staining or mechanical damage to finishing.

5

The Contractor shall make safe and reinstate all areas affected by Temporary Works.

14.3

TEMPORARY EQUIPMENT

14.3.1

General

1

The Contractor shall provide and maintain in good condition on the Site all plant, tools and vehicles necessary for the proper and safe execution of the Works.

2

Temporary equipment shall be fit for the purpose for which it is to be used.

Section 2 Quality

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Section 01: General Part 14: Temporary Works and Equipment

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Temporary equipment shall only be operated by personnel who are trained and qualified.

14.4

TEST CERTIFICATES FOR CRANES AND LIFTING TACKLE

14.4.1

General

1

Cranes, whether used to construct the Works or provided as part of the permanent Works, must have a current test certificate.

2

Each sling, shackle or other item of loose lifting tackle, whether used to construct the Works or provided as part of the permanent Works, must have either a current test certificate.

3

Test certificates must be issued by a competent testing authority approved by the Engineer.

4

The Contractor must have a copy of each test certificate on site available for inspection by the Engineer.

5

The following Standards and Code of Practice shall be complied with and where such documents are replaced or superseded the Contractor shall comply with the latest version:

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Mobile and Tower Cranes: BS 1757, BS 2799 and CP 3010.

(b)

Overhead Cranes: BS 466 and BS 5744.

(c)

Slings: BS 1290, BS EN 1492, ISO 4309 / 3481 Pt 2, ASME B30.9.

(d)

Chain Blocks: BS 3243.

(e)

Shackles: Alloy: BS 3551/ BS 6994.

(f)

Chain: BS 4942 part 1 & 6.

(g)

Hooks: BS 2903, ASME B30.10.

(h)

Ring and link: BS 2902.

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A monthly inspection of lifting appliances shall be carried out by a competent person employed by the Contractor. Full records of all such inspections and tests shall be kept by the Contractor in an approved form and shall be made available to the Engineer immediately upon demand. Copies of monthly inspection reports shall be submitted to the Engineer.

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END OF PART

QCS 2014

Section 01: General Part 15: Temporary Controls

Page 1

TEMPORARY CONTROLS ..................................................................................... 2

15.1 15.1.1

GENERAL ............................................................................................................... 2 Scope 2

15.2 15.2.1 15.2.2 15.2.3 15.2.4 15.2.5 15.2.6 15.2.7

TEMPORARY CONTROLS ..................................................................................... 2 Construction Cleaning 2 Dust Control 2 Noise 2 Nuisance and Trespass 2 Pollution Control 3 Surface Water and Groundwater Control 3 Environmental protection 4

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QCS 2014

Section 01: General Part 15: Temporary Controls

Page 2

15

TEMPORARY CONTROLS

15.1

GENERAL

15.1.1

Scope

1

This Part specifies the Contractor’s responsibilities with respect to temporary controls needed to protect the Works and the environment.

2

Related Sections and Parts are as follows: This Section

Part 5

Interference

TEMPORARY CONTROLS

15.2.1

Construction Cleaning

1

The Contractor shall be responsible for the proper upkeep and maintenance of the Site and Works and shall remove from the Site all rubbish and other waste as it accumulates. Materials and equipment shall be positioned, stored and stacked in an orderly manner.

2

Properly constructed rubbish chutes shall be used for clearing the debris from upper floors. Debris shall be accumulated in suitable pre-determined areas and removed from the Site as often as is practical.

3

On completion of the Works, any protective tape and other temporary coverings shall be removed and the internal and external surface of the structure shall be thoroughly cleaned to completely remove all dust, dirt, stains, handmarks, paint spots, plaster, mortar droppings and other blemishes.

15.2.2

Dust Control

1

The Contractor shall conduct his operations and activities in such a manner that no operation shall be included which will emit into the atmosphere any flying dust or dirt which might constitute a nuisance.

15.2.3

Noise

1

The Contractor shall restrict the use of plant, machinery, equipment and work practises likely to produce unacceptable noise levels to normal working hours.

15.2.4

Nuisance and Trespass

1

All reasonable means shall be used to avoid inconveniencing owners and occupiers of adjacent properties. All plant, machinery or equipment shall be placed and used on the Site so as to avoid any nuisance or trespass on adjoining property.

2

Should it be necessary for any plant, machinery or equipment to project or operate over adjoining property, the Contractor shall obtain the permission of the adjoining owner or occupier. Details of approvals shall be submitted to the Engineer in writing.

3

No workmen employed on the Works shall be allowed to trespass upon adjoining properties.

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If in the execution of the Works it is necessary for the Contractor to enter adjacent properties, he shall firstly obtain the permission of the owners of the property. The Contractor shall ensure that any instructions made by the owners of the properties are strictly adhered to.

5

The Contractor shall be held responsible for and shall indemnify the Employer against all claims, which may arise out of his failure to comply with provisions of items 1. 2. 3 and 4 of Clause 1.15.2.4

15.2.5

Pollution Control

1

The Contractor shall ensure that none of his operations or work practises result in the polluting of the air, underground strata or any existing watercourse, canal, lake, reservoir borehole and aquifer.

2

The Contractor shall rectify any problem resulting from pollution caused by the Contractor to the satisfaction of the Engineer.

3

The Contractor will be held responsible for and shall indemnify owner against all claims in connection with noise, vibration, dust, smoke, diesel spillage and any other nuisance arising from the execution of the Works.

15.2.6

Surface Water and Groundwater Control

1

The Contractor shall keep the Work well drained until the Engineer certifies that the whole of the Works is substantially complete and shall ensure that so far as is practicable all work is carried out in the dry. Excavated areas shall be kept well drained and free from standing water.

2

The Contractor shall construct, operate and maintain all temporary dams, water courses and other works of all kinds including pumping and well-point dewatering that may be necessary to exclude water from the Works while construction is in progress. Such temporary works shall not be removed without the approval of the Engineer.

3

Notwithstanding any approval by the Engineer of the Contractor’s arrangements for the exclusion of water, the Contractor shall be responsible for the sufficiency thereof and for keeping the Works safe at all times, particularly during periods of rainfall that may result in flooding. Any damage to the Works arising through the Contractor’s failure to provide sufficient protection against water, including flooding, shall be made good at his own expense.

4

It is the Contractor’s responsibility to dispose of all extracted groundwater and collected surface water. The Contractor shall submit details of his proposed disposal methods to the Engineer for approval. Discharge of groundwater and/or surface water to existing drainage facilities shall only be permitted if written approval is given by Public Works Authority and/or concerned other authorities; copies of such approvals shall be submitted to the Engineer.

5

The Contractor is to take all necessary precautions to avoid floatation of any structure.

6

The Contractor shall ensure that his groundwater control activities do not adversely affect any existing structure or service.

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15.2.7

Environmental protection

1

The Contractor shall comply with all conditions of the environmental clearance issued for the project by the Supreme Council for the Environment and Natural Reserves.

2

The Contractor shall comply with all rules and regulations regarding environmental protection and pollution control issued by the Supreme Council for the Environment and Natural Reserves.

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QCS 2014

Section 01: General Part 16: Traffic Diversions

Page 1

16

TRAFFIC DIVERSIONS................................................................................. 2

16.1

GENERAL ...................................................................................................... 2

16.1.1 16.1.2 16.1.3 16.1.4 16.1.5

Scope Conformance Safety System Description Traffic Police Requirements

16.2

TEMPORARY TRAFFIC DIVERSIONS ......................................................... 3

2 2 2 2 2 3 3

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QCS 2014

Section 01: General Part 16: Traffic Diversions

Page 2

TRAFFIC DIVERSIONS

16.1

GENERAL

16.1.1

Scope

1

This Part specifies requirements associated with traffic diversions. Traffic diversions include for work in, or affecting the use of, roads, footpaths and right of ways and may comprise the construction and maintenance of paved and unpaved detour carriageways including all earthworks and the provision of adequate drainage, lighting, sign posting, street furniture and traffic control devices.

2

Related Sections and Parts are as follows: Part 4

Protection

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16

Conformance

1

Signs, control and control devices associated with traffic diversions shall conform to the relevant provisions of “Traffic Control at Roadworks” produced by the Ministry of Public Works (latest edition/version) and shall be to the approval of the Traffic Police and the Public Works Authority.

16.1.3

Safety

1

The Contractor is responsible for all safety issues associated with the installation, operation, maintenance and removal of traffic diversions.

2

The Contractor shall provide lighting in accordance with the relevant provisions of Part 4 of this Section, Protection.

16.1.4

System Description

1

Where the diversion of any existing road, footpath or public right or way is temporarily necessitated by the Works, the Contractor shall provide and maintain an alternative which shall be operational before interference with the existing facility.

2

Temporary traffic control devices as well as any other traffic management requirement shall be erected and maintained by the Contractor for the duration of any activity in, or affecting the use of, roads, footpaths and right of ways.

16.1.5

Traffic Police Requirements

1

Before any work in, or affecting the use of, any road, footpath, and right of way is commenced, the Contractor’s proposed method of working shall be agreed with, and confirmed in writing to, the Engineer and the Traffic Police.

2

Throughout the execution of the Works and the maintenance period, the Contractor shall cooperate with the Traffic Police concerning works in, or access to, roads, footpaths and right of ways. The Contractor shall inform the Engineer of any requirements of, or arrangements made with, the Traffic Police.

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16.1.2

QCS 2014

Section 01: General Part 16: Traffic Diversions

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TEMPORARY TRAFFIC DIVERSIONS

16.2.1

General Requirements

1

The Contractor shall prepare detailed plans showing any proposed traffic diversions. The plans shall fully detail the diversion in all respects and shall include construction details if necessary. The plans shall show the position of ramps, traffic signs, cones, barriers, demarcation posts and tape, flashing lights and any other traffic control devices. The plans shall be submitted to the Engineer for review and shall be approved by the Traffic Police. Traffic diversion apparatus shall not be erected until the Traffic Police have reviewed and approved the traffic diversion plans.

2

Persons acting as flagmen shall be physically and mentally qualified, trained in their duties and courteous. Each flagman on duty shall be identified with appropriate and distinctive apparel approved by the Engineer and equipped with bilingual STOP/GO signs. Reflective apparel is required for flagging duties during darkness.

3

Where paved carriageways, unpaved carriageways or ramps are required, they shall be provided and maintained to a standard suitable in all respects for the class or classes of traffic or pedestrians requiring the use of them.

4

On completion, all traffic diversion works and apparatus shall be removed and land affected by them reinstated to its original condition.

16.2.2

Maintenance of Traffic flow

1

The Contractor shall allow for the construction of temporary diversions to permit all existing traffic movements for the duration of the Contract period.

2

All diversions shall be constructed in accordance with the latest edition/version of Qatar Traffic Manual “Traffic Control at Roadworks” booklet and the Qatar Highway Design Manual, and shall be approved prior to the implementation by both the Engineer and Traffic Police. It is the Contractor’s responsibility to ensure that any traffic diversion required is properly signed, demarcated, illuminated, controlled and maintained at all times.

3

Upon the Engineer’s request, the Contractor shall install and commission temporary traffic signals capable of handling the diverted traffic.

4

Sequential arrow boards operating on a 24-hour basis (engine or solar powered) must be used at all diversion points.

5

Within the limits of the project where pedestrian traffic is present, all excavated areas, regardless of depth, must be cordoned off by means of wired mesh panels of height no less than 1.8m connected together to form a continuous barrier wall.

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16.2

END OF PART

QCS 2014

17

Section 01: General Part 17: Project Co-ordination

Page 1

PROJECT CO-ORDINATION ........................................................................ 2

17.1 GENERAL ...................................................................................................... 2 17.1.1 Scope 2 17.1.2 Responsibility 2

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CO-ORDINATION .......................................................................................... 2 Contractor’s Activities 2 Sub-Contractors 3 Other Contractors 3 Other Ministries 3 Liaison with the Public Utility Authorities and other Contractors 3

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17.2 17.2.1 17.2.2 17.2.3 17.2.4 17.2.5

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17

PROJECT CO-ORDINATION

17.1

GENERAL

17.1.1

Scope

1

This Part specifies the co-ordination activities for which the Contractor is responsible.

2

Related Parts and Sections are as follows: Part 18

Other Contractors

Part 19

Regulatory Requirements

.

This Section

Responsibility

1

The Contractor shall be responsible for the proper co-ordination of all his activities associated with the construction of the Works including that required between the Engineer, utility owners, government departments, sub-contractors and other contractors.

2

No major operations shall be commenced or work outside the usual working hours be carried out without the consent in writing of the Engineer or without full and complete notice also in writing being given to him sufficiently in advance of the time of operation so as to enable him to make such arrangements as he may deem necessary for its inspection.

17.2

CO-ORDINATION

17.2.1

Contractor’s Activities

1

The Contractor shall undertake the following co-ordination activities:

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Co-ordinate construction activities under the various Sections of these Specifications to assure efficient and orderly installation of each part of the Works. Co-ordinate construction operations included under the various Sections of this Specification that is dependent upon each other for proper installation, connection, and operation.

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17.1.2

(c)

Where installation of one part of the Work is dependent on installation of other components, either before or after its own installation, the Contractor shall prepare schedules and construction activities in the sequence required to obtain the best results.

(d)

Where availability of space is limited, co-ordinate installation of different components to assure maximum accessibility for required maintenance, service and repair.

(e)

Make adequate provisions to accommodate items scheduled for later installation.

(f)

Where necessary, prepare memoranda for distribution of each party involved outlining special procedures required for co-ordination; include such items as required notices, reports and attendance at meetings.

(g)

Prepare similar memoranda for the Engineer, separate contractors and subcontractors where co-ordination of their work is required.

QCS 2014

Section 01: General Part 17: Project Co-ordination

Page 3

(h)

Take special care and precautions for specific co-ordination requirements for the installation of plant and items of equipment.

(i)

Co-ordinate the scheduling and timing of required administrative procedures with other construction activities to avoid conflicts and ensure orderly progress of the work.

Sub-Contractors

1

The Contractor is responsible for co-ordinating the work of his sub-contractors in all respects.

17.2.3

Other Contractors

1

The Contractor shall co-ordinate his work as necessary with other contractors in accordance with the relevant provisions of Part 18, Other Contractors, of this Section.

17.2.4

Other Ministries

1

The Contractor shall co-ordinate his work as necessary with other Ministries in accordance with the relevant provisions of Part 19, Regulatory Requirements, of this Section.

17.2.5

Liaison with the Public Utility Authorities and other Contractors

1

The Contractor shall liaise with all public utility authorities for water, electricity, telephones, etc and shall:

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17.2.2

Provide public utility authorities with storage areas where applicable.

(b)

Assist in unloading of stores and equipment.

(c)

Ensure that all services or diversions of services are installed under the carriageway and footways before they are surfaced.

(d)

Work out an overall programme for any works to be carried out by public utility authorities and ensure that this programme is maintained.

(e)

Keep public utility authorities informed of the Contractor’s own progress.

(f)

Arrange for supply of services for all the affected permanent and temporary accommodation, buildings, shops, trading areas etc even if it is not clearly mentioned in the Project Documentation for the duration for the Contract:

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Give the appropriate public utility authority adequate notice in writing that he intends to install dry ducts so that a representative of the utility concerned may attend the installation and record the location of the ducts together with the Contractor.

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(a)

2

The Contractor shall make due allowance for carrying out the works, whilst public utility authorities are working on the Site, during the Contract period. This due allowance shall include programming of the works to suit the programmes of the public utility authorities.

3

The Contractor shall at all times be responsible for the compliance with these requirements of his sub-contractors.

4

Before final surfacing of any carriageways or footways takes place, the Contractor is responsible for ascertaining from all public utility authorities that their underground works have been completed. In the event that the Contractor failing to carry out this obligation to the satisfaction of the Engineer and completed surfacing is subsequently disturbed, the Engineer may instruct the Contractor to carry out work at his own expense. END OF PART

QCS 2014

Section 01: General Part 18: Other Contractors

Page 1

18

OTHER CONTRACTORS.............................................................................. 2

18.1

GENERAL ...................................................................................................... 2

18.1.1 Scope 18.2

2

ACCESS FOR OTHER CONTRACTORS ..................................................... 2

18.2.1 Unhindered Access 18.3

2

CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS 2

18.3.1 Co-operation at Site Level 18.4

2

FACILITIES FOR OTHER CONTRACTORS ................................................. 2 2

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18.4.1 Site Facilities for Other Contractors

QCS 2014

Section 01: General Part 18: Other Contractors

Page 2

OTHER CONTRACTORS

18.1

GENERAL

18.1.1

Scope

1

This Part specifies the requirements for access to the Site for other contractors, for co-operation and co-ordination with other contractors and for the provision of facilities with other contractors.

18.2

ACCESS FOR OTHER CONTRACTORS

18.2.1

Unhindered Access

1

The Contractor shall allow other contractors unhindered access to any part of the Works when in the opinion of the Engineer those parts are sufficiently completed.

18.3

CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS

18.3.1

Co-operation at Site Level

1

The Contractor shall carry out his work in a manner that causes the minimum amount of interference to other contractors working on the Site.

2

The Contractor shall co-ordinate his operations with the activities of other contractors where necessary in order to avoid conflicts and ensure orderly progress of the Works.

3

Those works associated with existing or future service installation shall only be carried out by a contractor or sub-contractor approved by the public utility authority concerned. The Engineer shall require proof of such approval in writing prior to the commencement of works.

18.4

FACILITIES FOR OTHER CONTRACTORS

18.4.1

Site Facilities for Other Contractors

1

If specified in the Contract, the Contractor shall provide site facilities for other contractors.

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18

END OF PART

QCS 2014

Section 01: General Part 19: Regulatory Requirements

Page 1

REGULATORY REQUIREMENTS -------------------------------------------------------------------------- 2 GENERAL---------------------------------------------------------------------------------------------------------- 2

19.1.1

SCOPE --------------------------------------------------------------------------------------------------------------- 2

19.1.2

REFERENCES ------------------------------------------------------------------------------------------------------- 2

19.2

NOTICES ------------------------------------------------------------------------------------------------------------- 3

19.2.1

GENERAL ------------------------------------------------------------------------------------------------------------ 3

19.2.2

NOTICE OF INTENT ------------------------------------------------------------------------------------------------- 3

19.3

MISCELLANEOUS --------------------------------------------------------------------------------------------------- 3

19.3.1

W ORK REQUIRED TO BE CARRIED OUT BY THE DEPARTMENT ----------------------------------------------- 3

19.3.2

REGULATIONS OF ROAD OPENINGS----------------------------------------------------------------------------- 3

19.4

PROVISION FOR PERSONS WITH DISABILITIES ----------------------------------------------------- 4

19.4.1

SCOPE --------------------------------------------------------------------------------------------------------------- 4

19.5

THERMAL COMFORT ----------------------------------------------------------------------------------------------- 5

19.6

THERMAL INSULATION --------------------------------------------------------------------------------------------- 5

19.7

ACOUSTICAL CONTROL ------------------------------------------------------------------------------------------- 5

19.8

W ASTE MANAGEMENT -------------------------------------------------------------------------------------------- 5

19.8.1

CONSTRUCTION AND DEMOLITION W ASTE --------------------------------------------------------------------- 5

19.8.2

BULK W ASTE COLLECTION --------------------------------------------------------------------------------------- 6

19.8.3

W ASTE STORAGE -------------------------------------------------------------------------------------------------- 6

19.8.4

W ASTE COLLECTION ---------------------------------------------------------------------------------------------- 6

19.8.5

RECYCLABLE W ASTE MANAGEMENT FACILITIES: ------------------------------------------------------------- 6

19.9

BUILDING FACADE/ EXTERNAL CLADDING MATERIAL -------------------------------------------------------- 7

19.9.1

CERTIFICATION AND APPROVAL ---------------------------------------------------------------------------------- 7

19.9.2

MATERIAL PROPERTIES ------------------------------------------------------------------------------------------- 7

19.10

EXTERNAL FACADE CLEANING AND MAINTENANCE FOR HIGH RISE BUILDINGS -------------------------- 8

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19 19.1

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19.10.1 GENERAL ------------------------------------------------------------------------------------------------------------ 8 19.10.2 MAINTENANCE MANUAL ------------------------------------------------------------------------------------------- 8

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19.10.3 ACCESS OF CLEANING AND MAINTENANCE -------------------------------------------------------------------- 8 19.10.4 CLEANING ----------------------------------------------------------------------------------------------------------- 9 19.10.5 INSPECTION --------------------------------------------------------------------------------------------------------- 9 19.11

PROVISION OF ABLUTION FACILITIES IN PUBLIC BUILDINGS ------------------------------------------------- 9

QCS 2014

Section 01: General Part 19: Regulatory Requirements

Page 2

REGULATORY REQUIREMENTS

19.1

GENERAL

19.1.1

Scope

1

This part specifies the requirements for co-ordination, co-operation and liaison with the following utility and infrastructure owners:

This part also specifies the requirements for co-ordination, co-operation and liaison with the following authorities and departments:

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ASHGHAL- Infrastructure Affairs ASHGHAL- Building Affairs ASHGHAL- Assets Affairs Qatar General Electricity & Water Corporation- KAHRAMAA Qatar Telecom - Provider Qatar Petroleum, QP Q Rail

.

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Civil Aviation Authority Ministry of Awqaf and Islamic Affairs Ministry of Environment

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Authorities having Municipal jurisdiction (Ministry of Energy & Industry, New Industrial area, RLIC, MIC etc.)

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Ministry of Interior (Civil Defense Department, Traffic Police, Department of Immigration, Security Systems Department, etc)

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Ministry of Municipal Affairs and Urban Planning (MMUP) Private Engineering Office The above shall collectively be known as “Department” in this Part.

4

Related Sections and Parts are as follows:

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Traffic Diversions Project Co-ordination

Section 7 Section 11 Section 15 Section 25

Green Construction Health and Safety Insulation of Buildings Glass and Glazing

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This Section Part 16 Part 17

5

Where any requirement(s) conflict with any other requirement(s) of Authorities or Departments in the State of Qatar, the most stringent requirement(s) shall prevail.

19.1.2

References Al Wakra City Zoning Plan and Regulations Report, 2008, Ministry of Municipality & Urban Planning, State of Qatar Civil Defense Regulations, Fire Prevention Department, General Administration of Civil Defense, Ministry of Interior, State of Qatar

QCS 2014

Section 01: General Part 19: Regulatory Requirements

Page 3

Code on Barrier-Free Accessibility in Buildings, 2002 (ver 1.0), Building and Construction Authority, Singapore Conditions and Descriptions of the Expedient Workers Residences, Resolution of the Minister of Civil Service and Housing Affairs No. (17) of 2005, State of Qatar NFPA 101 Life Safety Code, 2012 Edition, National Fire Protection Association, U.S.A. Planning and Building Regulations for Flats & Flat Complexes, 1994, Planning Department, Ministry of Municipal Affairs & Agriculture, State of Qatar Planning and Building Regulations for Villas & Villa Complexes, 1995, Planning Department, Ministry of Municipal Affairs & Agriculture, State of Qatar Qatar Highway Design Manual, 1997 (Rev 0), Civil Engineering Department, Ministry of Municipal Affairs & Agriculture, State of Qatar Qatar Survey Manual, UPDA, The Centre for GIS – State of Qatar.

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Qatar Traffic Manual – Vol. 1 Qatar Traffic Manual – Vol. 2

Universal Design Guidelines, 2006, Building and Construction Authority, Singapore

NOTICES

19.2.1

General

1

All notices required to be given by the Contractor to the Department shall be in writing and delivered by hand. The Contractor shall furnish the Engineer with a copy of all notices issued by the Contractor.

19.2.2

Notice of Intent

1

The Contractor shall give at least seven days notice to the Department of the date upon which it is intended to operate plant or equipment or carry out any work for which permission has been given in writing by the Department: such operations or work shall only be carried out in the presence a representative of the Department unless written confirmation shall have been obtained that this unnecessary.

19.3

MISCELLANEOUS

19.3.1

Work required to be carried out by the Department

1

If the Department requires work to be carried out on its installations during the execution of the Works, the Contractor shall provide all facilities to the Department’s contractor or workmen. The Contractor shall co-ordinate the work of the Department and his own activities, and when necessary shall amend his programme to suit the requirements of the Department and shall keep the Engineer informed of all arrangements made.

19.3.2

Regulations of Road Openings

1

For Works including road openings, the Contractor shall comply with all relevant provisions of the following Parts of this Section or direction of the Engineer.

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19.2

Part 16 Part 21

Traffic Diversions. Final Inspection and Handover

QCS 2014

Section 01: General Part 19: Regulatory Requirements

Page 4

19.4

PROVISION FOR PERSONS WITH DISABILITIES

19.4.1

Scope

1

The aim of this provision is to set out the fundamental design and construction requirements and guidelines for making those buildings specified in Table 1 accessible to persons with disabilities. Table 1: Accessibility for Persons with Disabilities No

Accessible areas

Residential buildings: (a) 3-storeys and below

All communal areas and facilities at ground floor.

(b) 4-storeys and above

All communal areas and facilities.

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Types of buildings

Office buildings

All areas intended for access by employees or public.

3

Shophouses

The ground floor for non-residential use shall be accessible to employees or public.

4

Shopping complexes and multipurpose complexes

All areas intended for access by employees or public.

5

Hotels and boarding houses

All areas intended for access by employees or public.

6

Religious buildings and Mosques

All areas intended for access by worshippers or public.

7

Places of public resort

8

Cinemas, theatres, concert halls, stadia or other places of public resort where permanent seating arrangement is provided

All areas intended for access by employees or public.

9

Schools, colleges, universities or institutions of learning

All areas intended for access by employees or public.

10

Hostels, halls of residence or dormitories All areas intended for access by staff, students or public.

11

Sports complexes and public swimming pools

All areas intended for public access.

12

Restaurants and eating establishments

All areas intended for access by employees or public.

13

Markets and hawker or food centres

All areas intended for public access.

14

Hospitals, clinics, dispensaries, nursing homes, homes for the aged and welfare homes

All areas intended for access by staff, patients, inmates or public.

15

Factories, workshops and industrial buildings 4-storeys and above

All areas intended for access by employees or public.

16

Transport stations, interchanges, passenger terminals and administration buildings in depots

All areas intended for access by employees or public.

17

Vehicle parks (surface parking or vehicle parking buildings)

Prescribed areas.

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All areas intended for access by employees or public.

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Section 01: General Part 19: Regulatory Requirements

Page 5

The Owner is recommended to follow and adopt suitable and relevant international barrier free access guidelines which will allow persons with disabilities to enter, move around and leave an establishment without hindrances.

3

Universal Design is a continuous process of innovation targeted at improving usability for everyone. It is also known that Universal Design is the design of products and environment to be usable by all people, to the greatest extent possible, without the need for adaptation or specialised design. It is highly recommended that the Owner adopt Universal Design until the authority (MMUP) approve reference.

19.5

THERMAL COMFORT

1

The heating, ventilation and air conditioning (HVAC) system must be capable of providing the following range of conditions for 95% of the year Lower Limit DB: 22.5 ˚C

Relative humidity

RH: 30% (min)

Upper Limit

DB: 25.5 ˚C RH: 60% (max)

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Dry bulb temperature

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2

For occupant comfort, normal occupied spaces should have a terminal air velocity between (0.2-0.3) m/s.

19.6

THERMAL INSULATION

1

As specified in section 15

19.7

ACOUSTICAL CONTROL

1

As specified in section 15

19.8

WASTE MANAGEMENT

19.8.1

Construction and Demolition Waste

1

For all new buildings unless or until specified otherwise, at least fifty percent (50%) by volume or weight of waste material generated during the construction and/ or demolition of buildings must be diverted from disposal in landfills. Diverted materials must be recycled or reused.

2

This should be done through one or more of the following three paths:

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(a)

Concrete and Asphalt waste must be diverted to Construction Waste Treatment Plant.

(b)

Excavated soil, land-clearing debris and hazardous waste must be diverted to places designated by the concerned Department of MMUP.

(c)

Other recyclable materials such as woods plastics and metals can be used at site or diverted to a Recycling Facility.

The following materials are exempt from the calculation of the percentage of waste diverted from disposal at landfill facilities: (a)

Excavated soil and land-clearing debris; and

(b)

Hazardous waste

QCS 2014

Section 01: General Part 19: Regulatory Requirements

Page 6

Bulk Waste Collection

1

For all new residential apartment buildings, an area must be provided for residents to place items of bulky waste such as furniture, electrical appliances and sanitary ware. The area 2 provided must cover a space of approximately ten square meters (10 m ). The area does not have to be designated solely for the purpose of bulky waste collection (eg: set aside to the car park).

2

The bulky waste storage area must be reachable, must not restrict access to the building and comply with safety and fire requirement.

19.8.3

Waste Storage

1

For all new villas and apartments (single family units), domestic kitchen must be provided with a minimum storage facility of two ten (10) liter waste receptacles clearly labeled for ‘recyclable’ and ‘non-recyclable’. The storage facility should be in a proper place within the kitchen.

19.8.4

Waste Collection

1

All new buildings which require chute for general waste, in accordance with Qatar MMUP Regulations, one of the following must be provided:

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19.8.2

A second chute must be provided to handle recyclable material and discharge into a separate receptacle within the waste management area; or

(b)

The garbage room on each floor must have a minimum floor area of two square 2 meters (2 m ) where recyclable waste can be stored until collected daily by the building operator. Waste must be transported through designated medium (chute, service elevator etc.) into the waste management area.

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(a)

All new buildings which does not require chute for general waste, in accordance with Ministry of Municipal Affairs and Urban Planning Regulation, the garbage room on each floor must 2 have a minimum floor area of three square meters (3 m ) where non-recyclable and recyclable waste can be stored until collected daily by the building operator. Waste must be transported in a service left discharge into a designated receptacle within the waste management.

19.8.5

Recyclable Waste Management Facilities:

1

For all new buildings other than villas, a sorting and storage facility for recyclable materials must be provided.

2

This facility must be easily accessible and comply with the requirements of the location, access and specifications of general waste areas in accordance with Qatar Municipality Building Regulations.

3

The sorting and storage facility may be part of the general waste management facility or a separate facility.

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(a)

Recycled waste facility incorporated into the general waste collection: 2

The size of the room must be increased by 10% and not less than 5 m , to allow additional room to sort and store the recyclable waste.

QCS 2014

(b)

Section 01: General Part 19: Regulatory Requirements

Page 7

Recycled waste facility separated from the general waste collection: The recycled waste facility must be sized as a percentage from the total Built Up Area (BUA) of the building in accordance with Table 2.

Where the Total Built Up Area (BUA) of the building falls between the figures outlined in the Table, linear interpolation must be used to determine an appropriate percentage area for the recyclable storage space. Table 2: Sizing Requirements for Storage of Recyclables Built Up Area (BUA)

Minimum Space for Storage of Recyclables

Less than 500 m2

7.5m

2

1.5% of BUA

5,000 m

2

0.8% of BUA

.

1,000 m

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2

0.35% of BUA

2

10,000 m or greater

0.25% of BUA

BUILDING FACADE/ EXTERNAL CLADDING MATERIAL

19.9.1

Certification and approval

1

External Cladding material must be tested by an approved 3 manufacturer shall have certified ISO 9000 compliant QMS.

2

External Cladding materials that are combustible must be submitted to the Qatar Civil Defense for review and approval. Submissions shall include copies of relevant test reports and details on the proposed fixings used to secure the material to the building. On approval, a Qatar Civil Defense certificate for the External Cladding material will be issued to the submitting party.

19.9.2

Material properties

1

External Cladding Material (ECM) fixed to buildings shall be non-combustible and shall be composed of environmentally friendly materials and substances.

2

ECM not complying with 19.8.2.1 above must have the following fire propagation and flame spread properties.

rd

party test laboratory. The

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19.9

(a)

(b)

When tested in accordance with BS 476 Part 6: (i)

Fire Propagation index, no greater than 4.0

(ii)

any sub index must not be greater than 2.0, and

When tested in accordance with BS 476 Part 7: (i)

flame spread after 10 minutes must be less than 25 mm

3

Alternative test methods and Standards such as AS, BSI and ISO may be used to verify compliance in test reports provided the method of testing is demonstrated to be equivalent and verifies an equal or better fire performance result to those nominated in 19.8.2.2 above.

4

Details of the ECM's approval and listings, its method of fixing and the extent of usage shall be included in the proposed Building Plans fire safety submission for compliance verification.

QCS 2014

19.10

Section 01: General Part 19: Regulatory Requirements

Page 8

EXTERNAL FACADE CLEANING AND MAINTENANCE FOR HIGH RISE BUILDINGS

19.10.1 General 1.

Any building measuring 28 meters or above in height is classified as a high rise building as per Qatar Civil Defense Department. This section is intended to provide a framework for the cleaning and maintenance of the façade for high rise buildings. The façade will require both cleaning and maintenance to achieve its anticipated life and desired purpose. Failure to undertake this work can considerably reduce the life of materials, components and finishes. The provision of correct documentation and instruction at the completion of construction will permit the building owner to gain the best achievable performance from the façade.

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A maintenance manual should be produced for the completed works. The number and specific requirements for the manual should be specified at tender stage. The manual should be developed in parallel with the design and should include, but not be limited to, the following information: The name, address and telephone number of each firm and/ or sub-contractor involved in the supply of materials, components, assemblies and finishes.

(b)

A clear and concise description of the construction used to form the various areas of façade on the particular project.

(c)

Copies of material, component and finishes certification and test reports as required by the Specifier.

(d)

A method statement showing the means of access to all parts of the wall and safe loadings.

(e)

A method statement covering the procedures for replacement of damaged or otherwise defective materials or components, and materials and components that have a design life less than the design of the façade and will therefore require replacement during the life of the façade.

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(a)

Recommendations for routine maintenance, cleaning, suitable cleaning agents and any lubrication/adjustments to working parts.

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19.10.2 Maintenance Manual

(g)

A full set of construction drawings updated to include any changes made up to the time of completion.

(h)

The terms and conditions of any guarantees.

19.10.3 Access of Cleaning and Maintenance 1

The Building Owner/ Specifier should provide a means of access which enables all parts of the façade to be safely reached for the purpose of cleaning, inspection and maintenance. The intended method of access should be established at the design stage and the relevant loads catered for. Particular care should be made to define all possible imposed loads including impact loads and uplift forces on projections by snagging.

2

The access system should comply with the appropriate British Standards (BS 6037, BS 5974). Specifiers should also make themselves aware of any statutory obligations related to Occupational Health and Safety at Work.

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Section 01: General Part 19: Regulatory Requirements

Page 9

3

The access system should not be capable of imparting forces upon the cladding system exceeding those agreed at the design stage. It is important that the various parties agree the design parameters early in the design process.

4

The access equipment should be maintained, examined periodically by a competent person and certified in accordance with statutory regulations.

19.10.4 Cleaning The supplier of the façade should provide instruction for the proper cleaning and routine maintenance of the façade.

2

Cleaning of the façade should be undertaken by trained personnel working to an agreed procedure, based upon the façade contractor’s recommendations, at a frequency not less than the recommended intervals.

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19.10.5 Inspection

The façade should be inspected at regular intervals to an agreed method. The façade contractor, in consultation with the project team, should suggest methods and procedures to be utilized. The purpose of this inspection includes, but is not necessarily limited to, the following:

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To review the effectiveness of cleaning methods employed.

(b)

To monitor the performance of the materials and components of the façade system against their anticipated life.

(c)

Inspecting for damage or failure of any part of the system.

(d)

Checking on the effectiveness of maintenance or remedial work.

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It is recommended that a detailed inspection plan is drawn up at the time of construction in consultation between the design and construction teams. The inspection plan should include procedures and recording methods to enable a systematic monitoring of the condition of the Curtain wall and assist in the prediction of the need for preventative maintenance or replacement of component parts.

3

Inspections should be carried out by suitably experienced persons to the specific procedures detailed in the inspection plan. The results of these inspections should be compared with previous inspections where appropriate. The building owner should ensure these results are available for reference.

19.11

PROVISION OF ABLUTION FACILITIES IN PUBLIC BUILDINGS

1

The public buildings, for the purpose of provision of Ablution facilities are considered to be Offices, Shopping Centres, Malls and Hypermarkets.

2

The occupant load (population) for each building type shall be calculated as per guidelines of Qatar Civil Defense Department.

3

Separate Ablution facilities are to be provided for Men and Women close to the Prayer Area.

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QCS 2014

Page 10

The number of Ablution stalls shall be calculated as per Table 3 below. Table 3: Provision of Ablution Facility Facility Type

Occupant Population

No. of Ablution Stalls

Up to 50

02

For 51 and above

01 For each additional 50

Up to 200

02

For 201 and above

01 For each additional 200

Up to 200

02

Office Building

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Shopping Mall

01 For each additional 400 01 For each additional 1000

201- 2000 people

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END OF PART

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Section 01: General Part 19: Regulatory Requirements

QCS 2014

Section 01: General Part 02: Use and Maintenance of the Site

Page 1

USE AND MAINTENANCE OF THE SITE ............................................................... 2

2.1 2.1.1

GENERAL ............................................................................................................... 2 Scope 2

2.2 2.2.1

USE OF THE SITE .................................................................................................. 2 General 2

2.3 2.3.1

MAINTENANCE OF THE SITE................................................................................ 2 General 2

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Section 01: General Part 02: Use and Maintenance of the Site

Page 2

2

USE AND MAINTENANCE OF THE SITE

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the uses and maintenance requirements of the Site.

2

Related Sections and parts are as follows: This Section

Part 10 Part 11 Part 12

Occupational Health and Safety Engineer’s Site Facilities Contractor’s Site Facilities

USE OF THE SITE

2.2.1

General

1

The Site shall not be used for any purpose other than that of carrying out the Works.

2

Temporary camps, housing and cooking facilities shall not be permitted on the Site unless otherwise stated in the Project Documentation. When temporary camps, housing and cooking facilities are permitted they shall comply with Section 1 Part 10.

2.3

MAINTENANCE OF THE SITE

2.3.1

General

1

In accordance with the Conditions of Contract the Site, the equipment used upon it and the Works shall be kept clean at all times.

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2.2

END OF PART

QCS 2014

Section 01: General Part 20: Clearance of the Site

Page 1

CLEARANCE OF SITE ............................................................................................ 2

20.1 20.1.1

GENERAL ............................................................................................................... 2 Scope 2

20.2 20.2.1 20.2.2 20.2.3 20.2.4

FINAL CLEARING ................................................................................................... 2 General 2 Internal and External Surfaces 2 The Site 2 Miscellaneous 3

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QCS 2014

Section 01: General Part 20: Clearance of the Site

Page 2

CLEARANCE OF SITE

20.1

GENERAL

20.1.1

Scope

1

This Part specifies the requirements for the final clearance of the Site.

20.2

FINAL CLEARING

20.2.1

General

1

Final clearing shall be done before the final inspection.

2

All waste materials shall be removed from the Site and disposed of properly.

20.2.2

Internal and External Surfaces

1

The Contractor shall clean all interior and external surfaces exposed to view. The Contractor shall undertake the following to the satisfaction of the Engineer:

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Remove temporary labels, stains and foreign substances.

(b)

Polish transparent and glossy surfaces.

(c)

Clean roofs, gutters, downspouts, and drainage systems.

(d)

Remove debris and surface dust from limited access spaces.

(e)

Broom clean concrete floors and unoccupied spaces.

(f)

Clean light fixtures and lamps so they operate at maximum efficiency.

(g)

Other cleaning tasks as specified by the Engineer.

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The Site

1

The Contractor shall clean the Site and shall undertake the following to the satisfaction of the Engineer:

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2

(a)

Sweep paved areas and rake all other surfaces.

(b)

Remove litter and foreign substances.

(c)

Remove stains, chemical spills and other foreign deposits.

(d)

Any other cleaning tasks as specified by the Engineer.

The Contractor shall abide by the latest regulations of the Ministry of Municipal Affairs and Agriculture and relevant municipalities in clearance of construction works refuse.

QCS 2014

3

Section 01: General Part 20: Clearance of the Site

Page 3

Clearance and transportation of construction works refuse: (a)

The Contractor shall undertake to carry out the following within a maximum period of 30 days after completion of the agreed building or project and preparing it for use or stoppage of work for an indefinite period. (i)

Removal of the entire Contractor’s equipment, machinery and other belongings from the work site.

(ii)

Clearance of all earth, debris and refuse whatsoever and transporting them to the location designated by the concerned municipality, delivering the building or project absolutely clean and free of any such materials and delivery of the surrounding area levelled to the natural level of the street pavement.

In the case of Contractor’s delay or refusal to carry out such a job, he shall have to pay a penal compensation as defined in the contract for delay for each day or part of day. This compensation shall be final and the judiciary shall not be entitled to mitigate it and it does not require establishing the occurrence of any damage to the owner.

(c)

In addition, the Owner shall be entitled to clear the refuse himself and transport it to the location designated by the concerned municipality. The Owner shall deduct the cost of refuse clearance, transport and any other related costs including the office expenses and overhead cost from the payment or the money due to the Contractor. He may also stop the final payment due to the Contractor until such refuse has been cleared and a certificate confirming this has been obtained from the concerned Municipality.

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(b)

Miscellaneous

1

The Contractor shall clean or replace all mechanical filters for equipment included in the Works and for equipment directly affected by the construction of the Works.

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20.2.4

END OF PART

QCS 2014

Section 01: General Part 21: Final Inspection and Handover Procedures

Page 1

21

FINAL INSPECTION AND HANDOVER PROCEDURES .............................. 2

21.1

GENERAL PROCEDURES FOR INSPECTION AND HANDOVER .............. 2

21.1.1 21.1.2 21.1.3 21.1.4

Scope Pre-requisite for Final Inspection Approvals from Public Authorities Hand Over

21.2

ITEMS TO BE PROVIDED BY THE CONTRACTOR .................................... 4

2 2 3 3

21.2.1 Provision of Tools, Spare Parts and Maintenance Materials 21.2.2 Guarantee Warrantees and Bonds

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21.3.1 Operation Data 21.3.2 Operation and Maintenance Manuals 21.3.3 Operational, Field and Performance Testing

.

MECHANICAL AND ELECTRICAL WORKS ................................................. 4

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4 4 4 4 5

PROJECT RECORD DOCUMENTS.............................................................. 5

21.4.1 21.4.2 21.4.3 21.4.4

General Record Drawings Record Specifications Maintenance Period Final Inspection

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5 6 6 6

QCS 2014

Section 01: General Part 21: Final Inspection and Handover Procedures

Page 2

21

FINAL INSPECTION AND HANDOVER PROCEDURES

21.1

GENERAL PROCEDURES FOR INSPECTION AND HANDOVER

21.1.1

Scope

1

This Part specifies the requirements and procedures associated with the inspection and handover of the Works.

2

Related sections and Parts are as follows: Part 7 Part 9 Part 20

Submittals Materials Clearance of Site

Section 2 Section 9

Quality Assurance and Quality Control Mechanical and Electrical Equipment

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Pre-requisite for Final Inspection

1

The Contractor shall complete the following to the satisfaction of the Engineer before requesting the pre-handover Inspection:

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21.1.2

Submit final manufacturer certification, guarantees, warranties and similar documents.

(b)

Submit occupancy permits, operating certificates, final inspection and test certificates and similar releases enabling full and unrestricted use of the Works.

(c)

Submit record drawings, operation and maintenance manuals, final project photographs, damage or settlement surveys, property surveys and similar physical items.

(d)

Complete submittal of record documents.

(e)

Make final changeover of locks and deliver the keys to the Engineer.

(f)

Complete start-up, testing of system, and training of the Owner’s operations and maintenance personnel; submit equipment operating data as well as all test reports and test data required by the Contract.

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(g)

Dismantle and remove temporary facilities and services from the Site; this includes utilities, construction tools, buildings and facilities, mock-ups, and similar elements

(h)

Complete final cleaning.

(i)

Repair and restore exposed finishes which have been marred or otherwise damaged.

(j)

Handover all spare parts, tools and maintenance equipment.

(k)

In Network Projects, partial handling over would be acceptable, if it completely met all the above mentioned requirements.

(l)

Closure of all identified Non-conformance and deficiencies to the satisfaction of the Engineer

QCS 2014

Section 01: General Part 21: Final Inspection and Handover Procedures

Page 3

When the Contractor has completed and cleaned the Works to the satisfaction of the Engineer the Contractor shall request a final inspection. The request shall be forwarded to the Owner by the Engineer’s Representative and a suitable date for the inspection shall be arranged. The Contractor, Engineer’s Representative, maintenance department (if any) and the supervising consultant (if any) shall be present. A list of outstanding items (if any) shall be agreed and issued to the Contractor.

3

Upon completion of the listed outstanding items a further inspection shall be requested by the Contractor, the request shall be forwarded to the Owner by the Engineer’s Representative and a suitable date for the inspection shall be arranged. The Contractor, Engineer’s Representative, maintenance department (if any) and the supervising consultant (if any) shall be present.

4

A list of any items still outstanding shall be issued to the Contractor. If any of these are deemed to be significant the Contractor shall complete these items and then request another inspection as described in clause 21.1.2-2.

5

In respect of pumping station or Works involving mechanical or electrical equipment if items outstanding are deemed not to be significant or if no outstanding items remain then a 7 day commissioning and running test shall be initiated. On completion of all tests and agreement by the Engineer’s Representative that the plant is considered operable then it shall be handed over. A 14 day training period for the maintenance department staff on the operation of the pumping station shall commence.

6

For works that have no mechanical or electrical equipment if the outstanding items are deemed not to be significant or if no outstanding items remain the Works inspected shall be handed over.

21.1.3

Approvals from Public Authorities

1

The Contractor shall obtain all clearance certificates and approvals required as a prerequisite to connecting the Works to the permanent water and/or power supply.

2

The Contractor shall co-ordinate with the Engineer to obtain the necessary documents from the Qatar General Electricity & Water Corporation regarding connection to the permanent water and/or power supply.

21.1.4

Hand Over

1

When the Contractor considers that the Works are complete he shall submit the following:

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(a)

A certificate stating that the Works are complete and that all the requirements of the Project Documentation have been met.

(b)

A certificate stating that the Works have been inspected.

(c)

A certificate from the appropriate Municipality regarding cleanliness of the Site.

(d)

Approval from the PWA regarding satisfactory trench reinstatement in the Highway (if applicable).

QCS 2014

Section 01: General Part 21: Final Inspection and Handover Procedures

Page 4

ITEMS TO BE PROVIDED BY THE CONTRACTOR

21.2.1

Provision of Tools, Spare Parts and Maintenance Materials

1

The Contractor shall provide all tools, spare parts and maintenance materials specified in the Project Documentation.

2

The Contractor shall provide an itemised list of all the items to be furnished under this Clause. Each item to be furnished shall be given a unique reference number. The list shall include the reference number, a description of the item and the appropriate Specification Section and Paragraph.

3

All the items furnished under this Clause shall be packaged for long term storage. Any items requiring special storage conditions shall be brought to the attention of the Engineer.

4

All items furnished under this Clause shall be provided with a mark or tag for identification purposes. The mark or tag shall include the reference number detailed in Clause 21.2.1-2.

5

Unless otherwise instructed, all items furnished under this Clause shall be delivered to the Government Stores in accordance with the relevant provision of Part 9 of this Section, Materials.

21.2.2

Guarantee Warrantees and Bonds

1

The Contractor shall provide notarised copies of all guarantees, warranties and bonds as required by the Project Documentation. The guarantees, warranties and bonds should be assembled in a binder with a durable plastic cover, complete with a table of contents.

2

The start of the warranty or guarantee period shall be either:

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21.2

The date when any item is placed into full time operation for the Government’s benefit and with the Engineer’s approval.

(b)

The date of issue of the completion certificate.

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MECHANICAL AND ELECTRICAL WORKS

21.3.1

Operation Data

1

The Contractor shall provide all operating data for all mechanical and electrical equipment supplied under the Contract.

2

The operating data shall be presented on A4 size paper in ring binder with a durable plastic cover.

21.3.2

Operation and Maintenance Manuals

1

The Contractor shall provide approved Operation and Maintenance Manuals in accordance with the relevant provisions of Section 9, Mechanical and Electrical Equipment and Part 7 of this Section, Submittals.

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QCS 2014

Section 01: General Part 21: Final Inspection and Handover Procedures

Page 5

Operational, Field and Performance Testing

1

After all construction and starting is complete and before taking-over of any part of the Works, the Contractor shall perform operational, field and performance tests as called for in the Project Documentation.

2

The Contractor shall demonstrate operation of the facilities of the Engineer showing proper sequence of operation as well as satisfactory performance of the system and individual components. Any improper operation of the system or any improper, neglected or faulty construction shall be repaired or corrected to the satisfaction of the Engineer. The Contractor shall make such changes, adjustments or replacement of equipment as may be required to make same comply with the Specifications, or replace any defective parts or material.

3

Failure of the system to perform at the specified level at the time of testing will be the responsibility of the Contractor. In the event of failure of equipment to meet the specified performance, the Owner reserves the right to reject such equipment or system, withhold retention money or make claims on the Performance Bond.

4

The Contractor shall submit a consolidated schedule of operation, field and performance tests no later than three (3) months before the schedule start of the first test and weekly a schedule of tests to be carried out the following week. The Contractor shall inform the Engineer not later than 24 hours in advance of changes in the scheduling of a test.

5

For all specified performance tests, the Contractor shall prepare and submit the following:

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A draft test procedure no later than two (2) months in advance of the schedule test date.

(b)

A final test procedure no later two (2) weeks in advance of the scheduled test date.

(c)

A test report within two (2) weeks of the successful completion of the test.

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PROJECT RECORD DOCUMENTS

21.4.1

General

1

Project Record Documents shall be kept separate from construction/working documents.

2

Project Record Documents shall be stored in facilities that provide a suitable environment to prevent damage or deterioration and to prevent loss.

3

Project Record Documents shall include, but not be limited to the following:

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(a)

Drawings.

(b)

Specifications.

(c)

Addenda.

(d)

Variation orders.

(e)

Correspondence.

(f)

Transmittals

(g)

Inspection and Test Records

QCS 2014

Section 01: General Part 21: Final Inspection and Handover Procedures

Page 6

Record Drawings

1

Record drawings shall be clearly and correctly “red-marked” by the Contractor to show all changes made during the construction process. The record drawings shall show the Works as executed in accordance with the relevant provisions of Part 7 of this Section - Submittals.

21.4.3

Record Specifications

1

Record specifications shall be clearly and correctly annotated to show all changes made during the construction process.

21.4.4

Maintenance Period Final Inspection

1

During the last month of the period of maintenance the Engineer will notify the maintenance department that the maintenance period is about to expire. An inspection of the Works by the Engineer’s Representative, maintenance department, and the Contractor shall be undertaken to verify that all outstanding items have been completed.

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END OF PART

QCS 2014

Section 01: General Part 22: New Technologies and Innovations

Page 1

22

NEW TECHNOLOGIES AND INNOVATIONS............................................... 2

22.1

GENERAL PROCEDURES FOR APPROVAL............................................... 2

22.1.1 22.1.2 22.1.3 22.1.4 22.1.5

Scope Pre-requisite for Approval Technologies And Innovations Of Interest Documentation Final Inspection And Approval

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2 2 2 3 3

QCS 2014

Section 01: General Part 22: New Technologies and Innovations

Page 2

NEW TECHNOLOGIES AND INNOVATIONS

22.1

GENERAL PROCEDURES FOR APPROVAL

22.1.1

Scope

1

Qatar is committed to researching and using new technology and innovations within construction industry. Because of this commitment it is open to proposals from outside agencies in the use of new technologies and innovations.

2

This Part specifies the requirements associated with the proposal and approval of new technologies and innovations for use in construction in Qatar.

22.1.2

Pre-requisite for Approval

1

New technologies / innovations are allowed for use in any project on experimental or research basis after getting an approval from National Committee For Construction and Building materials Specifications (NCCBS) of the Ministry of Environment and any other concerned parties.

2

The period allowed for such an experiment or research shall be limited to a trial period of a maximum of two years after which it will be evaluated prior to approval or otherwise by the concerned parties.

3

The supplier will be required to submit a guarantee certificate for an agreed period of time.

4

The supplier shall submit a written warranty to bear all fiscal and legal responsibilities as a result of using the experiment if not meeting the suppliers’ claims/specifications. He shall remove any material or debris left from the experiment.

22.1.3

Technologies And Innovations Of Interest

1

The following are of particular interest to Qatar : (a)

Polymer Modified Bitumen (PMB) Superpave

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2

(c)

Performance Grade Binders suitable for the climatic conditions of Qatar (i.e. PG 76-10)

(d)

Cold Laid Asphalt

(e)

Rubber Recycling

(f)

Stone Mastic Asphalt (SMA)

(g)

Glass Reinforced Plastic (GRP) pipes

(h)

Polyethylene (PE) Plain and Corrugated pipes

(i)

Fibre Reinforced Concrete

(j)

Recycling of materials from demolished buildings and roads

Notwithstanding the above Qatar wishes suppliers to propose technology and innovations that it believes can benefit Qatar and the environment.

QCS 2014

Section 01: General Part 22: New Technologies and Innovations

Page 3

22.1.4

Documentation

1

The technology provider shall be requested to submit with his proposals the following documents: Drawings

(b)

Specifications

(c)

Technology Reference and Manual

(d)

Specifications and Source

(e)

Reference from previous clients

(f)

Transmittals

(g)

Inspection and Test Records

(h)

Health and Safety requirements

(i)

Environmental requirements

(j)

Material Safety Data Sheet (MSDS) regarding but not limited to transportation, handling & storage, and First Aid requirements

(k)

Financial arrangements

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Final Inspection And Approval

1

Final approval of the technology will be dependant on NCCBS visits, inspection and tests. Upon satisfaction of the committee, written approval shall be given and the specifications incorporated into the QCS.

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22.1.5

END OF PART

QCS 2014

Section 01: General Page 1 Part 23: Design & Supervision Consultant Quality Requirements

DESIGN & SUPERVISION CONSULTANT QUALITY REQUIREMENTS................................ 2

23.1 23.1.1 23.1.2 23.1.3

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definitions 2

23.2 23.2.1 23.2.2 23.2.3 23.2.4 23.2.5 23.2.6

DESIGN CONSULTANT QUALITY REQUIREMENTS ............................................ 3 Quality Responsibility and Duties 3 Quality System Documentation 3 Quality Plan 4 Construction Inspection and Test Requirements Specification 5 Design Consultant Verification of Sub Consultants 5 Quality Records 5

23.3 23.3.1 23.3.2 23.3.3 23.3.4 23.3.5 23.3.6 23.3.7 23.3.8 23.3.9 23.3.10 23.3.11 23.3.12 23.3.13 23.3.14 23.3.15

SUPERVISION CONSULTANT QUALITY REQUIREMENTS.................................. 5 Quality Responsibilities and Duties 5 Quality System Documentation 7 Quality Plan 8 Inspection and Test Plan’s (ITP’S) 9 Technical Procedures, Work Instructions and Method Statements 9 Monitoring by Supervision Consultants 10 Review of Contractor Quality Documentation 10 Inspection Responsibilities 11 Inspections and Test Surveillance Points 11 Visits 12 Supervision Consultant Verification 12 Interfacing 12 Punch Lists 12 Protection of the Works 12 Quality Records 12

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QCS 2014

Section 01: General Page 2 Part 23: Design & Supervision Consultant Quality Requirements

DESIGN & SUPERVISION CONSULTANT QUALITY REQUIREMENTS

23.1

GENERAL

23.1.1

Scope

1

This Part specifies the Quality Assurance activities to be performed by Design and Supervision Consultants during all phases of the Contract and should be read in conjunction with all other parts of the Contract.

2

The purpose of this part is to define Design and Supervision Consultants responsibility for demonstrating that the work under the contract is executed to the quality standards required by the contract and to outline verification activities.

23.1.2

References

1

The following standards are referred to in this part:

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Quality Management systems. Fundamentals and vocabulary

BS EN ISO 9001:2008

Quality Management systems. Requirements

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BS EN ISO 9000:2005

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BS ISO 10006:2003 ...Quality Management systems, Guidelines for Quality Management in Projects BS EN ISO 19011:2011

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BS ISO 10005:2005 ...Quality Management systems. Guidelines for Quality Plans Guidelines for auditing management systems

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QCS Qatar Construction Specification Definitions

1

Defect or Non-conformance: any part of the Works not executed, provided or completed in accordance with the Contract. For the avoidance of doubt and without limiting the generality of the expression the term shall be taken to include any item of Plant, material, goods or work incorporated or used in the Works which does not or may not conform to the relevant quality standards or pass the tests prescribed in or to be inferred from the Contract

2

Owner: The Ministry, Municipality, Department, Affairs, Agency, Authority, or individual for whom the Project is being undertaken and to whom the handover of the final product will be made.

3

QA & QC: Quality Assurance & Quality Control and this may be written as QA/QC.

4

QA: Quality Assurance. Part of quality management focused on providing confidence that quality requirements will be fulfilled. QA involves a continuous evaluation of the adequacy and effectiveness of the overall Quality Management System in order to evaluate the deviation from established quality objectives.

5

QC: Quality Control. Part of quality management focused on fulfilling quality requirements. The QC involves specific control points during design, fabrication or construction stages to check the fulfilling of design criteria, acceptance criteria (tolerance, etc.), performance criteria or functional criteria.

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QCS 2014

Section 01: General Page 3 Part 23: Design & Supervision Consultant Quality Requirements

QMS: Quality Management System. A set of interrelated or interacting processes, activities or tasks to direct Project resources to achieve established quality policy and objectives.

7

Quality Management: Coordinated activities to direct and control an organization with regards to quality.

23.2

DESIGN CONSULTANT QUALITY REQUIREMENTS

23.2.1

Quality Responsibility and Duties

1

The Design Consultant shall be responsible for setting up implementing and monitoring his own Contract Specific Quality Management System meeting the requirements of this part.

2

The Design Consultant shall be responsible for quality auditing, monitoring and oversight of any sub-consultants under their control.

3

The Design Consultant shall perform and or witness any examinations and tests necessary to demonstrate conformance of the works to the requirements of the Contract and shall accept only works by the Contractor that so conform:

4

The Design Consultant shall establish and maintain a system of records which shall provide objectives evidence that the supervision Consultant is meeting the requirements of this specification and that the Contractors control and inspections are effective in meeting the minimum standards required under their contract. Records shall be made available to the Engineer in accordance with the requirements stated herein or elsewhere in the contract.

5

The Design Consultant will be subject to monitoring through audit and surveillance by the Engineer. In both cases the Design Consultant shall promptly rectify any negative findings with their Quality System rectify non-conformities and corrective actions found during audit and surveillance activities directed at them.

6

No part of the Quality system shall be used to preclude or otherwise negate the requirement of any part of the contract, or the obligation of the Design Consultant pursuant to the Contract.

7

The Design Consultant shall appoint a suitably qualified, Quality Manager to verify that the requirements of this specification are met. The proposed Quality Manager shall be subject to approval by the Engineer.

23.2.2

Quality System Documentation

1

The Design Consultant Quality system shall Include as a minimum the following

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(a)

Quality Plan as detailed in 23.2.3 below

(b)

Procedures and work instruction: The Design Consultant Quality system must include all relevant technical procedures and other pertinent documentation to ensure that the design works are completed in accordance with the contract, with specific reference to the minimum requirements of standards reference in 23.1.2 above and including the mandatory procedures required by ISO 9001:2008.

QCS 2014

Section 01: General Page 4 Part 23: Design & Supervision Consultant Quality Requirements

(c)

Quality Records: In addition to (and including) quality records identified in the contract or other applicable codes, standards or procedures, the Design Consultant shall identify project quality records in compliance with the minimum requirements standards referenced in 23.1.2 above.

(d)

Reference and other related documents.

Quality system documents shall be submitted to the owner for review, comment and approval within 30 days after contract award. In the event that comments are made on the contract Quality system documentation submitted for review and comment, the design consultant shall make adjustments, correction, amendment or alteration required. Such comment will be made on the premise that the adjustment, correction, amendment or alteration is within the scope of the contract and will not affect the contract conditions, specifications, guarantees, price or the like in anyway.

3

Adjustments, corrections, amendments or alterations made by the Design Consultant to the contract quality system shall, after revision be resubmitted by the Design Consultant to the owner for review and approval.

23.2.3

Quality Plan

1

Design Consultants are required to submit Quality Plan (addressing their design activities) which are specific (not generic) to the Contract, meeting as a minimum the requirements of the standards referenced in 23.1.2 above. This plan shall reference, or include other documentation which is relevant to the Contract. However as a stand-alone document, the Quality Plan shall clearly indicate how the Quality process shall be applied to meet the requirements of the contract. Particular emphasis is to be placed on the following. Relevant extracts from the Corporate Quality Manual reference to specifications, standards etc;

(b)

List of all procedures applicable to the project;

(c)

QA/QC Organisation;

(d)

Document Control;

(e) (f)

(g)

List of all procedures applicable to the Consultants Project Quality System;

(h)

Audits (including internal and external Audits Plans);

(i)

Management Review;

(j)

Quality objectives, Key Performance Indicators (KPIs)

(k)

Allocation of resources;

(l)

Responsibilities and authority for all phases of work;

(m)

Control of Non-conformance, corrective and preventive actions.

(n)

Contract Changes;

(o)

Lessons learned and continual improvement;

(p)

Purchasing Process e.g. Sub Consultants.

(q)

Quality Records

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Inspection and Test;

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2

The Design Consultants Quality plan will make reference to and take into account applicable codes, standards, specifications, quality characteristics and regulatory requirements as necessary. It will identify the criteria by which the design and developments inputs and outputs should be accepted, and how, at what stage(s) and by whom, the outputs should be reviewed, verified and validated.

3

The Design Consultants Quality Plan will also state the following. How request for changes and development will be controlled to meet Contractual requirements;

(b)

Who is authorised to initiate a change request;

(c)

How changes will be reviewed in terms of their impact;

(d)

Who is authorised to approve or rejects changes;

(e)

How the implementation of changes will be verified;

(f)

When design and development reviews take place;

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(a)

Construction Inspection and Test Requirements Specification

1

The Design Consultant shall provide a specification addressing the complete inspection and testing regime related to their design output, taking into account the requirements of the QCS. This shall be guiding document by which Supervision Consultants and Contractors will be held accountable for all on and off site tests and inspections to be performed. The Inspection and Test Requirements Specifications must be sufficiently detailed to leave no questions regarding the number of samples required or types of tests to be made over and above the requirements of the QCS and which standards must be complied with.

23.2.5

Design Consultant Verification of Sub Consultants

1

The Design Consultant is required to perform audits and verification activities at any sub consultants premises to gain assurance that the subcontracted product conforms to specified requirements.

23.2.6

Quality Records

1

In addition to (and including) quality records identified in the contract or other applicable codes, standards or procedures, the Design Consultant shall determine project Quality records in compliance with requirements of ISO 9001:2008 and other relevant standards stated in contract documents and 23.1.2 above.

2

The list of quality records generated during the life of the contract, and made available upon request for review by the Owner, shall be indexed by the Design Consultant in his Quality Plan.

3

The Design Consultant shall maintain Registers for all incoming and outgoing documents.

23.3

SUPERVISION CONSULTANT QUALITY REQUIREMENTS

23.3.1

Quality Responsibilities and Duties

1

The Supervision Consultant shall be responsible for setting up implementing and monitoring his own Contract Specific Quality Management System meeting the requirements of this part

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23.2.4

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The Supervision Consultant shall be responsible for quality auditing, monitoring and oversight of themselves any consultants, contractors, sub-contractors (Including laboratories) under their control.

3

The Supervision Consultant shall perform and/or witness any examinations and tests necessary to demonstrate conformance of the works to the requirements of the Contract and shall accept only works by the Contractor that comply with the specified requirements.

4

The Supervision Consultant shall witness sampling and related testing performed on as well as testing performed in external Third Party Laboratories.

5

The Supervision Consultant shall establish and maintain a system of records which shall provide objectives evidence that the supervision Consultant is meeting the requirements of this specification and that the Contractors control and inspections are effective in meeting the minimum standards required under their contract. Records shall be made available to the Engineer in accordance with the requirements stated herein or elsewhere in the contract.

6

The Supervision Consultant will be subject to monitoring through audit and surveillance by the Engineer. In both cases the Supervision Consultant shall promptly rectify any negative findings with their quality system rectify non-conformities and corrective actions found during audit and surveillance activities directed at them.

7

The Supervision Consultants shall follow up on all findings (NCR’s, CAR’s Observations) issued on the project to, or by the contractor or other entities under the contract.

8

No part of the quality system shall be used to preclude or otherwise negate the requirement of any part of the contract, or the obligation of the Supervision Consultant pursuant to the Contract.

9

The Supervision Consultant is responsible for ensuring the contactor’s Work meets all technical and quality requirements of the contract and shall keep continuous records of action taken and shall advise the Engineer in writing of significant alteration to construction or manufacturing techniques to ensure that specified requirements are met.

10

The Supervision Consultant shall conduct audit and surveillance activities to provide evidence of the use and effectiveness of the Contractors quality system throughout the execution of the contract.

11

The Supervision Consultant will ensure that the Contractor has included the quality assurance requirements of the contract into subcontracts entered into by the Contractor.

12

The Supervision Consultant shall provide an effective audit and surveillance process for works performed by a Contractor’s Subcontractors..

13

The Supervision Consultant shall verify that the Contractor’s Project Quality Plan, Inspection and Test Plans and other such quality documentation includes or references the Quality Plans, and Inspection and Test Plans of subcontractors and vice versa. All of these documents must be reviewed and approved by the Supervision Consultant.

14

The Supervision Consultant shall hold contract specific QA/QC meetings chaired by the Consultant on a monthly basis throughout the duration of the Work. Topics to be addressed at the site quality meeting shall include, but shall not be limited too:

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Section 01: General Page 7 Part 23: Design & Supervision Consultant Quality Requirements Reviewing of the previous months Quality

(b)

Current Performance of the activities

(c)

Providing 4 week look ahead of planned activities

(d)

Non Conformance of activities

(e)

Key performance indicators

(f)

Audit schedule

(g)

Status of inspection of test plans and method statements

(h)

Quality Training

(i)

Contractors Project quality plan and quality control plans review and on-going effectiveness

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(a)

The Supervision Consultant shall be responsible for providing a Monthly Quality Report template, meeting the Owner requirements, to the Contractor and reviewing the completed reports submitted by the Contractor.

16

The Supervision Consultant shall be responsible for completing any QA/QC Questionnaires or Reports required by the Owner.

17

The Supervision Consultant shall appoint a suitably qualified, full time, Quality Manager to verify that the requirements of this specification are met. The proposed Quality Manager shall be subject to approval by the Owner.

23.3.2

Quality System Documentation

1

The Supervision Consultant Quality System shall include as a minimum the following elements.

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Quality Plan as detailed in 23.2.3 below

(b)

Procedures and work instruction: The Supervision Consultant Quality system must include all relevant technical procedures and other pertinent documentation to ensure that the design works are completed in accordance with the contract, with specific reference to the minimum requirements of standards reference in 23.1.2 above including the mandatory procedure required by ISO 9001:2008

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(c)

Quality Records: In addition to (and including) quality records identified in the contract or other applicable codes, standards or procedures, the Supervision Consultant shall identify project quality records in compliance with the minimum requirements standards referenced in 23.1.2 above

(d)

Reference and other related documents

These Quality system documents shall be submitted to the Owner for review, comment and approval within 30 days after contract award. In the event that comments are made on the contract quality system documentation submitted for review and comment, the Supervision Consultant shall make adjustments, correction, amendment or alteration required. Such comment will be made on the premise that the adjustment, correction, amendment or alteration is within the scope of the contract and will not affect the contract conditions, specifications, guarantees, price or the like in anyway.

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Adjustments, corrections, amendments or alterations made by the Supervision Consultant to the contract quality system shall, after revision be resubmitted by the Supervision Consultant to the Owner for review and approval.

23.3.3

Quality Plan

1

Supervision Consultants are required to submit Quality Plans (addressing their supervision activities) which are specific (not generic) to the Contract, meeting as a minimum the requirements of the standards referenced in 23.1.2 above. This plan shall reference, or include other documentation which is relevant to the Contract. However as a stand-alone document, the Quality Plan shall clearly indicate how the Quality process shall be applied to meet the requirements of the contract. Particular emphasis is to be placed on the following requirements of ISO 9001:2008. Relevant extracts from the Corporate Quality Manual reference to specifications, standards etc;

(b)

List of all procedures applicable to the project;

(c)

QA/QC Organisation;

(d)

Document Control;

(e)

Inspection and Test;

(f)

Specific work practices;

(g)

List of all procedures applicable to the Consultants Project Quality System;

(h)

Audits (including internal and external Audits Plans);

(i)

Management Review;

(j)

Quality objectives, Key Performance Indicators (KPIs)

(k)

Allocation of resources;

(l)

Responsibilities and authority for all phases of work;

(m)

Control of Non-conformance, corrective and preventive actions.

(n) (o) (p)

Purchasing Process e.g. Sub Consultants.

(q)

Quality Records;

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Contract Changes;

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2

The Supervision Consultants Quality Plan will make reference to applicable codes, standards, specifications, quality characteristics and regulatory requirements as appropriate. It will identify the criteria by which inputs and outputs should be accepted, and how, at what stage(s), and by whom, the outputs should reviewed, verified and validated.

3

The Supervision Consultants Quality Plan will also address the following: (a)

How request for changes and development will be controlled to meet Contractual requirements;

(b)

Who is authorised to initiate a change request;

(c)

How changes will be reviewed in terms of their impact;

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Section 01: General Page 9 Part 23: Design & Supervision Consultant Quality Requirements

(d)

Who is authorised to approve or reject changes;

(e)

How the implementation of changes will be verified;

(f)

When reviews take place;

(g)

Redline and As-Built process;

Where design is required by the Contractors contract, the Supervision Consultant responsibilities for the Contractors design work shall be as defined under the contract, however not withstanding this the Supervision Consultant shall responsible for auditing this function of the Contractors quality system.

23.3.4

Inspection and Test Plan’s (ITP’S)

1

As per the requirements of QCS, the Supervision Consultants shall require the Contractor to submit Inspection and Test Plans to the Supervision Consultant a minimum 30 days prior to the programmed work start date covered by each Inspection and Test Plan.

2

The Minimum requirements for the Contractors Inspection and Test Plan are defined in QCS, and the supervision Consultant is responsible for ensuring the Contractors Inspection and Test Plan as a minimum meet these requirements or the recommendations of the Design Consultants.

3

The Supervision Consultants shall ensure that the Contactors Inspect and Test Plan adequately cover any Inspections and test points (Hold/Witness/Surveillance/Record Review) required for the Supervision Consultant to ensure that the works are completed in accordance with the contract.

4

Where the Design Consultant for the Contract has detailed specific specifications or inspection and test requirements, the supervision Consultants shall ensure these have been addressed within the Contractors Inspect and Test Plan. Where a discrepancy exits between Inspections and Test requirements of the Design Consultant and the requirements of QCS, the more stringent requirements shall be adopted.

5

The Supervision Consultant is responsible for reviewing and approving all Inspection and Test Plans and other such documentation submitted by the Contractor and returning to the Contractor within two weeks of their receipt unless otherwise agreed.

6

The Supervision Consultant shall ensure that inspection of processes, materials, good, services and subcontracted works are described in the Inspection and Test plan submitted by the Contractor.

23.3.5

Technical Procedures, Work Instructions and Method Statements

1

The Supervision Consultants shall verify through audit and surveillance that the Contractor’s quality system includes all relevant Technical Procedures, Work Instructions Method Statements and Inspection and Test Plans to ensure that the Works are completed in accordance with the contract. These shall be submitted by the contractor in accordance with the submission schedule agreed with the Supervision Consultant including those which form part of the Contractors Quality System.

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2

The Supervision Consultants own Quality system likewise shall include relevant Technical Procedures, Work Instructions Method Statements and Inspection and Test Plans to ensure that the works are completed in accordance with the contract with specific reference to the development and implementation of Quality Procedures specified in ISO 9001:2008. These shall be submitted to the Owner by the Supervision Consultant in accordance with the submission schedule agreed with the Owner including those which form part of the Supervision Consultants corporate quality system.

23.3.6

Monitoring by Supervision Consultants

1

Surveillance by the Supervision Consultants will include a variety of typical activities: review of contractor documentations

(b)

audits of Contractor

(c)

attendance at Hold/Witness/Surveillance Points

(d)

Record Review

(e)

Visits to Contractors off site works etc

(f)

Factory Acceptance Tests

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(a)

With the exception of visits, these activities will be announced to the Contractors in advance. The Supervision Consultants shall give reasonable notice to the Contractor who is required to make or arrange to be made available all facilities, documentations records and personnel, including those of any subcontractors, which are required for any surveillance activity to be taken.

3

The Supervision Consultants shall advise the Contractor in writing of any deficiency or deviation in the contract quality system which comes to the Supervision Consultant’s attention as a result of surveillance activities. The Contractor shall be required to rectify the system within as short a period as may be reasonably expected considering the deficiency or deviation. The Supervision Consultant may direct the Contractor in writing to stop the operation and immediately carry out any corrective action, and the Contractor must comply with such direction at his cost. All deficiencies uncovered shall be documented with a NonConformance Report or Corrective Action Request as appropriate (Refer to QCS, Section 2 for a NCR template).

23.3.7

Review of Contractor Quality Documentation

1

All audits of the Contractor shall be conducted in accordance with a schedule establish by the Supervision Consultant. These audits are to be performed in accordance with formal procedures by trained and qualified auditors.

2

The types of audit to be conducted are as follow:

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(a)

Systems Audit: One System audit will undertaken at or before the start of work on the contract deliverables (the specified Works). The audit will be conducted against the requirements of ISO9001:2008

(b)

Compliance Audits: A number of compliance audits will be conducted at defined milestones in the contract deliverable period. The scope of a compliance audit shall be set by the supervision Consultant to suit the timing of activities, and the findings of the system audit. For example, the scope of a compliance audit could cover any of the following:

QCS 2014

(c)

Section 01: General Page 11 Part 23: Design & Supervision Consultant Quality Requirements (i)

the complete requirements of the standards and the contract,

(ii)

specific elements of the standard

(iii)

specific clauses of the contract

(iv)

the whole or a part of a single end-to-end process.

Product audit: This is a Quality audit of particular deliverable products to check their compliance with specified requirements. Such audits should include performance testing where appropriate.

The Audit Notification shall also be copies to the Owner for information and they may attend these audits as an observes. The Audit Reports shall be submitted to the Owner within 7 days.

23.3.8

Inspection Responsibilities

1

For all work the Supervision Consultant shall:

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Review and check that the contractors Method statement and Inspection & Test Plans are in accordance with the contract Surveillance Points.

(b)

Inspect all works to verify Contractors compliance with the Method Statements, Inspections and Test Plans, Construction Drawings and Specifications.

(c)

Verify that notices of nonconformity have been properly actioned.

(d)

Oversee the sampling and testing of materials to ensure conformity to the specifications and the contract.

(e)

Review all test results and verify that they are in conformity with the Specifications and the Contract.

(f)

Maintain comprehensive records to verify the above.

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(a)

Inspections and Test Surveillance Points

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The Supervision Consultant shall nominate his own surveillance points to observe the Contractors and Subcontractors activities and maintain evidence of such surveillance.

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23.3.9

(a)

Hold Points – Specific critical task in procurement, manufacturing, inspection and testing for which the Supervision Consultant is pre-notified, in advance of the task and for which no further work is carried out until the supervision Consultant has verified and confirmed conformity by signing off the relevant Records Forms

(b)

Witness Points- Specific critical task in procurement, manufacturing, inspection and testing for which the Supervision Consultant is pre-notified in advance of the task and for which the Supervision Consultant may elect to attend or waive. When attended, the Supervision Consultant shall confirm conformity by signing off the relevant Record Forms. When then Supervision Consultant waives his right to inspect, it should be recorded as such on the appropriate Record Forms.

(c)

Surveillance points- Any procurement, manufacturing, inspection and testing task, so identified on the Inspection and Test Plan, performed on a random basis, without notification by the supervision Consultant.

(d)

Record Review- When specified this point requires the Supervision Consultant to Collect and review for approval the contractor Inspection & Rest Records.

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23.3.10 Visits 1

The Supervision Consultants is empowered to visit any of the Contractor’s or Subcontractor’s work sites for any purpose at reasonable times. The Contractors will assist with such visits and make available those records and personnel necessary to satisfy the supervision Consultants requirements. Such visits may include surveillance points identified by the Contractor and Subcontractors. These visits may include works situated outside of Qatar.

23.3.11 Supervision Consultant Verification 1

The Supervision Consultant has the right to perform verification activities at the Contractor’s and the Subcontractor’s premises (including the construction site) to gain assurance that the subcontracted product conforms to specified requirements.

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The Supervision Consultants shall be responsible to ensure that the Contractor prepares punch lists at appropriate inspection and acceptance stages to record the outstanding work. Defects identified during the punch list walk downs will also require NCR’s to be raised, other than for minor defects. The Owner or its nominee may at any time add pending items or defects or Nonconformances to Punch Lists.

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23.3.13 Punch Lists

The Supervision Consultant has the responsibility to ensure that the Contractor is taking necessary precautions for the protection of works before the Initial/Final Acceptance/Handover to owner or its nominee.

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23.3.14 Protection of the Works

23.3.15 Quality Records

In addition to (and including) quality records identified in the contract or other applicable codes, standards or procedures, the Supervision Consultant shall determine project Quality records in compliance with requirements of ISO 9001:2008 and other relevant standards stated in contract documents and 23.1.2 above.

2

The list of quality records generated during the life of the contract, and made available upon request for review by the Owner, shall be indexed by the Supervision Consultant in his Quality Plan.

3

The Supervision Consultant shall maintain Registers for all incoming and outgoing documents.

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CONSTRUCTION DEWATERING GENERAL Scope REQUIREMENTS Current Procedure Requirements Relevant Qatari Laws and Regulations EIA Requirements Air Quality Standards Noise Standards Discharge to Surface and Groundwater Network Standards Environmental Impact Assessment (EIA) Geotechnical and Geo-Environmental Study Requirements Existing Groundwater Monitoring Documents Risk Assessment of Construction Dewatering Dewatering Monitoring Plan Training Requirements DEWATERING TECHNIQUES Construction Dewatering Methods Guide Lines Sump Pits Well System Deep Wells Ditches/ French Drains Cut-Off Excavation Barriers Dewatering Effluent Treatment Settlement Tank Settlement Tank Types Tank Size OTHER TREATMENT Silt and Fine Grained Soils Contamination of Groundwater DISPOSAL OPTIONS DISCHARGE TO SEA Discharge to Sea via Surface and Groundwater Network Direct Discharge to Sea Discharge to Lagoons: Discharge by injection to deep groundwater aquifer (Deep well injection) Groundwater Recycle & Reuse Onsite Integrated Management of Construction Dewatering Construction Environmental Management Plan (CEMP) Monitoring Plan Training Plan Odour Control Health & Safety Considerations Site Investigation Design Considerations Housekeeping Considerations

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24 24.1 24.1.1 24.2 24.2.1 24.2.2 24.2.3 24.2.4 24.2.5 24.2.6 24.2.7 24.2.8 24.2.9 24.2.10 24.2.11 24.2.12 24.3 24.3.1 24.3.2 24.3.3 24.3.4 24.3.5 24.3.6 24.3.7 24.3.8 24.3.9 24.3.10 24.4 24.4.1 24.4.2 24.5 24.6 24.6.1 24.6.2 24.6.3 24.6.4 24.6.5 24.6.6 24.6.7 24.6.8 24.6.9 24.6.10 24.6.11 24.6.12 24.6.13 24.6.14

Section 01: General Part 24: Construction Dewatering

Appendices

2 2 2 2 2 2 3 3 3 3 3 3 4 4 5 6 7 7 8 8 8 9 9 9 9 9 10 10 10 12 12 13 13 15 16 17 18 19 19 19 20 20 20 21 21 21 22

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Section 01: General Part 24: Construction Dewatering

Page 2

CONSTRUCTION DEWATERING

24.1

GENERAL

24.1.1

Scope

1

This Part specifies the general procedures and requirements for construction dewatering.

2

It should be noted that legislative requirements, standards and requirements detailed in this Part are minimum standards, and methods should be employed with the intent to continually improve on these standards.

3

Related Parts and Sections are as follows: Earthworks Mechanical and Electrical Equipment

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24

REQUIREMENTS

24.2.1

Current Procedure Requirements

1

There are four types of construction dewatering disposal options that require licensing in Qatar, as follows:

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24.2

Discharge to the Sea via surface and groundwater network; the licensing authority should be ASHGHAL and MOE.

(b)

Direct discharge to the Sea; if the discharge is pumped directly to the sea, then the Ministry of Environment (MOE) should be the licensing authority.

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Discharge to Lagoon totally covered with geotextile from all sides. This method of disposal requires a license from MOE.

(ii)

Discharge to Lagoon not covered. This method of disposal requires a license from MOE.

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Discharge through Deep Well Injection. This method of disposal requires a license from MOE.

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24.2.2

Relevant Qatari Laws and Regulations

1

The list of parameters required by MoE for dewatering permit is included in Appendix A together with Annex 4 of Law 30 of 2002 which specifies the limits for the discharged water into the marine environment (refer to Appendix A). The annex controls the parameters of pollutants in the water disposed to the marine environment whether via the Surface and Groundwater Network, or direct discharge to the sea.

2

If the construction dewatering effluent is discharged to foul network, the discharging party is liable to having committed a criminal offence.

3

In the case of illegal discharge to Surface and Groundwater Network, the discharging party will be subjected to legal actions taken by the licensing authorities.

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Section 01: General Part 24: Construction Dewatering

Page 3

EIA Requirements

1

Environmental approvals from the MoE as per Article 7 of the Law No. 30 of 2002.

24.2.4

Air Quality Standards

1

The air quality standards are controlled by the Law No. 30 of 2002 under Annex (3/First).The standards applicable to dewatering activities may include the following:

2

Maximum limits (of air pollutants) allowed for emissions from the movable sources; and Ambient air quality standards.

24.2.5

Noise Standards

1

The noise levels are also controlled by the Qatari Legislation under Law No. 30 of 2002 Annex (2/Fifth).

24.2.6

Discharge to Surface and Groundwater Network Standards

1

Executive Bylaws of Environment Protection Law Issued under Ordinance Law No. (30) Of 2002. Annex No. (4) Criteria and Specifications of the Hazardous Materials when disposed of in the Water Environments (MoE regulations).

24.2.7

Environmental Impact Assessment (EIA)

1

For projects requiring an EIA at the design stage, the EIA should be carefully reviewed by the Design Consultant / Contractor. The EIA should be forwarded to MoE for their approval and for issuing the relevant Environmental Permit.

2

Where available, the EIA will contain details of geotechnical surveys including groundwater, adopted from the previously mentioned report.

3

Although the EIA may not directly contribute to the construction dewatering design, it will document possible contamination in the area and environmental constraints, and should therefore be considered when preparing construction dewatering application papers. Existing contamination, or potential for contamination, should be carefully considered and must be taken into account when dewatered groundwater is tested for compliance.

4

To ensure that dewatering systems are designed to maximise environmental protection and to assist in expediting license approval processes, the above investigations shall be taken into consideration as early in the project as possible and included when applying for the discharge permit.

24.2.8

Geotechnical and Geo-Environmental Study Requirements

1

After the awarding of the Contract to the Contractor and prior to obtaining the discharge permit, if required by the Contract or requested by the Engineer, the Contractor shall carry out a geotechnical and geo-environmental investigations in order to confirm the geotechnical and environmental conditions on site and groundwater levels.

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24.2.3

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2

The geotechnical and geo-environmental study must as a minimum identify soil types, permeability, groundwater hydrology, and the required drawdown for the construction activities. This study is required if the area is suspected for contamination or if the EIA at the design stage has indicated the existence of contamination.

3

The output of the geotechnical and geo-environmental study should include as a minimum the following items: (a)

Time required for construction dewatering.

(b)

Flow rate of the dewatering discharge.

(c)

Required drawdown.

(d)

Method of construction dewatering based on all of the above findings.

To assist in the approval process all of the above information must be provided in the application for discharge.

5

It is important to note that the requirements of the Geotechnical and Geo-environmental study are completely subject to project settings, type of contamination, and MoE’s specific requirements of each project.

24.2.9

Existing Groundwater Monitoring Documents

1

It is the Contractor’s responsibility to ensure he has been providing the latest existing groundwater level information from Ashghal and the MoE. This information should be used by the Contractor to assist in determining the current site conditions.

2

All groundwater information gathered during studies by the Contractor, are to be submitted to Ashghal for reference and inclusion in the country database. The collection of this information is paramount to the continuous improvement of government information databases.

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24.2.10 Risk Assessment of Construction Dewatering It is important to note that risks are site specific and depend on the intent of the Contractor. The Contractor is responsible for developing, implementing and managing a Risk Management System and conducting a Risk Assessment in terms of dewatering activities and otherwise onsite.

2

This Risk Management System and Risk Assessment shall be the submitted to the Engineer for the approval within the 30 days of the contract award.

3

Risk assessment in this instance can be defined as the identification and characterisation of the nature of existing and potential adverse effects to humans and the environment resulting from dewatering activities employed on site.

4

Risk is a function of the probability of an event occurring and the degree of damage that would result should it happen.

5

Details and information gathered during the concept design and associated site studies (geotechnical, groundwater & environmental) are needed to assess the risks associated with the proposed activities. The assessment allows significant risks to be identified so that they can be targeted for action.

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6

The initial risk assessment needs to also be regularly reviewed and will become an integral part of the Construction Environmental Management Plan. This includes a review of existing risks and the identification of new risks detected through the surveillance or the monitoring program.

7

To conduct the Risk Assessment the Contractor should undertake the following key steps: (a)

Information gathering: A risk assessment requires information about site conditions.

(b)

Risk identification:

Risk analysis:

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Hazard identification involves the identification of risks/hazards that could lead to an adverse effect on the receiving environment and/or health & safety.

Risk analysis considers the likelihood of the risk being realised. Consequence analysis:

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Consequence analysis determines the effect on the environment and health & safety should a risk be realised. The overall risk is a function of the likelihood of the activity or event causing environmental harm or impacting on health & safety and the consequence should that risk be realised.

9

The risks are then ranked according to their magnitude and mitigation strategies developed.

10

The objective of this process is to identify and rank all potential risks that may arise from the dewatering of the construction site and then reduce risks to acceptable levels by implementing a suitable method of dewatering and/or action plan.

11

Risks generally associated with dewatering activities onsite include but not limited to the following: (a)

Soil and slope stability and soil erosion due to dewatering activities. Soil contamination. Whether contamination exists in the project area prior to commencement of construction or is caused by dewatering activities.

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(c)

Change of groundwater properties due to dewatering practices.

(d)

Excessive abstraction (dewatering) of groundwater which affects nearby groundwater related activities.

(e)

Health and safety related issues.

(f)

Risks associated with impacts of dewatering activities on surrounding environment and sensitive receptors.

(g)

Risks associated with failure of dewatering system and/or disposal methods.

24.2.11 Dewatering Monitoring Plan 1

When dewatering activities are included within the project site, the Contractor shall prepare a Dewatering Monitoring Plan as detailed below.

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2

The Dewatering Monitoring Plan shall be submitted to the Engineer for approval within 30 days of contract award.

3

The monitoring plan will assist the licensing authority, as well as the Contractor, in keeping track of dewatering activities onsite, and identify corrective actions to be carried out.

4

The monitoring plan can also assist in identifying liability issues concerned with reported dewatering problems and accidents.

5

Outline and components of monitoring plan are as follow: Identification of opportunities to reuse the dewatering effluent onsite in order to reduce the amount of disposed effluent.

(b)

Dewatering techniques being employed on site

(c)

Disposal methods employed on-site and relevant monitoring plan to ensure compliance with discharge limits.

(d)

Copy of discharge limits.

(e)

Roles and responsibilities of the Environmental Advisor on site.

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(a)

Roles and responsibilities have to be clearly defined when designing a dewatering system. These roles and responsibilities are to be submitted as an essential element to satisfy the Construction Environmental Management Plan requirements when applying for the dewatering effluent discharge permit.

7

Refer to Appendix B for an example of inspection sheet for the dewatering process.

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24.2.12 Training Requirements

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The Contractor shall prepare a Construction Dewatering Training Plan submitted along with the necessary documentation for a discharge permit.

2

The construction dewatering training plan shall be submitted to the Engineer for approval within 30 days of contract award.

3

The training plan will assist the licensing authority in evaluating the level of knowledge passed on to the Contractor’s staff, and is therefore an indirect indication on how well the dewatering process is being executed. The components of the submitted training plan are detailed below.

4

The integration of construction dewatering training into the Training Plan of the Contractor is essential to introduce all staff to construction dewatering related information.

5

It is recommended that information on dewatering equipment and related emergencies are included in the training provided to staff entering or working on the site.

6

The training for all staff does not have to be comprehensive; however, it should include basic items such as:

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(a)

Brief explanation of the construction dewatering purpose

(b)

Introduction to the dewatering equipment. Inclusion of photos in the training presentation.

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Health and safety related concerns, education on related emergencies, and contact information of person in charge of dewatering to be provided in the presentation.

24.3

DEWATERING TECHNIQUES

24.3.1

Construction Dewatering Methods Guide Lines

1

The design of effective construction dewatering methods should be based on a number of information sources: Geotechnical and groundwater site investigations undertaken at the commencement of any project;

(b)

Information provided by any geotechnical study undertaken during the concept design stage[if applicable];

(c)

Groundwater information sourced from relevant authorities; and,

(d)

A site risk assessments.

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(a)

The Contractors choice of dewatering method will depend primarily on the soil type and permeability and the amount of groundwater to be removed. Whilst the Contractor will be trying to find the most cost effective method of dewatering (based on the geotechnical report) he shall implement the most effective dewatering method which minimises environmental damage, protects the health & safety of on-site personnel and meets all legislative discharge limits.

3

It is important to note that if contamination exists in the area all precautions need to be implemented. Contamination will be dealt with in coordination with MoE by safe disposal in designated areas as per the Environmental Law number 30 for 2002.

4

The figure below demonstrates the range of common dewatering techniques, whilst accounting for soil permeability and drawdown.

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Range of Application of Pumped Well Groundwater Control Techniques ** Source: Preene, M. Roberts, T. Powrie, W. Dyer, M R (2000)- Groundwater Control Design & Practice (CIRIA C515), London, CIRIA.

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As seen in the above figure, the choice of dewatering method depends on the required drawdown and permeability. The drawdown is determined during the design stage of structures and the groundwater investigation stage at the start of the project and the permeability is tested during the geotechnical investigation stage.

6

After the drawdown is determined, the Contractor shall choose the method of dewatering based on the permeability of soil. The method can vary during the stages of the project depending on the required drawdown. The shaded areas near the methods’ boundaries indicate that the choices can overlap, and then the Contractor can decide between the two (or more) options.

7

Filtering and filling materials of aggregate is required by most dewatering methods. Therefore when required, aggregates to be used shall be free draining, washed and free of debris (organic or non-organic). Preference is for a single sized aggregate (less than 10% fines).

8

Whilst the range of dewatering practices varies across sites depending on their size, construction depth and site conditions, the most commonly used methods of dewatering in Qatar are indicated below. Each method’s use depends on the requirements and stage of project.

24.3.2

Sump Pits

1

The Sump Pit method is the simplest form of dewatering system on a construction site. Sump pits are generally utilised as a quick, least cost, solution and can be seen to be used at the start of projects as the excavation stage commences. Provided with an aggregate lining, as per O&M requirements, sump pits can be an effective means of filtering groundwater, unless the groundwater has come into contact with silt and/or limestone, which usually results in reported high turbidity.

2

If soil has silty characteristics; it is recommended that proper installation of geotextile and aggregates in sump pits be implemented in order to improve the quality of dewatering effluent and significantly decrease turbidity.

24.3.3

Well System

1

The most common practice of dewatering used in Qatar is the implementation of a Well System. Wells are systematically drilled around the construction area and submersible pumps placed into these wells. This practice appears to work effectively for many projects, especially those building projects that require excavations for deep basements.

24.3.4

Deep Wells

1

Deep wells are rarely used in Qatar. Deep wells are usually equipped with filter packs & submersible pumps, and are operated using a control cabin.

2

Although not found to be present in Qatar at present, deep wells have unlimited drawdown, they require a minimum spacing of 10 meters, and have far greater efficiency.

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Ditches/ French Drains

1

Ditches and French drains (commonly known as trenches in construction projects in Qatar) are also used on Qatar’s construction sites. The ditches are formed in a pre-planned manner, allowing groundwater flow to surface in the deeper level trenches. Perforated pipes are then placed in the trenches, and groundwater extracted through these pipelines to be filtered. These trenches were particularly common in infrastructure network projects.

2

Graded aggregates and geotextile layer to be used when laying out the pipelines.

24.3.6

Cut-Off Excavation Barriers

1

Cut Off barriers are designed to limit and/or control groundwater entering the construction site from a neighbouring property. An assessment of groundwater infiltration is required to determine to what extent barriers are required and how they are constructed.

2

Commonly used excavation barriers in Qatar include structural concrete walls and secant piles. Both techniques are applicable to most types of soil and provide slope stability for deep excavated areas.

24.3.7

Dewatering Effluent Treatment

24.3.8

Settlement Tank

1

The settlement tank is the most common and most effective methods of treatment in Qatar. The settlement tank is primarily used to maximise the distance that the effluent has to travel prior to reaching the discharge point, and therefore increasing the settlement efficiency.

2

All projects in Qatar which apply for a discharge permit are obligated to provide a settlement tank.

3

When choosing the settlement tank, the choice should be based on the following factors: The type of soil to be dewatered.

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24.3.5

(d)

Retention time required for solids to settle. This will also be based on the soil type.

Flow rate quantity and frequency. Possible peak factors flows.

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24.3.9

Settlement Tank Types

1

The common types of weir tanks used are Regular tank and V-notch tanks (30°, 60°, and 90°). The V-notch tanks serve to accelerate the passing of the effluent through the tank.

2

For safety purposes, it is recommended that tanks be suitably covered with a top cover or specific lid, to ensure unauthorised access is not permitted.

3

It is important to note that sometimes these tanks are used onsite as a discharge tanks. Therefore, it is important that tanks are used as settlement tanks and be marked clearly as such.

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24.3.10 Tank Size 1

In order to make a decision on the tank size, the volume of tank are to be estimated as per the below equations.

2

The volumes calculated depend primarily on the retention time of water in the tank, and the flow rate of discharge.

Equation 3

V=Qt

The tank's depth

d = V/A

d: depth (m) 3 V: volume(m ) 2 A: surface area(m )

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Tank volume

V: Volume (m ) 3 Q: Expected flow rate (m /hour) t: retention period (hour)

It is important to note that these equations are to be used as a guide only, but do provide a basis for calculating the minimum tank size required based on the flow rate provided by the Contractor.

4

For fine grained type of soils, it is preferred to have secondary methods of treatment as detailed below.

24.4

OTHER TREATMENT

24.4.1

Silt and Fine Grained Soils

1

For the removal of silt and fine grained suspended particles, the following inexpensive methods can be effectively applied:

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Dewatering Tank:

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a dewatering tank can remove sediment (sand, silt, and visible oil). The dewatering tank is equipped with a fabric filter. The flow passes through the filter before being discharged at the bottom end of the tank. The tank can be used in addition to the weir tank or any other treatment method. It is portable, inexpensive and many types of filter clothes can be used. Yet, the dewatering tanks should be subjected to periodic cleaning based on the visual inspection or reduced flow, through lifting the sand and silt from the tank.

(b)

Gravity Bag Filter: (Also known as dewatering bag) is made of geotextile fabric that can filter out silt and fine grained soil particles. This filter is easy to install, inexpensive, and becomes more effective as sediment builds up inside the bag. The type of bag should be selected based on the flow rates of discharge and permeability of soil. This method is to be used as a secondary treatment for groundwater. It requires continuous monitoring to avoid hose failure, particularly if sediment builds up in a manner that interferes with the acquisition of a reasonable flow rate discharge.

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The Gravity Bag Filter does not require cleaning, as it is a disposable filter. The filter is to be disposed of in accordance with the waste management guidelines of the project. The filter is to be replaced when it starts passing solids, or blocks the passing of water at a rate that is adequate. (c)

Slurry Water “The drilling [slurry] muds containing substantial quantities of organic liquids and water-soluble salts are treated to render them environmentally acceptable for disposal” (C M Wilwerding 1989)

.

Slurry water occurrence is common during dewatering processes in Qatar. While there is filtration equipment and water treatment technology available to treat slurry water, these are best used in countries with a different climate to that of Qatar’s. The best option for treating slurry by filtration is using a Centrifugal Filter. However, as previously mentioned, this is not a preferable to be used in Qatar as slurry can be dried easily in a more environmentally friendly manner.

3

It is also important to note that even when treatment equipment is used, the resulting silt will have to be disposed at a licensed landfill, along with having to dispose of the equipment at its end of service life.

4

If the silt contains hazardous material, then a license should be issued from MoE as per the procedures detailed in Annex (7.2) of the Qatari Law of Environment (Copy of the procedures together with the form of application is provided in Appendix (C)). And if the silt has no hazardous materials then the license shall be issued from the concerned Municipality.

5

To eliminate the issues with incompatible equipment and hot climates, it is recommended that treatment methods be designed to manage the slurry either onsite by drying the first instance before transfer to landfill, or by transfer to the landfill directly.

6

The conventional drying process comprises laying out of slurry mud on an air permeable drying bed lined with suitable material.

7

The drying process must commit to the following environmental considerations:

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(a)

Amount of slurry generated must not exceed the capacity of the spreading system.

(b)

Drying process must not impose nuisance or emit odor.

(c)

Drying process must not impose health and safety risks.

8

The choice of drying process, whether by using a centrifuge machine or a drying lagoon is subject to project settings and expected amount of slurry to be generated.

9

The slurry handling process is to be submitted with the dewatering permit application if generation of slurry is expected to occur.

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24.4.2

Contamination of Groundwater

1

In the event of discovering the contamination of the receiving environment such as groundwater by dewatering effluent, the contractor is obligated to report the discovery to the licensing authority (ASHGHAL, MoE) and the effluent is to be dealt with as per the construction Environmental Management Plan (CEMP). Samples of groundwater should be taken and tested. Reasonable suspicion can be established by one of the following methods: Possible history of contamination in the area; such as prior land use (eg. petrol station), or the area is known to have septic tank issues.

(b)

EIA: if there is an EIA prepared for the project, it should be reviewed and approved by MoE in order to eliminate the possibility of contamination. If the EIA indicates the presence of contamination, the Contractor is obligated to report the findings to MoE for their feedback, and test for the type of contamination detected in the EIA.

(c)

The Contractor shall use the following Water Quality Assessment to establish the possibility of contamination in the area.

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Water Quality Assessment

The following questions provide n initial assessment of the quality of the water to be discharged from the dewatering operation.

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Common Sense Test

1. Review the project records. Is there any reason to suspect that the water may be polluted by something other than sediment? No Yes 2. Is the water located in an area of known contamination? No Yes Does the water have an abnormal visual feature, such as: (circle) Oily Sheen, Floating Foam, Murky Appearance, Unusual Colour Other

Smell Test

Does the water have an odor? No Yes Possible odors include gasoline, petroleum, ammonia, sewage, etc.

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If you answered YES to any of the above questions, explain: If you answered YES to any of the questions in the assessment or suspect that the water contains pollutants other than sediments, contact the Engineer for assistance with additional testing and management options.

Water Quality Assessments ** Adapted from Source: The office of Environmental Engineering, California Department of Transportation (Caltrans), Field Guide to Construction Site Dewatering, USA, 2001. In the event of discovering groundwater contamination, the Contractor is obligated to report the discovery to the Engineer and Licensing Authority (MOE / ASHGHAL) and the effluent is to be dealt with as per the Construction Environmental Management Plan (CEMP), or as directed by the Engineer.

24.5

DISPOSAL OPTIONS

1

Qatar construction sites use four (4) common means of disposal, namely: (a)

Discharge to sea via the Surface and Groundwater Network;

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(b)

Direct Discharge to the sea;

(c)

(A) Discharge to lagoon totally covered by geotextile from all sides; (B) Discharge to lagoon not covered, and;

(d)

Discharge by injection to deep groundwater aquifer (Deep well injection).

The following section discusses the options available in Qatar in terms of dewatering effluent disposal, and describes the best option depending on the circumstances of the project.

24.6

DISCHARGE TO SEA

24.6.1

Discharge to Sea via Surface and Groundwater Network

1

Disposal of dewatering effluent to the Surface and Groundwater Network is the most common practice in Qatar. The Surface and Groundwater Network eventually leads to outfalls that discharge to Sea.

2

The disposal to the network directly via pipelines, or via tankers, depends on the availability of Surface and Groundwater Network in the project area.

3

The Surface and Groundwater Network is an acceptable option for disposal given that Contractor is also reusing the effluent on site whenever possible.

4

If a Contractor chooses to discharge to the Surface and Groundwater Network, obtaining a license from ASHGHAL is required to allow the discharge of groundwater to the Surface and Groundwater Network. A license from the Ministry of Environment is also required through the submission of an Environmental Permit Application.

5

Measurements of flow rates must be undertaken in order to monitor the discharge flow and ensure that it is within the limits provided to the licensing authority (refer Appendix A for discharge limits).

6

The Contractor must provide the licensing authority with the maximum expected flow rate (i.e the peak flow) and the expected average flow rate, in order to avoid back flooding when flows exceed the capacity of the manhole assigned to the Contractor. Therefore, the contractor should install a flow meter at the construction site in order to measure the quantities of groundwater flow.

7

The Contractor should also notify the licensing authority if peak flows are expected to be reached frequently during the winter season, particularly when heavy rain is forecast, so as to avoid penalties if the manhole back floods.

8

If a Contractor is operating from an area which is not served by a Surface and Groundwater Network, and determines that the most cost effective solution is to use tankers to transport dewatering effluent to the nearest assigned manhole, the Contractor is then obligated to provide a brief statement demonstrating the traffic impacts caused by their tankers.

9

If the resultant traffic impact proves to be significant, the Contractor is either to consider other options of disposal, or retain dewatering effluent onsite and then transport the effluent when traffic is less congested, therefore minimising traffic impacts.

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In the event that tankers are used to transport dewatering effluent, in order to monitor discharge to Surface and Groundwater Network the Contractor must record all particulars associated with its removal, such as: (a)

Installing a flow meter at the construction site in order to measure the quantities of groundwater flow.

(b)

Record of tankers coming to and leaving the site (eg. registration plate no., capacity, records of water quality)

(c)

Volumes of effluent transported.

The recording of tanker movements is in addition to the installation of a meter on the weir/sediment tank.

12

When applying for the discharge permit the following documents are required:

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Official letter from the company addressed to: The Manager of Drainage Networks O&M Dept- Asset Affairs- ASHGHAL. (Includes start and end date of dewatering works & method of statement for dewatering).

(b)

Application form for pumping groundwater to be filled and stamped.

(c)

Copy of building permit.

(d)

Copy of the site map.

(e)

Copy of ID card of the applicant’s engineer.

(f)

Copy of the registration company.

(g)

Copy of Road Opening (RO) Permit.

(h)

Copy of Traffic Department Approval, as part of the RO Permit

(i)

Testing of samples, and conformation of compliant results prior to obtaining the twomonth permit. The Contractor must note that the sample testing is to be carried out after obtaining the five-day temporary permit, and is to be submitted after the previous requirements are submitted and a temporary permit is granted.

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(a)

Once the application is submitted, the project is given a reference number which includes a serial number, type of discharge (e.g groundwater) and the date of application. Drawing and comments are then returned to the applicant for information and/or action and the applicant will be advised the applicable disposal option and a manhole to be assigned for the discharge.

14

The applicant is issued a temporary permit for five days. The purpose of the temporary permit is to allow the applicant to obtain approvals from the concerned authorities, and install the equipment in order to take water samples.

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During the temporary dewatering permit; only discharge is allowed for collecting samples and to proceed with other department requirements. All samples are taken by laboratory representative from the list of laboratories approved by ASHGHAL and MOE; it’s prohibited for samples to be taken by the Contractor. The collected samples should be tested for Total Suspended Solids (TSS, turbidity and the short list of parameters included in Appendix A. Test results should be uploaded online to QSD by the laboratory. Yet, it should be highlighted here that any testing activities are not only limited to the parameters provided on the short list developed by QSD; it should also cover the list of parameters required by MOE for dewatering permit. Approval is then granted if the test results meet the requirements of discharge. The Quality Limits are attached in Appendix A.

16

If the installation requires a road crossing, a RO permit is required. If not, a RO is not required. The applicant must obtain a license from the concerned authorities for installation of all tanks and hoses.

17

Following the issuance of the permit, regular inspections by the O&M staff are carried out. The Contractor is then required to undertake weekly laboratory tests for TSS and turbidity of effluent samples, and bi-monthly tests prior to renewing the permit. Permit renewal request should be submitted in 7 days advance before expiry day of the previous permit. The bimonthly tests are for TSS, turbidity and the short list of parameters included in Appendix A together with the parameters listed under Annex (4) of the law of Environment number 30/2002.

18

A copy of the Permitting Application and pro-forms are attached in Appendix C.

19

Refer to Appendix D for a flowchart of the permitting procedure for the discharge to sea via Surface and Groundwater network.

24.6.2

Direct Discharge to Sea

1

MOE is the licensing authority for discharging dewatering effluent direct to the Sea.

2

If a Contractor found that the applicable option for dewatering is the direct discharge to sea, a secondary method of treatment must be installed to allow the dewatering effluent to settle before reaching the discharge outfall point. The discharge to the outfall point is achieved through the use of pipelines or transportation via tankers. Based on the number of tankers, the transportation may be subjected to a traffic impact assessment study based on the requirements of MOE.

3

The Contractor may therefore be subject to a number of pertinent laws and regulations:

4

When issuing direct sea discharge permits, MOE have the following concerns that need to be addressed as per Annex 4 of the Qatari Law of Environment and the list of parameters required by MOE for dewatering permit (included in Appendix A), which includes the test of the following parameters:

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(a)

Bacterial counts

(b)

Turbidity and TSS levels

(c)

Presence of Petroleum compounds.

(d)

Presence of heavy metals.

(e)

Others, as per MoE requirements.

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5

Refer to Appendix D for a flowchart of the permitting procedure for the direct discharge to sea. A copy of the environmental permit application form is included in Appendix E.

6

For more information, contact MoE on: Telephone +974 4420 7777

24.6.3

Fax

+ 974 4420 7000

Email

[email protected]

Discharge to Lagoons:

A. Discharge to Lagoon totally covered with geotextile from all sides Lagoons are licensed by MOE.

2

It is recommended that a lagoon totally covered with geotextile from all sides, formed in a depressive area, is used in locations where it is logistically impossible or cost and socially prohibitive to deliver effluent to the Surface and Groundwater Network using other means.

3

If Contractor chooses to discharge the dewatering effluent to a lagoon, license is given by MOE. The dewatering to lagoons is mainly based on the requirements by MOE which is given for case by case. The use of this option is depending on the water quality. Yet, the general requirements of MOE can be summarised in the following information:

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Dewatering effluent quantity.

(b)

Detailed Engineering drawings for the lagoon showing the geotextile lining of the lagoon.

(c)

Duration of dewatering discharge

(d)

Dewatering effluent quality. Dewatering effluent quality is tested initially against the list of parameters required by MoE for dewatering permit (included in Appendix A). And then tested weekly. Monthly testing is also required for selected parameters.

(e)

Coordinates of lagoon, inclusive of dewatering discharge points.

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Location map Others, as per MOE requirements.

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Refer to Appendix D for a flowchart of the permitting procedure for the discharge through the use of lagoons. A copy of the environmental permit application form is included in Appendix E.

5

For more information, contact MOE on: Telephone +974 4420 7777 Fax

+ 974 4420 7000

Email

[email protected]

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B. Discharge to Lagoon not covered 6

The discharge to a logon which is not covered is depending on the discharged water quality. Similar to the above option, the licensing authority for this option is the Ministry of Environment. The list of parameters required by MOE for dewatering permit is included in Appendix A. The general requirements of MOE are similar to the above option.

7

Refer to Appendix C for a flowchart of the permitting procedure for the discharge through the use of lagoons. A copy of the environmental permit application form is included in Appendix E.

8

For more information, contact MOE on: Telephone +974 4420 7777 + 974 4420 7000

Email

[email protected]

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Discharge by injection to deep groundwater aquifer (Deep well injection)

1

Disposal by injection to groundwater aquifer is a common method in Qatar to dispose of treated effluent of sewage treatment plants. Yet, the use of deep well injection for the discharge of dewatering effluent to groundwater aquifer is also done in few big projects.

2

However and prior to the discharge to the deep well, a careful assessment of geological conditions must be conducted in order to determine the suitable depth and location of porous aquifer reservoirs and identifying the safe rate of injection to the deep aquifer. Generally, the depth of the deep well should not be less than 400 – 600 m deep, which is the expected depth of Umm Er Radhumma (UER) aquifer.

3

In all cases, MOE require the contractor to conduct an Environmental Assessment for the impact from the project as soon as drilling of the deep well and the analysis of the samples is achieved. This shall be done by a qualified consultant with previous experience in similar projects.

4

The general requirements of MOE for the use of the deep well injection can be summarised in the following information:

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24.6.4

(a)

Duration of dewatering discharge.

(b)

Dewatering effluent quality. Dewatering effluent quality is tested initially against the parameters specified in the standards for the water use for irrigation purpose of the Qatari Law of Environment. And then periodically testing each week based on MoE requirements.

(c)

The parameters required for the physical, chemical, biological, microbiological analysis includes but not limited to: EC, Temperature, DO, pH, Turbidity, FRC, TPH, O&G, Sulphide, Metals, BOD, COD, TOC, surfactants, VOC, BETX, TDS, TSS, PAHs, TAlk, Nitrate, Nitrite, Ammonia, TKN, Phosphorus, Chloride, Sodium, Sulphite, Total Phenol, Carbonate, E-Coli, Faecal Coliform, Bacteria and SAR.

(d)

A0 design map for the whole project including the location of the injection well and network of shallow trenches connecting the wells.

(e)

Comparison study between the use of the shallow networking and the perforated pipelines.

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(f)

Drilling of monitoring wells to suitable depth to monitor the impact on the shallow aquifer.

(g)

Providing the injection wells with emergency valves to stop injection in case of contamination.

5

Refer to Appendix D for a flowchart of the permitting procedure for the discharge through the use of deep well injection. A copy of the environmental permit application form is included in Appendix E.

6

As mentioned above, the injection of dewatering effluent to groundwater aquifer is licensed by MOE and is completely subject to their approval, therefore for further information, please contact MOE on:

Fax

+ 974 4420 7000

Email

[email protected]

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Groundwater Recycle & Reuse Onsite

1

It is recommended, where environmentally safe and cost effective, that dewatering effluent is reused or recycled onsite.

2

The reuse options onsite will depend on a number of factors, including the type of project. The contractor should propose the treatment in case the water is polluted by organic and inorganic chemicals or subjected to biological contamination. The treatment should focus but not limited to low DO, presence of Bacteria, elevated levels of TSS or turbidity and presence of oil.

3

The CEMP should be used to identify all opportunities of reuse onsite. Yet, the options for the reuse of the groundwater should be discussed with MOE and shall be subjected to the approval by MOE.

4

Options could include but not be limited to: Control of dust onsite. (Subject to the level of safety and quality of dewatering effluent).

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(b)

Reuse of dewatering effluent.

(c)

Concrete curing.

(d)

Excavation activities requiring water.

(e)

Washing of machinery and site equipment.

(f)

Watering of onsite landscaping, when the turbidity is very low to avoid compromising the integrity of the soil.

(g)

If the dewatering effluent quality is within limits of soil compaction parameters requirements (refer to QCS), it can be used for soil compaction purposes.

Contractor to conduct a feasibility study to evaluate whether it’s feasible to erect an RO system for dewatering effluent treatment, in order to use the dewatering effluent instead of fresh potable water.

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The feasibility study is to compare both options in terms of financial viability.

24.6.6

Integrated Management of Construction Dewatering

1

Construction dewatering practices are better managed if they are integrated with existing construction management systems, such as a CEMP, monitoring plan and training programmes. The dewatering practice will then form part of the regular construction inspection/monitoring program.

24.6.7

Construction Environmental Management Plan (CEMP)

1

The CEMP is prepared to minimise the impacts of the project and its activities on the receiving environment. The CEMP is prepared prior to mobilising to site.

2

The Contractor should uses the geotechnical investigations and previous EIA (if applicable) as guidelines when preparing the CEMP.

3

When dewatering activities are included within the project site, the preparation of the CEMP should include the following:

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Identification of opportunities to reuse the dewatering effluent onsite in order to reduce the amount of disposed effluent.

(b)

Dewatering techniques being employed on site

(c)

Disposal methods employed on-site and relevant monitoring plan to ensure compliance with discharge limits.

(d)

Copy of discharge limits.

(e)

Roles and responsibilities of the Environmental Advisor on site.

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Roles and responsibilities have to be clearly defined when designing a dewatering system. These roles and responsibilities are to be submitted as an essential element to satisfy the CEMP requirements when applying for the dewatering effluent discharge permit.

5

Refer to Appendix B for an example of inspection sheet for the dewatering process.

24.6.8

Monitoring Plan

1

The environmental monitoring plan is used to monitor the anticipated impacts of the project o the surrounding and receiving environments. It is imperative that, should dewatering activities exist on site, there is integration all testing and monitoring requirements.

2

Integration of monitoring plans may be between systems within individual sites or between several sites, depending on management systems or owners

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(a)

Environmental monitoring plan: The environmental monitoring plan is to outline the steps required for monitoring of construction dewatering practices. The integration of dewatering practices into the monitoring plan will pave the way to introduce a dewatering monitoring plan.

(b)

The findings of the dewatering monitoring reports are to be summarised and included in the environmental monitoring reports.

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The dewatering practices monitoring plan: Introduction of a dewatering practices monitoring plan, sampling points, variables, frequencies and reporting. This plan should be cyclic which stands to be audited as part of the master environmental monitoring plan. Corrective actions from audits are to be implemented to ensure improved performance.

Training Plan

1

The integration of construction dewatering training into the training plan of the Contractor is essential to introduce all staff to construction dewatering related information.

2

It is recommended that information on dewatering equipment and related emergencies are included in the training provided to staff entering or working on the site.

3

The training for all staff does not have to be comprehensive; however, it should include basic items such as:

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Brief explanation of the construction dewatering purpose

(b)

Introduction to the dewatering equipment. Inclusion of photos in the training presentation.

(c)

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24.6.10 Odour Control

The odour levels have been given a threshold value as indicated in the Qatar Construction Specifications (QCS). Therefore, it is highly recommended to measure the level of odour parameters, a devise should be installed within the construction site to measure odour parameters (eg: H2S).

2

The QCS has identified two types of odour control equipment; control equipment carbon type and control equipment scrubber type. Refer to Section 9 Part 9 and Part 10 for details.

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24.6.11 Health & Safety Considerations 1

Health and safety issues are the most important part of any construction project. It is recommended that health and safety measures in relation to dewatering practices are enforced strictly, in order to prevent and/or minimise on-site accidents.

2

In addition to the conventional health and safety measures implemented in construction sites, the following considerations are to be incorporated to contribute to the health and safety practices relating to construction dewatering:

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24.6.12 Site Investigation 1

During the initial site investigations, the Contractor has to identify potential health and safety risks in the project area. Examples of risks are: potential contamination posing health and safety concern to labour workers and site staff, slope stability issues due to dewatering practices... etc.

2

Identified risks have to be considered and mitigated against during design and execution of dewatering.

3

This exercise can be undertaken during the Risk Assessment process as described earlier in this Guideline.

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24.6.13 Design Considerations The design of dewatering stage is the most convenient stage to plan properly in order to prevent foreseeable health and safety issues arising during operational dewatering.

2

All designs must take into account the health & safety considerations associated with dewatering, which include but are not limited to:

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Preparation of layout plan for dewatering equipment.

(b)

Ensure access to dewatering equipment, without compromising the safety of staff.

(c)

Ensure that all dewatering equipment –especially equipment placed offsite- is marked clearly with name of project and Contractor, and contact person details.

(d)

Provide protective covers for assigned manholes which do not hinder the discharged flow.

(e)

The mandatory use of PPE. All staff entering a project’s safe zone have to be wearing appropriate safety gear. This also applies to staff managing dewatering equipment offsite.

(f)

The Contractor is to exercise duty of care when designing, installing and operating the dewatering equipment and process.

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24.6.14 Housekeeping Considerations It is recommended that during the regular inspection of projects, the licensing authority is to observe the status of housekeeping of dewatering equipment. Inadequate housekeeping can expose staff and visitors to injury.

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APPENDICES Short List of Parameters as provided by ASHGHALMoE list of Parameters for Dewatering Permit Environmental Laws and Regulations- Annex 4, Law 30 of 2002

23

Appendix B:

Dewatering Process Inspection Sheet

32

Appendix C:

Discharge Permit Forms

36

Appendix D:

Application for Permit- Procedure Flowchart for each Dewatering Option

40

Appendix E:

Environmental Permit Application- MoE

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Appendix B DEWATERING PROCESS INSPECTION SHEET

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Appendix A SHORT LIST OF PARAMETERS AS PROVIDED BY ASHGHAL MOE LIST OF PARAMETERS REQUIRED FOR DEWATERING PERMITS ENVIRONMENTAL LAWS AND REGULATIONS‐ ANNEX 4, LAW 30 OF 2002

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Appendix E ENVIRONMENTAL PERMIT APPLICATION‐ MOE

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Appendix D

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Application for Permit‐ Procedure Flowchart for each Dewatering Option

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CONTRACTORS INSPECTION AND TEST PLAN TEMPLATE

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QUALITY NON-CONFORMANCE TEMPLATE

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END OF PART

Page 17

QCS 2014

Section 02: Quality Assurance and Quality Control Part 02: Submittals

Page 1

SUBMITTALS .......................................................................................................... 2

2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7

GENERAL ............................................................................................................... 2 Project Quality Plan 2 Quality Organisation Plan 3 Inspection and Test Plans 4 Quality Checklists 5 Key Performance Indicators 5 Method Statements 6 Commissioning Plan 6

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Section 02: Quality Assurance and Quality Control Part 02: Submittals

Page 2

SUBMITTALS

2.1

GENERAL

2.1.1

Project Quality Plan

1

The Contractor shall prepare the necessary Contract specific Project Quality Plan as specified in this Section, the Contract Documents and as a minimum meeting the requirements ISO 9001 and ISO 10005 and submit them to the Engineer for review and approval within 30 days of the award of Contract. The Contractor is not permitted to Work on the worksite until such time as the plan has been approved by the Engineer.

2

The Contractor shall regularly review the suitability of the Project Quality Plan. The Contractor shall undertake a full formal review of the quality plans annually with reference to the date of award of the Contract and submit the findings of the review to the Engineer within 14 days of that date along with an amended plan should any amendments be required.

3

The Project Quality Plan shall describe the Contractor’s Quality Management System that will be used throughout the Contract and the contents shall include but not be limited to the following: Front Cover

(b)

Table of Contents

(c)

Project Scope, Requirements and Quality Objectives

(d)

Quality Policy and ISO 9001 Certificate (if applicable)

(e)

Control of Project Quality Plan

(f)

Reference Documentation

(g)

Project Management, Planning and Resources

(h)

Management, Organisation and Responsibilities

(i)

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Contract Review Project Deliverables

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Communication with the Engineer

(l)

Management of Documents, Data and Records

(m)

Design (Including Temporary Works)

(n)

Procurement of Services, Equipment and Materials

(o)

Method Statements

(p)

Inspection and Test

(q)

Product Identification and Traceability

(r)

Owner Supplied Product

(s)

Handling, Storage, Packaging and Delivery

(t)

Non-conformance, Corrective and Preventative Action

(u)

Control of Inspection, Measuring and Test Equipment

QCS 2014

Section 02: Quality Assurance and Quality Control Part 02: Submittals Audits

(w)

Training

(x)

Key Performance Indicators and Continual Improvement

(y)

Management Review

(z)

Quality Meetings

(aa)

Monthly Quality Report

(bb)

Commissioning

(cc)

Interface Management

(dd)

Project Completion and Handover

(ee)

Appendices

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And include as a minimum:

a detailed description of procedures, instructions, and reports to be used to ensure compliance with the Project Documentation

(b)

a detailed description of procedures for reviewing shop drawings, samples, certificates and other submittals necessary for compliance with the Project Documentation

(c)

a detailed description of procedures used to identify, report and resolve problems

(d)

a description of the services provided by outside organisations such as testing laboratories, architects, and consulting engineers

(e)

a detailed description of inspections and tests required

(f)

copies of forms and reports to be used to document quality assurance operations

(g)

the names of personnel responsible for each part of the Works

(h)

a submittal status log listing required submittals and action required by the Contractor and Engineer

(i)

a detailed description of document and submittal control procedures

(j)

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an inspection and test schedule keyed to the construction programme procedures to identify and control the use of items and materials

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No construction shall begin and no requests for payment from the Contractor shall be processed until the Contractor’s Project Quality Plan is approved.

6

A Contractors Project Quality Plan Template with guidance notes is included in Part 15 Appendix B of this Section. The format of the Contractors Project Quality Plan must follow this template including all clauses contained within.

2.1.2

Quality Organisation Plan

1

The Contractor shall submit a Quality Organisation Plan to the Engineer for approval no later than thirty (30) days from the start of the Contract.

2

The Quality Organisation Plan shall provide the names, qualifications, experience and skills of all the QA/QC Team including Corporate QA/QC Manager, Quality Management Representative and key support staff.

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Page 4

The Quality Organisation Plan shall show the organisation of Contractor’s quality team and shall include, but not be limited to, the following: (a)

an organisation chart identifying all personnel responsible for quality

(b)

Identify the quality team showing that the team is independent of the job supervisory staff with clear lines of authority to top tier management.

(c)

Indicate and describe the area of responsibility and authority of each individual in the quality assurance team.

The Quality Organisation Plan should also define quality responsibilities of any of the Contractors team with responsibilities under the Contractors Project Quality Plan.

5

The Contractor’s Quality staff shall have relevant educational and professional qualifications, and training as defined in 3.1.7 (1). The Contractor is not permitted to execute any form of the works at the worksite until such time as approved quality personnel have been deployed on a fulltime basis to the worksite. The Contractor shall not remove or replace the appointed quality personnel without prior approval from the Engineer.

6

The Quality Organisation Plan may form part of the Project Quality Plan or be prepared as a standalone document and cross-referenced within the Project Quality Plan.

2.1.3

Inspection and Test Plans

1

As part of the Project Quality Plan the Contractor shall submit an Inspection and Test Plan Schedule to the Engineer for approval no later than thirty (30) days from the start of the Contract.

2

The Inspection and Test Plan schedule shall define the Inspection and Test Plans to be prepared for the Works and the target dates for their submission to the Engineer for his approval.

3

The Inspection and Test Plans shall consider the requirements of each Section of the Specification and shall identify, as a minimum, the following:

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(c)

the required inspection and testing frequency

(d)

the acceptance/rejection criteria

(e)

whom from the Contractors team is responsible and qualified to perform the inspection or test

(f)

Quality Records to be generated

(g)

Hold, Witness, surveillance and Record Review points of the Contractors team, the Engineer and any other agencies having jurisdictional authority over the work relating to each inspection and test to be performed.

Details each activity, inspection and test to be performed Reference to specifications, standards etc.

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Each inspection and test shall have a unique reference number.

5

Inspection and Test Plans are required to address the Contractors on and off site Work and preparation, submission and approval of related documentation.

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Inspection and Test Plans are required for all operations including major temporary works and commissioning.

7

No work covered by the Inspection and Test Plan shall begin until the plan has been approved by the Engineer.

8

A Contractors Inspection and Test Plan Template with guidance notes is included in Appendix B of this Section and must be used by the Contractor

2.1.4

Quality Checklists

1

The Contractor shall develop specific quality checklists for all activities to be checked as per the Inspection and Test Plans and submit to the Engineer for the approval with the Inspection Test Plans submission prior to the start of the activity.

2

The Contractor shall inspect the work and sign off the relevant checklist and Inspection Request prior to the final inspection with the Engineer.

3

The checklist shall be attached with the Inspection Request and other relevant attachments and submitted to the Engineer.

2.1.5

Key Performance Indicators

1

The Contractor shall develop and report Key Performance Indicators (KPI’s). KPI’s are a set of quantifiable measures that are used to gauge performance of the Contractors Performance.

2

The KPI’s shall be defined in the Contractors Project Quality Plan and be subject to Engineers approval.

3

The Contractor is responsible for developing his own KPI’s for all elements of his contract (Contractual, Commercial, Safety etc.) but as a minimum shall address the following KPI’s.

Time between opening and closure of Nonconformance Reports (NCR) and Corrective Action Requests (CAR).

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Time between identification of a Nonconformance or Corrective Action and actual raising on the system.

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NCR and CAR statistics per areas, sections, discipline, subcontractor etc.

(d)

Percentage of reoccurring NCR’s and CAR’s – Trends on NCR’s and CAR’s.

(e)

Approval status of critical documentation for the progress of the works (Method Statements, ITPs etc.).

(f)

Statistical data from inspections as per the Inspection & Test Plans (Pass vs failed, pass first time, etc.).

(g)

Completion packages (As-Built folders) progress.

Reporting of the KPI’s shall include a graphical bar chart representation on a month by month basis from the start of the Contract.

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Method Statements

1

Contractor shall ensure that Method Statements address quality issues. Refer to Section 11 Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in particular section 2.4

2.1.7

Commissioning Plan

1

The Contractor shall submit a Commissioning Plan to the Engineer for approval no later than sixty (60) days unless agreed otherwise with the engineer before the start of the commissioning of the Works or any part thereof.

2

The Commissioning Plan shall consider the requirements of each Section of the Specification in turn and shall identify the following:

.

2.1.6

all required commissioning work required by that Section of the Specification

(b)

any prerequisites to commissioning

(c)

a list of the commissioning procedure

(d)

a detailed description of the duties and responsibilities on the personnel involved in the commissioning process

(e)

a detailed list of the tests/checks/activities that will be performed, linked to the relevant construction activities and referenced to any links/documents to the ITPs performed during the construction

(f)

specific reference to the witness/hold and review points of the engineer

(g)

a detailed list of the standards /specifications/regulatory requirements that need to be performed

(h)

a detailed description of the interactions/communication organization/public service or other legal/regulatory institutions

(i)

a detailed description of the test/activities of the maintenance needed during the life time of the project, with reference to any special requirements/qualifications of the personnel involved in the maintenance activities

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a detailed description of any spare parts/equipment/fixtures and other type of the of consumables that might be needed, with an estimation of quantities, for the life time of the project

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a detailed description of the as built project file that will be created after the commission phase

(l)

a procedure for up-date and revision of the commissioning plan

No work covered by the Commissioning Plan shall begin until the plan has been approved. END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 03: Contractor’s Quality Personnel

Page 1

CONTRACTOR’S QUALITY PERSONNEL ............................................................. 2

3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8

INTRODUCTION ..................................................................................................... 2 General 2 Quality Assurance Manager 2 Quality Control Manager 2 Quality Engineer 2 Quality Inspector 3 Personnel Qualifications 3 Quality Staff Requirement 3 Quality Training for Contractor’s Employees and Labour 5

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Section 02: Quality Assurance and Quality Control Part 03: Contractor’s Quality Personnel

Page 2

CONTRACTOR’S QUALITY PERSONNEL

3.1

INTRODUCTION

3.1.1

General

1

Contractor shall, throughout the execution and completion of the Works and the remedying defects therein have on his staff at the Site office(s) a dedicated Quality Team dealing only with matters regarding the quality and protection against damage before, during and after execution of Works as specified in this section. This team shall be qualified and experienced in their work and shall have the authority to issue instructions and shall take protective measures to prevent execution of Works that do not comply with the Specifications.

2

The Contractor shall notify the Engineer in writing prior to re-assigning or replacement of any of the quality team designated in the Quality Organisation Plan.

3

The Contractor shall have adequate quality personnel on the site during all production operations, including adequate coverage during night shift operations and off site work.

4

The Contractor's quality team shall have the authority to stop any portion of the work which does not comply with the requirements of the Project Documentation.

5

Minimum qualifications and experience of the Contractors Quality Personnel shall be as defined in the Contract.

3.1.2

Quality Assurance Manager

1

Where required by this section, the Contractor shall designate and assign a full time Quality Assurance Manager who shall be responsible for overseeing the implementation and operation of the Project Quality Plan at all levels. The Quality Assurance Manager shall report directly to Top Tier Management and be independent of the Contractors organisation responsible for construction.

3.1.3

Quality Control Manager

1

Where required by this section, the Contractor shall designate and assign a full time Quality Control Manager who reports directly to the Quality Assurance Manager and shall be responsible for supervision of the construction quality control management activities and ensuring compliance with the Contractors Inspection and Test Plans and associated specification and contract documentation.

3.1.4

Quality Engineer

1

Where required by this section, the Contractor shall designate and assign a Quality Engineer who reports directly to the Quality Assurance Manager or Quality Control Manager and shall be responsible for assisting them with their day to day responsibilities and may be assigned to cover several locations or areas of work relating to the Contract. Where a Quality Assurance Manager or Quality Control Manager are not required by this section the Quality Engineer shall be assigned all the responsibilities defined in clause 3.1.2, 3.13, and 3.1.7.

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Section 02: Quality Assurance and Quality Control Part 03: Contractor’s Quality Personnel

Page 3

Quality Inspector

1

The Contractor shall designate and assign a Quality Inspector for each shift for each location where work is being performed. Each Quality Inspector shall be qualified by training and experience in all the construction or fabrication activities being conducted at the location of work and is directly responsible for ensuring compliance with the Contractors Inspection and Test Plans and associated specification and contract documentation.

3.1.6

Personnel Qualifications

1

The Contractor shall identify activities requiring qualified production, inspection, and test personnel and establish their minimum competence level.

2

The Contractor shall maintain records of personnel qualifications as quality records.

3.1.7

Quality Staff Requirement

1

Unless otherwise specified by the Engineer the Contractor shall employ fulltime qualified quality personnel for the Work as per below tables.

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3.1.5

No of workers on Worksite

Requirement

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Quality Staff Requirement

1 Quality Inspector (Part time, 15 hours of duty per week)

Less than 10

2.

More than 11 but less than 50

3.

More than 51 but less than 500

4.

More than 501 but less than 1500

1 Quality Assurance Manager and 1 Quality Engineer per 500 workers and 1 Quality Inspector per 100 workers

More than 1501

1 Quality Assurance Manager and 1 Quality Control Manager and 1 Quality Engineer per 500 workers and 1 Quality Inspector per 100 workers

1 Quality Inspector

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1 Quality Engineer and 1 Quality Inspector per 100 workers

QCS 2014

Section 02: Quality Assurance and Quality Control Part 03: Contractor’s Quality Personnel

Page 4

Quality Management and Control staff Qualifications & Experience Matrix Minimum Qualifications Required

Position

Minimum Years of Experience

Minimum Key Competencies

Degree in relevant 12 years, 5 of which at Engineering discipline and Management Level and 3 related training in Quality years Regional experience Management Techniques. Internationally recognised Lead Auditor Certificate

Qualified Professional who can manage a Quality Management System and coordinate specialised activities. Excellent written & verbal communication skills in English

Quality Control Manager

Degree in relevant 12 years, 5 of which at Excellent written & verbal Engineering discipline and Management Level and 3 communication skills in related training in Quality years Regional experience English Management Techniques. Internationally recognised Lead Auditor Certificate

Quality Engineer

Degree in relevant Engineering discipline. Internationally recognised Lead Auditor Certificate

Quality Inspector

Certificate or Diploma in the appropriate engineering discipline

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Quality Assurance Manager

Good written & verbal communication skills in English

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10 years’ experience in related Quality Control Activities and 3 years Regional experience

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5 years’ experience in Good written & verbal related Quality Control and communication skills in Materials Testing activities English along with 2 years Regional Experience

The Contractor shall appoint deputy quality personnel who are capable of performing all the duties of the quality personnel in the event of their absence.

3

The Contractor shall appoint support staff in sufficient numbers to ensure the effective function of the quality related work within the Contractor’s organisation.

4

The Contractor shall ensure that every Sub-contractor employed on the Worksite appoints suitably qualified quality staff to ensure the effective function of the quality related issues within the Sub-contractor’s organisation. The Sub-contractor shall appoint and deploy fulltime on the Worksite one Quality Inspector for every 100 workers that they employ at the Worksite. Any Sub-contractor that employs more than 100 workers will appoint a Quality Engineer. This shall be in addition to the Contractor’s Quality Team.

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Section 02: Quality Assurance and Quality Control Part 03: Contractor’s Quality Personnel

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Quality Training for Contractor’s Employees and Labour

1

The Contractor shall conduct quality training including Contract specific induction, pre-work briefings, skills training, tool box talks and formal training conducted by training professionals or agencies for all the Contractor’s employees. The Contract specific induction will be at least 1 hour duration, approved by the Engineer and provided for all persons involved in the Works. Such induction training will be reviewed, revised and repeated at intervals not exceeding 12 months throughout the duration of the Work. All training shall be provided in the languages preferred by the recipients of the training. Training shall focus on improving competency and skill for those performing activities that impact quality.

2

The Contractor must conduct regular tool box talks to his Labour workforce Such training should include as a minimum Health and Safety issues and Construction Method best practice.

3

The Owner may organise quality related training, meetings, seminars, workshops or similar events at any time throughout the Contract Period. The Contractor is required to participate in such events when requested at his own expense.

4

The Contractor shall maintain records of all training conducted including details of the training given and a list of attendees, including attendee’s signature and ID numbers.

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3.1.8

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END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 04: Document & Data Control

Page 1

DOCUMENT & DATA CONTROL ............................................................................ 2

4.1 4.1.1 4.1.2 4.1.3

INTRODUCTION ..................................................................................................... 2 General 2 Document and Data Approval and Issue 2 Document and Data Changes 2

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Section 02: Quality Assurance and Quality Control Part 04: Document & Data Control

Page 2

DOCUMENT & DATA CONTROL

4.1

INTRODUCTION

4.1.1

General

1

The Contractor shall establish and maintain documented procedures to control all documents and data that relate to the requirements of the Specification. Documents and data can be in the form of any type of media, such as hard copy or electronic media.

2

The Contractor shall maintain up to date copies of all industry codes and standards that apply to the Contract.

4.1.2

Document and Data Approval and Issue

1

The documents and data shall be reviewed and approved for adequacy by authorised personnel prior to issue. A master list or equivalent document control procedure identifying the current revision status of documents shall be established and be readily available to preclude the use of invalid and/or obsolete documents. This control shall ensure that:

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4

The pertinent issues of appropriate documents are available at all locations where operations essential to the effective functioning of the quality system are performed

(b)

Invalid and/or obsolete documents are promptly removed from all points of issue or use, or otherwise assured against unintended use

(c)

Any obsolete documents retained for legal and/or knowledge preservation purposes are suitably identified

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(a)

Document and Data Changes

1

Where practicable, the nature of the change shall be identified in the document or appropriate attachments.

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4.1.3

END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 05: Quality Records

Page 1

QUALITY RECORDS..................................................................................... 2

5.1 5.1.1

INTRODUCTION ........................................................................................... 2 General 2

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Section 02: Quality Assurance and Quality Control Part 05: Quality Records

Page 2

QUALITY RECORDS

5.1

INTRODUCTION

5.1.1

General

1

The Contractor shall establish and maintain documented procedures for identification, collection, indexing, access, filing, storage, maintenance and disposition of quality records.

2

The Contractor shall supplement these quality records as necessary to monitor quality throughout the Contract period.

3

Quality records shall be maintained to demonstrate conformance of materials and equipment to specified technical requirements and the effective operation of the quality system.

4

All quality records shall be legible and shall be stored and retained in such a way that they are readily retrievable in facilities that provide a suitable environment to prevent damage or deterioration and to prevent loss.

5

As a minimum, the quality record for any particular item shall include: name of item

(b)

item number

(c)

item description

(d)

suppliers name

(e)

serial number or other identification (where applicable)

(f)

Specification reference (where applicable)

(g)

verification of receipt of all required supporting documentation

(h)

quantity of items

(i)

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location and installation of item inspection/test procedure reference

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(k)

non-conformance number (if applicable)

(l)

Observations / comments.

(m)

Signatures of responsible person

END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 06: Quality Audits

Page 1

QUALITY AUDITS ................................................................................................... 2

6.1 6.1.1 6.1.2

GENERAL ............................................................................................................... 2 Contractor’s Quality Audit 2 Engineer’s Quality Audit 2

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Section 02: Quality Assurance and Quality Control Part 06: Quality Audits

Page 2

QUALITY AUDITS

6.1

GENERAL

6.1.1

Contractor’s Quality Audit

1

The Contractor shall establish and maintain documented procedures in line with ISO 190011 for planning and implementing internal quality audits to verify whether quality activities and related results comply with planned arrangements and to determine the effectiveness of the quality system.

2

Internal quality audits shall be scheduled on the basis of the status and importance of the activity to be audited and shall be carried out by personnel independent of those having direct responsibility for the activity being audited. Unless otherwise agreed with the Engineer in writing, the Contractor shall carry out a full system quality audit every three months.

3

The results of the audits shall be recorded and brought to the attention of the personnel having responsibility in the area audited. The management personnel responsible for the area shall take timely corrective action on deficiencies found during the audit.

4

Follow-up audit activities shall verify and record the implementation and effectiveness the corrective action taken.

5

The results of the Contractor’s quality audits shall be made available for review by the Engineer. The Contractor shall implement any recommendations made by the Engineer based on the results of the internal audit.

6

The Contractor shall allow the Engineer to observe the Contractor’s internal audit upon request.

7

Quality audits must be undertaken by suitably qualified personnel with an internationally recognized audit qualification to recognized standards.

6.1.2

Engineer’s Quality Audit

1

The Engineer may undertake a quality audit of any of the Contractor’s activities at any time during the course of the Contract. The Contractor shall make all personnel and facilities available to the Engineer as necessary to undertake quality audits.

2

The Engineer shall make the results of his quality audit available to the Contractor for review. The Contractor shall implement any recommendations made by the Engineer based on the results of the Engineer’s quality audit.

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END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 07: Inspection and Test

Page 1

INSPECTION AND TEST ........................................................................................ 2

7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7

INTRODUCTION ..................................................................................................... 2 General 2 Inspections and Tests 2 Inspection and Test Status 3 Inspections by the Engineer during construction 3 Inspections by the Engineer during Defects Liability Period 4 Workmanship 4 Measuring and Test Equipment 4

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7

Section 02: Quality Assurance and Quality Control Part 07: Inspection and Test

Page 2

INSPECTION AND TEST INTRODUCTION

7.1.1

General

1

The Contractor shall provide equipment, instruments, qualified personnel, and facilities necessary to inspect the work and perform the tests required by the Project Documentation.

2

The Contractor shall repeat tests and inspections after correcting non-conforming work until all work complies with the requirements. All re-testing and re-inspections shall be performed at no additional cost to the Client.

3

The Engineer may elect to perform additional inspections and tests at the place of the manufacture or the shipping point to verify compliance with applicable Specifications. Inspections and tests performed by the Engineer shall not relieve the Contractor of his responsibility to meet the Specifications. Inspections and tests by the Engineer shall not be considered a guarantee that materials delivered at a later time will be acceptable. All costs associated with the foregoing shall be borne by the Contractor.

4

Inspections and tests conducted by persons or agencies other than the Contractor, shall not in any way relieve the Contractor of his responsibility and obligation to meet all Specifications and referenced standards.

7.1.2

Inspections and Tests

1

All inspections and tests shall be conducted in accordance with written test procedures as detailed in the Project Quality Plan and Inspection and Test Plans that have been reviewed and approved by the Engineer.

2

Mandatory Products and Materials Sampling and Testing Frequencies are included in Part 14, Appendix A of this section. The Contractor shall follow the Sampling and Testing Frequencies stipulated in Appendix A unless otherwise stated in the Contract. The table in Appendix A shall be read and understood in tandem with the footnotes in Appendix A.

3

Inspection and test procedures submitted for approval shall include, but not be limited to, the following:

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7.1

(a)

inspection/test procedure reference

(b)

references to Clauses of this Specification and other standards along with applicable inspection/test levels specified therein

(c)

prerequisites for the given inspection/test

(d)

required tools, equipment

(e)

necessary environmental conditions

(f)

acceptance criteria

(g)

data to be recorded

(h)

reporting forms

(i)

Identification of items inspected and tested.

(j)

Contractors and Engineers Hold, Witness, Surveillance and Record Review Points

QCS 2014

Section 02: Quality Assurance and Quality Control Part 07: Inspection and Test

Page 3

Approved procedures and instructions shall be readily available and used by inspection and test personnel at the time of inspection or test. All revisions to these procedures and instructions shall be approved prior to being used to inspect or test the work. No deviations from the approved procedures and instructions shall be allowed without written authorisation from the Engineer.

5

Inspection and testing work shall be performed by personnel designated by the Contractor. Such personnel shall not be the same as those performing the work.

6

The Contractor shall furnish the Engineer with a signed inspection report for each item of work inspected and tested. The report shall indicate whether the item of work, material and/or equipment complies with all the inspection/test criteria. The Contractor shall submit inspection/test results to the Engineer prior to incorporating the item(s) into the work. Inspection/test failures shall be reported to the Engineer immediately.

7

Inspection and test reports shall, as a minimum, identify the following: inspection/test procedure reference

(b)

name of inspector/tester

(c)

observations/comments

(d)

specified requirements

(e)

acceptability

(f)

deviations/non-conformance

(g)

corrective action

(h)

evaluation of results

(i)

authorised signature

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4

The Contractor shall clearly document and identify the inspections and test status of all materials and equipment throughout construction. Identification may be by means of stamps, tags, or other control devices attached to, or accompanying, the material or equipment.

7.1.3

Inspection and Test Status

1

The inspection and test status of materials, equipment and construction work shall be identified by suitable means, which indicates the conformance or non-conformance of materials, equipment and construction work with regard to inspection and tests performed. The identification of inspection and test status shall be maintained, as defined in the Quality Assurance Plan and/or documented procedures, throughout the course of construction to ensure that only materials, equipment and construction work that have passed the required inspections and tests are used or installed.

7.1.4

Inspections by the Engineer during construction

1

The Contractors Inspection and Test Plans will define Hold, Witness, Surveillance and Record Review points for the Engineer during construction. The contractor shall prepare, document and implement a Request for Inspection system that defines how the Engineer will be given sufficient notice to inspect the works in accordance with the Inspection and Test Plans.

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Section 02: Quality Assurance and Quality Control Part 07: Inspection and Test

Page 4

Inspections by the Engineer during Defects Liability Period

1

The Engineer will give the Contractor due notice of his intention to carry out any inspections during the defects liability period.

2

The Contractor shall arrange for a responsible representative to be present at the times and dates named by the Engineer.

3

The Contractor’s representative shall render all necessary assistance and take note of all matters to which his attention is directed by the Engineer

7.1.6

Workmanship

1

The Contractor shall comply with industry standards except when more restrictive tolerances or specified requirements indicate more rigid standards or more precise workmanship.

2

Only persons qualified to produce workmanship of the required quality shall perform works

3

The Contractor shall comply with manufactures’ published installation instructions / guides in full, including each step in sequence. Should instructions conflict with project documentation, the Contractor shall request clarification from the Engineer before proceeding.

7.1.7

Measuring and Test Equipment

1

The Contractor shall establish and maintain documented procedures which conform to accepted and approved national or international standards to control, calibrate and maintain inspection, measuring and test equipment used by the Contractor to demonstrate the conformance of materials, equipment and/or construction work with the requirements of the Project Documentation.

2

Inspection, measuring and test equipment shall be used in a manner which ensures that the measurement uncertainty is known and is consistent with the required measurement capability

3

The Contractor shall establish a unique identification number for each item of measuring and test equipment. This unique identification number shall be permanently affixed to each item of measuring and test equipment

4

The Contractor shall ensure that each item of inspection, measuring and test equipment is calibrated at intervals recommended by the manufacturer. Valid calibration certificates for measuring and testing equipment shall be present and available for inspection during inspections and tests.

5

The Contractor shall establish a log of all measuring and test equipment and record:

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7.1.5

(a)

equipment description

(b)

identification number

(c)

date of the last calibration

(d)

date that the next calibration is due.

QCS 2014

Page 5

The Contractor shall assess and record the validity of the previous measuring results when the equipment is subsequently found not to confirm to requirements. The Contractor shall take appropriate action on the equipment and any product affected.

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END OF PART

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QCS 2014

Section 02: Quality Assurance and Quality Control Part 08: Materials

Page 1

MATERIALS .................................................................................................. 2

8.1 8.1.1 8.1.2 8.1.3

GENERAL ...................................................................................................... 2 Plant, Materials, Goods and Workmanship 2 Handling and Storage of Materials 2 Identification and Control of Items and Materials 2

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Section 02: Quality Assurance and Quality Control Part 08: Materials

Page 2

MATERIALS

8.1

GENERAL

8.1.1

Plant, Materials, Goods and Workmanship

1

All Plant, materials, goods and workmanship shall be of the respective kinds described in the Contract with necessary approvals from the concerned authorities and in accordance with the Engineer's instructions and shall be subjected from time to time to such tests as the Engineer may direct at the place of manufacture or fabrication or on the Site or at all or any such places. The Contractor shall provide such assistance, instruments, machines, labour and material as are normally required for examining, measuring and testing any work and the quality, weight or quantity of any materials used and shall supply samples of materials before incorporation in the Works for testing as may be selected and required by the Engineer.

8.1.2

Handling and Storage of Materials

1

The Contractor shall establish procedures for handling and storage of materials and equipment.

2

The Contractor’s storage and handling procedures shall be designed to prevent damage, deterioration, distortion of shape or dimension, loss, degradation, loss of identification, or substitution.

3

The handling procedures shall address the use, inspection and maintenance of special devices such as crates, boxes, containers, dividers, slings, material handling and transportation equipment and other facilities.

4

The Contractor shall identify equipment and/or material requiring special handling or storage.

8.1.3

Identification and Control of Items and Materials

1

The Contractor shall establish control procedures to ensure that equipment and materials are properly used and installed.

2

The Contractor shall identify all items and materials so that they are traceable throughout all inspections, test activities, and records. For stored items, the identification method shall be consistent with the expected duration and type of storage.

3

The Contractor shall record equipment and material identifications and ensure that they are traceable to the location where they are incorporated into the Works.

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END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 09: Nonconformance Monitoring

Page 1

NONCONFORMANCE MONITORING .................................................................... 2

9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6

INTRODUCTION ..................................................................................................... 2 General 2 Review and Disposition of Nonconforming Items 2 Corrective Action 3 Identification of Nonconforming Items 3 Acceptance and Approval of Nonconforming items 4 Nonconformance Records 4

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Section 02: Quality Assurance and Quality Control Part 09: Nonconformance Monitoring

Page 2

9

NONCONFORMANCE MONITORING

9.1

INTRODUCTION

9.1.1

General

1

The Contractor shall ensure that product which does not conform to Specification requirements is identified and controlled to prevent its unintended use or delivery. A documented procedure shall be established to define the controls and relate responsibilities and authorities for dealing with nonconforming product: by taking action to estimate the detected nonconformity

(b)

by authorizing its use, release or acceptance under concession by the Engineer

(c)

by taking action to preclude its original intended use or application

(d)

by taking action appropriate to the effects, or potential effects, of the nonconformity when nonconformity product is detected after delivery or use has started .

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(a)

When Conforming product is corrected it shall be subject to re-verification to demonstrate conformity to requirements.

3

Records of the nature of nonconformities and any subsequent actions taken, including concessions obtained by the engineer, shall be maintained.

4

The monitoring system shall apply to material and equipment as well as installation and construction which fail to conform to the Contract.

5

A Contractors Quality Nonconformance Template is included in Part 15 Appendix B of this Section and must be used for recording Nonconformance.

9.1.2

Review and Disposition of Nonconforming Items

1

The responsibility for review and authority for the disposition of nonconforming items shall be defined in the Quality Plan.

2

Nonconforming items shall be reviewed in accordance with documented procedures. A nonconforming item may be:

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(a)

reworked to meet the specified requirements

(b)

accepted with or without repair if agreed in writing by the Engineer

(c)

re-graded for alternative applications

(d)

rejected or scrapped.

3

The proposed use or repair of an item which does not conform to the requirements of the Project Documentation shall be reported to the Engineer. The description of the nonconformity and of repairs shall be recorded to denote the actual condition.

4

Repaired and/or reworked products shall be inspected in accordance with the Quality Assurance Plan and/or documented procedures

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Section 02: Quality Assurance and Quality Control Part 09: Nonconformance Monitoring

Page 3

9.1.3

Corrective Action

1

The Contractor shall take action to eliminate the causes of nonconformities in order to prevent recurrence. Corrective actions shall be appropriate to the effects of the nonconformity encountered. A documented procedure shall be established to define requirements for: Reviewing nonconformities (including Engineer complaints)

(b)

Determining the causes of nonconformities

(c)

Evaluating the need for action to ensure that conformities do not occur

(d)

Determining and implementing actions needed

(e)

Records of the results of action taken and

(f)

Reviewing the effectiveness of the corrective action taken

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Any corrective or preventive action taken to eliminate the causes of actual or potential nonconformities shall be to a degree appropriate to the magnitude of problems and commensurate with the risks encountered.

3

The Contractor shall implement and record any changes to the documented procedures for implementing corrective and preventive action.

4

The Contractor shall take prompt action to identify the causes of each nonconformance and the corrective action necessary prevent recurrence. The results of failure and discrepancy report summaries, Contractor evaluations, and any other pertinent applicable data shall be used for determining corrective action. Information developed during construction, tests, and inspections that support the implementation of required improvements and corrections shall be used to support the adequacy of corrective action taken.

5

The procedures for preventive action shall include:

determination of the steps needed to deal with any problems requiring preventive action

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(b)

the use of appropriate sources of information such as processes and work operations which affect product quality, concessions, audit results, quality records and service reports to detect, analyse and eliminate potential causes of nonconformities

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(c)

initiation of preventive action and application of controls to ensure that it is effective

(d)

ensuring that relevant information on actions taken is submitted for management review

9.1.4

Identification of Nonconforming Items

1

The Contractor shall clearly identify each nonconforming item with a status tag or other distinguishing mark. The Contractor shall establish procedures for installing, monitoring, and removing these status tags and identify personnel authorised to remove status tags.

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Section 02: Quality Assurance and Quality Control Part 09: Nonconformance Monitoring

Page 4

9.1.5

Acceptance and Approval of Nonconforming items

1

Acceptance of the Contractors proposed disposition of Nonconforming items should be his obtained in writing from the Engineer prior to the undertaking of any remedial works by the his Contractor.

2

Close out of Nonconforming items must be agreed in writing by the Engineer.

9.1.6

Nonconformance Records

1

The Contractor shall provide the Engineer with the following information for each nonconformance:

(b)

description of nonconformance

(c)

evaluation of nonconformance to establish the cause

(d)

recommended corrective action

(e)

date nonconformance was identified

(f)

date corrective action was completed

(g)

description of final corrective action.

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identification of nonconformance

unique sequential reference number

(b)

date issued

(c)

originator

(d)

description of item deemed to be in nonconformance

(e)

description of nonconformance

(f) (g)

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The Contractor shall establish and maintain a nonconformance log. The log shall contain the following information as a minimum:

Contractors recommended and final disposition Engineers acceptance of Contractors recommended and final disposition

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(a)

(h)

date closed

(i)

remarks, as applicable

END OF PART

QCS 2014

Section 03: Ground Investigation Part 01: General

Page 1

GENERAL ............................................................................................................... 2

1.1 1.1.1 1.1.2 1.1.3

INTRODUCTION ..................................................................................................... 2 Scope 2 References 2 Definitions 2

1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7

SUBMITTALS .......................................................................................................... 3 Programme of Works 3 Preliminary Logs 3 Exploratory Hole Logs 4 Preliminary Laboratory Test Results 5 Digital Data 5 Form of Report 5 Approval of Report 6

1.3

QUALITY ASSURANCE .......................................................................................... 6

1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.4.10 1.4.11 1.4.12 1.4.13 1.4.14 1.4.15 1.4.16

GENERAL PROJECT/SITE CONDITIONS .............................................................. 7 General 7 Working Areas 7 Turf and Topsoil 7 Paved Areas 7 Paving Slabs and Blocks 7 Claims for Damage 8 Geotechnical and Environmental Personnel 8 Location of Exploratory Holes 8 Ground Elevation of Exploratory Holes 8 Exploratory Work 8 Methods of Investigation 8 Safety and Management 9 Anomalous Conditions 9 Surface Water Control 9 Photographs 9 Facilities for the Engineer 10

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QCS 2014

Section 03: Ground Investigation Part 01: General

Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

General requirements and information for the execution of ground investigations.

2

Related Sections are as follows:

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Section 1 ......... General Section 2 ......... Quality Assurance and Quality Control Section 4 ......... Foundations and Retaining Structures Section 6 ......... Roadworks Section 8 ......... Drainage Works Section 12 ....... Earthworks Related to Buildings References

1

The following standards and other documents are referred to in this Part:

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1.1.2

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BS 5930......................Code of practice for site investigations BS EN 1997................Ground Investigation and testing

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes

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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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Deere D. U. et al., Design of surface and near-surface construction in rock. Proc. 8th US symposium on rock mechanics. AIME, New York, 1967

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Code of Practice and Specifications for Road Openings in the Highway issued by the Government. Definitions

1

Topsoil: the surface layer of earth that contains organic material and can also support vegetation.

2

Soil: earthen material not classified herein as topsoil or hard stratum.

3

Hard stratum and obstruction: The words 'hard stratum' and 'obstruction' shall mean natural or artificial material, including rock, which cannot be penetrated except by the use of chiselling techniques, rotary drilling, blasting or powered breaking tools. The term 'hard stratum' shall apply during boring, where it is shown that condition (1) or condition (2) below are fulfilled, provided that the boring rig involved is in good working order and is fully manned:

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1.1.3

(a)

Condition (1) 100 mm diameter undisturbed sample tubes cannot be driven more than 300 mm

(b)

Condition (2) a standard penetration resistance test shows a resistance in excess of 35 blows/75 mm.

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Section 03: Ground Investigation Part 01: General

Page 3

Fill: deposits or embankments which have been formed by persons, as distinct from geological agencies.

5

Exploratory Hole/Trench/Excavation: any boring, pit trench, ditch or shaft formed for the purpose of ground investigation.

6

Boring: hole in earth, excavated by either percussion or auger equipment.

7

Drilling: any hole in rock, excavated by rotary equipment.

8

Borehole: exploratory hole excavated by boring or drilling techniques.

1.2

SUBMITTALS

1.2.1

Programme of Works

1

The Geotechnical Investigation Contractor shall prepare a programme of works for the investigation which will give a detailed schedule showing proposed time schedule for all aspect of the work, details of all plant and equipment to be used in addition to a list of personnel who will work on the project.

1.2.2

Preliminary Logs

1

The Geotechnical Investigation Contractor shall prepare a preliminary log of each exploratory hole. For trial pits and trenches, a trial pit or trench map showing each face of the pit or trench shall be provided, as appropriate. Preliminary logs shall be submitted to the Engineer in duplicate within seven working days of completion of the explorations to which they refer to, and shall contain the information required for the exploratory hole logs.

2

Geotechnical Investigation Contractor activities shall fully comply with Ministry of Environment (MOE) requirements and/or those of other Government Departments, Ministries and Statutory Organizations.

3

The Geotechnical Investigation Contractor shall obtain all necessary work permits and security permits prior to commencement of Geotechnical investigation of the site.

4

The investigation shall provide detailed information on the nature of the sub-strata, superficial deposits and ground water table at the site together with general recommendations for designing foundations and earthworks, new road pavements, culverts, retaining walls, etc.

5

The geotechnical investigation Exploratory Boreholes shall be spaced as mentioned in Section 2.

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Section 03: Ground Investigation Part 01: General

Page 4

The geotechnical investigation Exploratory Boreholes depths shall be as mentioned in Table 1.1. Table 1.1: Minimum Depth of Boreholes No of floors

Depth of Boreholes (m)

3 or Less

6

4

8

5

9

6

10

7

12

8

13 0.7

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2m below the inverted level; 1.5width of excavation. 2D (D=Diameter or equivalent diameter of the tunnel/underground structure.

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  

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For trenches, pipeline and Tunnels, the depth of Boreholes shall be the larger value of:

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Notes:  The depth of boreholes is measured from foundation level.  S is the number of floors.  For structures small in plan area, exploration should be made at a minimum of three points, unless other reliable information is available in the immediate vicinity. Where a structure consists of a number of adjacent units, one exploration point per unit may suffice.  For piles the depth of Boreholes is at least below the depth of pile tip by 5m or 5D (D is the diameter of the pile at the toe) whichever is greater.  For roads, the depth of Boreholes shall be greater than 2m below the proposed formation Level.

Exploratory Hole Logs

1

The exploratory hole logs shall be prepared and presented to a suitable vertical scale. The logs shall include all the information that follows, such information having been updated as necessary in the light of laboratory testing and further examination of samples and cores.

2

Information for exploratory hole logs:

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Drilling

Pit and Trench

Static and Dynamic Probing









National grid co-ordinates









Ground level related to the datum









Elevation of each stratum referred to the datum







()

Rotary Borehole

All the designated information

QCS 2014

Section 03: Ground Investigation Part 01: General

Page 5

Drilling

Pit and Trench

Static and Dynamic Probing







()

Details of groundwater observations







()

Symbolic legend of strata in accordance with BS 5930







()

Rotary Borehole Description of each stratum in accordance with BS 5930 and initials of person who carried out the logging (and responsible Supervisor if under training)

Core recovery as percentage of each core run



Rock Quality Designation, RQD (Deere et al. 1967)



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_____ Note:  means information required; () means information required if applicable. Preliminary Laboratory Test Results

1

Laboratory test results shall be submitted to the Engineer in batches at the completion of each week's testing. Legible photocopies of work sheets are acceptable.

1.2.5

Digital Data

1

Data from the investigation shall be provided in digital form to the approval of the Engineer.

1.2.6

Form of Report

1

The report shall comprise of a factual or interpretative or both types of reports as required by the Employer or Engineer. Reports shall begin with a cover page showing the name of the Contract and the names of the Employer, Engineer and Geotechnical Investigation Contractor. Report pages shall be numbered consecutively.

2

The factual report shall contain, as a minimum, the following information: A statement from the Engineer on the purpose and rationale of the investigation.

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1.2.4

(b)

A description of the work carried out, including reference to specification and standards adopted and any deviations from them.

(c)

Exploratory hole logs.

(d)

In-situ test records.

(e)

Laboratory test results.

(f)

Plan with locations of exploratory holes.

(g)

Site location plan.

(h)

Geological cross-sections (if appropriate).

The plans shall be to a stated scale and shall include a north arrow. Additional information shall be provided as designated.

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Section 03: Ground Investigation Part 01: General

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The interpretative report shall contain the following information: (a)

A written appraisal of the ground and water conditions.

(b)

Analysis and recommendations as designated.

When so designated, the Geotechnical Investigation Contractor shall supply the calculations and analyses on which recommendations are based. Approval of Report

1

A draft copy of the factual report and the interpretative report shall be submitted to the Engineer for approval before submission of the final report.

1.3

QUALITY ASSURANCE

1

Only Geotechnical Investigation Contractors holding a current approval certificate from the Central Materials Laboratory shall be permitted to carry out ground investigations.

2

The work shall be carried out in accordance with the relevant British Standards or equivalent.

3

Where specifically designated, all work shall be carried out in accordance with a quality management system established in accordance with Section 2 Quality Assurance and Quality Control of the QCS. Records to indicate compliance with quality management shall be made available to the Engineer on request.

4

The Geotechnical Investigation Contractor shall provide full time professional attendance on site. The professional attendant shall be approved by the Engineer, and shall be responsible for the technical direction of all fieldwork.

5

The Geotechnical Investigation Contractor’s geotechnical and environmental personnel employed on the Contract shall be competent to undertake the work required. Categories of personnel who may be required by the Contract are as follows:

(b)

Graduate Engineer/Geologist/Environmental Scientist. Graduate Engineer/Geologist/Environmental Scientist with at least three years of

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(c)

Technician.

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1.2.7

relevant experience since graduation.

(d)

Professional Engineer/Geologist/Environmental Scientist with at least five years of relevant experience.

(e)

6

Professional Engineer/Geologist/Environmental Specialist with at least ten years of relevant experience.

All drillers employed on the Contract shall be experienced and competent in percussion or auger boring or rotary drilling, to the complete satisfaction of the Engineer. One competent drilling supervisor per site shall be permanently on the Site during borehole operations.

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Section 03: Ground Investigation Part 01: General

Page 7

GENERAL PROJECT/SITE CONDITIONS

1.4.1

General

1

Geotechnical Investigation Contractor shall only use access routes to and between exploration sites that are approved by the Engineer.

2

Where the presence of underground services is likely, exploratory holes shall be started by means of a hand excavated inspection pit.

3

In addition to any designated notice, at least one working day's notice of the intended time of entry shall be given to the land owner and occupier of the exploration site.

4

All work shall be carried out with the least possible damage to the Site and its environs.

5

All barriers breached or otherwise disturbed during the execution of site operations shall be immediately repaired or replaced to the same standard.

6

Working hours shall be restricted to those designated.

7

Daily allocation sheets detailing the work carried out shall be submitted in duplicate at the end of each day’s work.

1.4.2

Working Areas

1

Operations shall be confined to the minimum area of ground required for the Works. Unless otherwise designated, on completion of each exploration all equipment, surplus material and rubbish of every kind shall be cleared away and removed from the Site. Damage to land or property in the vicinity of the exploratory hole and on access routes shall be made good. The whole of the Site and any ancillary works shall be left in a clean and tidy condition.

1.4.3

Turf and Topsoil

1

Turf and topsoil shall be stripped from the site of each exploration and stockpiled for future replacement. Vegetation and topsoil adjacent to the exploration which may be damaged by the operations shall either be removed and stockpiled as above, or otherwise protected from damage. After completion of the exploration all topsoil shall be replaced and the Site restored to its original condition.

1.4.4

Paved Areas

1

Pavement from paved areas (other than paving slabs and blocks) shall be broken out to the minimum extent necessary for each exploration. After completion of the exploration and backfill of the excavation, the disturbed subgrade shall be compacted and the paving replaced.

2

Restoration of highway pavement shall be in accordance with the current Code of Practice and Specification for Road Openings in the Highway issued by the Government.

1.4.5

Paving Slabs and Blocks

1

Paving slabs and blocks shall be removed from the Site, as required for each exploration, and stored for reuse.

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Section 03: Ground Investigation Part 01: General

Page 8

Contiguous paving slabs and blocks which are liable to be damaged by the operations shall either be removed and stored as above or otherwise protected from damage.

3

After completion of the exploration and backfill of the excavation, the disturbed subgrade shall be compacted and the paving slabs and blocks relayed.

1.4.6

Claims for Damage

1

Any damage, or claim for compensation for damage by owners or occupiers of the Site, shall be reported to the Engineer.

1.4.7

Geotechnical and Environmental Personnel

1

In addition to the provision of the designated personnel by the Geotechnical Investigation Contractor, the Engineer may specifically require the services of geotechnical and environmental personnel for advice, assistance or preparation of interpretative reports. The form of interpretative reports shall be agreed with the Engineer. Details of the qualifications and experience of the personnel shall be supplied to the Engineer.

1.4.8

Location of Exploratory Holes

1

The location of each exploratory hole shall be measured from an approved grid co-ordinate system, and shall be accurate to within 1 m, and the position recorded on a plan as

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designated.

Ground Elevation of Exploratory Holes

1

The elevation of the ground at each exploratory hole shall be established, on the basis of the Qatar National Datum unless otherwise designated or approved by the Engineer, to the nearest 0.05 m.

1.4.10

Exploratory Work

1

The location and depth of each exploratory hole shall be as designated. The Engineer may, after consultation with the Geotechnical Investigation Contractor, vary the location and depth of any exploratory hole and the sequence or quantity of in-situ testing depending on the actual ground conditions encountered. When the position of an exploratory hole has been varied, the Geotechnical Investigation Contractor shall take all necessary measurements and shall inform the Engineer of the revised co-ordinates and ground elevation or other measurements required to locate the exploratory hole.

1.4.11

Methods of Investigation

1

The Engineer will have the option to require any of the following methods of investigation. These options will comprise, but not necessarily be limited to, the following:

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1.4.9

(a)

Desk study.

(b)

Geological mapping.

(c)

Topographic survey.

(d)

Aerial photographs.

or any other methods described in this Section.

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Section 03: Ground Investigation Part 01: General

Page 9

Safety and Management

1

The Geotechnical Investigation Contractor shall submit detailed Job Hazard Analysis (JHA) to all site activities including but not limited to potential hazard, who/what might be harmed, control/ recovery measure, responsible person…etc.

2

The presence and nature of known areas of hazardous or contaminated ground are designated, based on available records. If evidence of further hazardous or contaminated ground is encountered, the Geotechnical Investigation Contractor shall immediately so inform the Engineer. If required by the Engineer, the Geotechnical Investigation Contractor’s work plan shall be revised appropriately to take into account the nature and level of contamination encountered. Where contaminated land is present or suspected the Geotechnical Investigation Contractor shall take the appropriate health and safety precautions as directed by the Engineer and where appropriate by the Civil Defence Department of the Government. Care shall be taken to avoid contaminating the egress from the Site.

3

A method statement indicating the safety procedures to be followed during the investigation of hazardous or contaminated ground shall be provided by the Geotechnical Investigation Contractor before beginning the investigation in the hazardous or contaminated ground.

4

Traffic safety and management measures shall be provided, in accordance with the provisions of traffic control of Section 1, General. Where the circumstances of any particular case are not designated, proposals for dealing with such situations shall be submitted to the Engineer for approval.

1.4.13

Anomalous Conditions

1

Where anomalous or unexpected features are revealed, the Geotechnical Investigation Contractor shall immediately inform the Engineer.

1.4.14

Surface Water Control

1

Surface water or other water shall be prevented from entering the exploratory hole, except as permitted by the Engineer.

1.4.15

Photographs

1

Colour photographs shall be taken and supplied by the Geotechnical Investigation Contractor as designated. Each photograph shall clearly show all necessary details, and shall have its scale identified.

2

A single gloss colour print (size 150 mm by 100 mm) copy of each photograph shall be submitted to the Engineer for his approval, within seven working days of the photography. In the event that the photographs are of a quality unacceptable to the Engineer, they shall be retaken.

3

On acceptance of the quality of the photograph, two complete sets of prints of all the photographs shall be presented, annotated and submitted in bound volumes, together with the original photograph digital format with the factual report.

4

Particular requirements for photographs of cores and pits and trenches are given in Parts 3 and 4

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1.4.12

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Section 03: Ground Investigation Part 01: General

Page 10

1.4.16

Facilities for the Engineer

1

When required by the particular contract documentation, facilities to the designated standard shall be provided for the use of the Engineer, as described in Section 1.

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END OF PART

QCS 2014

Section 03: Ground Investigation Part 02: Boreholes

Page 1

BOREHOLES .......................................................................................................... 2

2.1 2.1.1 2.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

2.2 2.2.1 2.2.2 2.2.3

BOREHOLES GENERALLY .................................................................................... 2 Method and Diameter 2 Addition of Water to the Borehole 3 Backfilling 3

2.3 2.3.1

PERCUSSION BORING .......................................................................................... 3 Hard Stratum or Obstruction in Percussion Boring 3

2.4 2.4.1 2.4.2 2.4.3

AUGER BORING ..................................................................................................... 3 Hand Auger 3 Continuous Flight Auger Boring 3 Hollow Stem Flight Auger 3

2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6

ROTARY DRILLING ................................................................................................ 3 General 3 Drilling Fluid 4 Rotary Drilling with Core Recovery 4 Rotary Drilling without Core Recovery 6 Backfilling 6 Photographs 6

2.6

BOREHOLES OVERWATER .................................................................................. 6

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Section 03: Ground Investigation Part 02: Boreholes

Page 2

2

BOREHOLES

2.1

GENERAL

2.1.1

Scope

1

Advancement of boreholes by percussion boring, auger boring, and rotary drilling.

2

Related Sections and Parts are as follows: This Section

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Section 4, ........ Foundations and Retaining Structures Section 6, ........ Roadworks Section 8, ........ Drainage Works Section 12, ...... Earthworks Related to Buildings

.

Part 1 ............... General

References

1

The following standards and other documents are referred to in this Part:

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BS 5930 ......................Code of practice for site investigations.

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BS EN 1997 ................Ground Investigation and testing

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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Engineering Group of the Geological Society Working Party Report The logging of rock cores for engineering purposes (1970).

BOREHOLES GENERALLY

2.2.1

Method and Diameter

1

The method of advancement and the diameter of a borehole shall be such that the boring can be completed and logged to the designated depth, and samples of the designated diameter can be obtained, in-situ testing carried out and instrumentation installed.

2

The following methods may be employed for advancement of a borehole unless otherwise designated:

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(a)

Percussion boring.

(b)

Auger boring (If hollow stem augering is proposed, the Contractor shall satisfy the Employer that the SPT values obtained are not effected by disturbance of the soil by the auger head, or the presence of material within the hollow stem.).

(c)

Rotary drilling.

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Section 03: Ground Investigation Part 02: Boreholes

Page 3

Addition of Water to the Borehole

1

Jetting with water shall not be used to assist the advance of the borehole, except where approved by the Engineer. Where the borehole penetrates below the water table and disturbance of the soils is likely, a positive hydraulic head shall be maintained in the borehole.

2.2.3

Backfilling

1

The Contractor shall backfill boreholes in such a manner as to minimise subsequent depression at the ground surface due to settlement of the backfill. In some circumstances, grout or special infilling may be required by the Engineer. Where artesian or other water conditions make normal backfilling impracticable, the Contractor shall consult and agree with the Engineer a procedure for sealing the borehole.

2.3

PERCUSSION BORING

2.3.1

Hard Stratum or Obstruction in Percussion Boring

1

In a borehole where percussion boring is employed and a hard stratum or obstruction is encountered, the Contractor shall employ chiselling techniques for a period of up to 1 h.

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Should this not penetrate through the hard stratum or obstruction the Contractor shall inform the Engineer, who may instruct the use of one or more of the following: continuation of chiselling techniques

(b)

rotary or other approved drilling until the stratum is penetrated

(c)

abandonment of the borehole.

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AUGER BORING

2.4.1

Hand Auger

1

Hand auger boring may be appropriate in suitable self-supporting strata.

2.4.2

Continuous Flight Auger Boring

1

Where continuous flight auger boring is used, it shall be carried out under the full-time supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) who shall produce, as boring proceeds, a record of the material and groundwater encountered.

2.4.3

Hollow Stem Flight Auger

1

Where hollow stem flight auger boring is used, the equipment used shall be such as to bore and recover samples as designated. Sampling shall be carried out through the hollow stem.

2.5

ROTARY DRILLING

2.5.1

General

1

Rotary drilling may be required for the recovery of cores, or for the advancement of a hole in rock, with or without core recovery.

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2.4

QCS 2014

Section 03: Ground Investigation Part 02: Boreholes

Page 4

Drilling Fluid

1

The drilling fluid shall normally be clean water, air or air mist. However, with the approval of the Engineer, drilling muds, additives or foam may be used.

2.5.3

Rotary Drilling with Core Recovery

1

Unless otherwise designated rotary core drilling shall be carried out by a double or triple tube coring system incorporating a removable inner liner or split tube. The triple tube system may be affected by use of a double tube barrel with an approved semi-rigid liner.

2

Rotary core drilling shall produce cores of not less than the designated diameter throughout the core length. Care shall be exercised in the drilling so as to optimise core recovery.

3

The first drill run in each hole shall not exceed 1 m in length. Subsequent drill runs shall not

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2.5.2

normally exceed 3 m in length and the core barrel shall be removed from the drill hole as

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Removal of cores and labelling of liners shall be carried out as follows: All operations entailed in recovering the cores from the ground after completion of drilling shall be carried out in a manner such as to minimise disturbance to the cores.

(b)

Core barrels or inner tube in case of wireline shall be held horizontally while the innermost liner containing the core is removed without vibration and in a manner to prevent disturbance to the core. The core should be rigidly supported at all times while it is being extruded and during subsequent handling, and the liner containing the core must not be allowed to flex

(c)

Immediately after removing the liner the top and bottom shall be marked in indelible ink. The ends of liners shall be capped and sealed using adhesive tape. Liners shall

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(a)

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often as is required to obtain the best possible core recovery or alternatively the core samples shall be retrieved by means of wireline. The Engineer may designate in-situ testing between drill runs.

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be cut to the length of the enclosed core. Alternatively, should a metallic split tube be used, the samples shall be placed in half cut PVC pipes sealed with the second half after core samples description with marking of the core run on the PVC tube and the core box.

5

(d)

Where the length of core recovered from any single core run is such that it cannot be accommodated in one channel of the core box, the liner shall be cut to coincide, if possible, with existing fractures. The liner either side of the cut shall be marked 'cut' and the ends capped as above.

(e)

Each section of liner shall be marked with the contract title, exploratory hole reference number, date and the depths of the top and bottom of the drill run.

(f)

Core obtained without a liner and that from within the core catcher but not inside the liner shall be wrapped in two layers of plastic cling film and labelled to indicate the depth and exploratory hole reference number.

Core boxes, packing, labelling, storing shall be carried out as follows: (a)

Core boxes shall be soundly constructed and fitted with stout carrying handles, fastenings and hinged lids. The total weight of the cores and box shall together not exceed 60 kg.

QCS 2014

Section 03: Ground Investigation Part 02: Boreholes

Page 5

Cores shall be rigidly and securely packed at the site of drilling and during all subsequent handling and storage the cores shall remain packed unless required for examination or testing. Cores shall be placed in the box, in their liners where used, with the shallowest core to the top left hand corner, the top being considered adjacent to the hinged section. Cores from the core catcher shall also be placed in the core boxes at the correct relative depth.

(c)

Depth shall be indicated on the core box by durable markers at the beginning and end of each drill run. Rigid core spacers shall be used to indicate missing lengths. The contract title, exploratory hole reference number and the depth of coring contained in each bore shall be clearly indicated in indelible ink inside, on top and on the right-hand end of the box and on the inside of the box lid.

(d)

Core boxes containing core shall be kept horizontal and moved and handled with care at all times. Cores shall be protected from direct sunlight. At the end of each day's work, core boxes shall be stored secure from interference and protected from the weather.

Cores shall be prepared for examination as follows: (a)

Cores shall be prepared for examination by the removal of sealing materials and splitting of liners in such a way as not to damage the cores. Plastic liners shall be cut lengthways such that at least half the core circumference is exposed. If half PVC is used, care should be taken while removing and replacing the split half.

(b)

Before examination of the core, the Contractor shall photograph the cores. The time between beginning preparation and the examination of the prepared and photographed cores shall be minimised to prevent loss of moisture from the core samples.

(c)

Cores shall be examined and described on site by a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) in accordance with BS 5930 or ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society Working Party Report The logging of rock cores for engineering purpose (1970).

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(b)

When the examination of the cores has been completed, the Contractor may be required to retain separately designated core sub-samples for possible laboratory testing. The Contractor shall cut the liner and cap and seal the core sub-samples in such a way as to prevent loss of moisture and sample disturbance. They shall be clearly labelled so that the location, depth and origin of the sub-samples can be readily identified. Cores in their liners remaining after the designated sub-samples have been removed shall be end-capped and resealed and replaced in the original core box location. Rigid spacers shall be placed in the spaces in the cores boxes previously occupied by the core sub-samples to prevent movement of adjacent cores and these shall be labelled identically to the core sub-samples that they replace. The core sub-samples shall be retained in separate core boxes clearly marked to indicate the origin of the cores contained within.

8

The Contractor shall protect all cores and transport them including loading and unloading to

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(a)

The Contractor's premises.

(b)

For a number of selected cores, to the designated address.

After submittal of the approved final report, the Contractor shall retain cores, other than those delivered to the designated address, for a period of time required by the Engineer. The Engineer's written permission shall be obtained before disposal of the cores, but the required retention period will normally not exceed three months.

QCS 2014

Section 03: Ground Investigation Part 02: Boreholes

Page 6

2.5.4

Rotary Drilling without Core Recovery

1

Rotary blind bit or rotary percussive drilling may be used to advance a hole. The hole diameter shall be as designated.

2

When used for the purpose of locating mineral seams, mineworkings, adits, shafts, other cavities or anomalous conditions, drilling shall be under the full-time supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c). As drilling proceeds a systematic record shall be made of the drilling methods, rate of penetration, loss of flushing medium, the material penetrated and any cavities or broken ground encountered. Backfilling

1

Except where otherwise designated, the Contractor shall backfill rotary drill holes with clean, well graded aggregate. The aggregate size and gradation shall be approved by the Engineer. Under special circumstances grout may be required to backfill the holes. The grout shall consist of equal portions by weight of ordinary Portland cement and bentonite mixed by machine or hand to a uniform colour and consistency before placing, with a moisture content not greater than 250 %. The grout shall be introduced at the bottom of the hole by means of

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a tremie pipe, which shall be raised but kept below the grout surface as the filling proceeds. Where artesian water conditions or voids make normal grouting impracticable, the Contractor shall consult and agree with the Engineer a procedure for sealing the drill hole.

2.5.6

Photographs

1

In addition to the requirements of Part 1, the Contractor shall photograph cores where required in a fresh condition before logging and ensure that the following criteria are fulfilled:

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A graduated scale in centimetres is provided.

(b)

Labels and markers are clearly legible in the photograph.

(c)

A clearly legible reference board identifying the project title, exploratory hole number, date, and depth of drill runs shall be included in each photograph.

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Core boxes are evenly and consistently lit.

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(a)

(e)

The length of the core box in each photograph fills the frame.

(f)

The focal plane of the camera and the plane of the core box are parallel.

(g)

The camera is placed in the same position with respect to the core box in every photograph.

(h)

The resolution of the camera is not less than 8Mpixels.

(i)

The photograph taken should be in focus along all the core samples length.

2.6

BOREHOLES OVERWATER

1

When boreholes are required overwater the method of drilling and sampling shall comply in general with the other requirements given in this Section, with the exception of backfilling.

2

Overwater boreholes shall be undertaken by the use of overwater staging, work over platform (WOP) jack-up vessels, anchored floating vessels or any other methods agreed with the Engineer.

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Control of the elevation related to the borehole/seabed surface or varying stratums shall be related to the top of the casing installed. Anchored floating vessels will keep a constant record of tidal movement between the vessel and the fixed casing elevation and make any allowances necessary.

4

Boring or drilling operations will cease when the wave height exceeds the designated maximum value relating to standing time due to inclement weather, if this item is applicable to the Contract under the contract specific documentation.

5

An accurate method of measuring wave height from trough to crest will be installed on the drilling vessel or platform and calibrated and approved by the Engineer before beginning drilling operations.

6

All overwater operations will comply with all local government regulations related to such work and will also comply fully with any Safety of Lives at Sea (SOLAS) regulations in force at the time.

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QCS 2014

Section 03: Ground Investigation Part 03: Pits and Trenches

Page 1

PITS AND TRENCHES ........................................................................................... 2

3.1 3.1.1 3.1.2 3.1.3

GENERAL ............................................................................................................... 2 Scope 2 References 2 Quality Assurance 2

3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

PITS AND TRENCHES GENERALLY ..................................................................... 2 Pit and Trench Dimensions 2 Contaminated Ground 2 Groundwater 3 Protection to Pits and Trenches Left Open 3 Backfilling and Restoration 3 Photographs 3

3.3 3.3.1 3.3.2 3.3.3

INSPECTION PITS .................................................................................................. 3 Excavation Method 3 Services 3 Sidewall Stability 4

3.4 3.4.1 3.4.2 3.4.3 3.4.4

TRIAL PITS AND TRENCHES ................................................................................ 4 Excavation Method 4 Services 4 Sidewall Stability 4 Trial Pits Examination 4

3.5 3.5.1 3.5.2 3.5.3

OBSERVATION PITS AND TRENCHES ................................................................. 4 Excavation Method 4 Services 5 Sidewall Stability 5

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Page 2

3

PITS AND TRENCHES

3.1

GENERAL

3.1.1

Scope

1

Inspection pits, trial pits and trenches, observation pits and trenches.

2

Related Sections and Parts are as follows: This Section

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Section 1, ....... General Section 4, ....... Foundations and Retaining Structures Section 6, ....... Roadworks Section 8, ....... Drainage Works Section 12, ..... Earthworks Related to Buildings.

.

Part 1, .............. General

References

1

The following standards and other documents are referred to in this Part:

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BS 5930 ...................... Code of practice for site investigations

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes

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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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Code of Practice and Specifications for Road Openings in the Highway issued by the Government. Quality Assurance

1

Trial pits and trenches and observation pits and trenches shall be examined and described by a geotechnical person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) and photographed, if required.

3.2

PITS AND TRENCHES GENERALLY

3.2.1

Pit and Trench Dimensions

1

Unless otherwise designated

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2.

(a)

Trial pits and observation pits shall have a minimum base area of 1.5 m

(b)

Trial trenches and observation trenches shall not be less than 1 m wide.

3.2.2

Contaminated Ground

1

Ground that is suspected of being contaminated shall be described by an environmental or geotechnical person, as appropriate, meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c).

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Groundwater

1

The Contractor shall divert surface water runoff from entering pits and trenches.

2

Groundwater shall be controlled by the use of wellpoints or sump pumps to permit continuous work if required.

3.2.4

Protection to Pits and Trenches Left Open

1

Where pits and trenches are required to be left open and unattended, the Contractor shall provide fencing together with all necessary lighting and signing.

2

Precautions shall be taken to protect the pits and trenches from the adverse effects of weather during this period.

3.2.5

Backfilling and Restoration

1

Pits and trenches shall be backfilled as soon as practicable and reinstated to their original condition.

2

The backfill shall be placed in lifts of 150 mm thickness and compacted in such a manner as to minimise any subsequent settlement of the ground surface.

3

The use of sand backfill compacted by flooding may be permitted, but this method requires the approval of the Engineer.

4

In paved areas, the pavement shall be restored.

3.2.6

Photographs

1

In addition to the requirements of Part 1, photographs shall clearly show details of the ground conditions in the pit and trench with any support in place and shall contain a graduated scale.

2

Material derived from the excavation shall be photographed, when directed by the Engineer. Artificial lighting shall be used where necessary.

3

Unless directed otherwise by the Engineer, three photographs will normally be required at every pit and trench.

3.3

INSPECTION PITS

3.3.1

Excavation Method

1

Inspection pits for the location of underground services shall be excavated by hand to a depth of 1.2 m unless otherwise designated.

2

Hand-operated power tools may be used to assist excavation where necessary.

3.3.2

Services

1

The locations, depths and dimensions of all services encountered shall be measured and recorded in the daily report with other designated information.

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3.2.3

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Sidewall Stability

1

Due care shall be exercised to ensure the stability of the sides of the excavation at all times.

3.4

TRIAL PITS AND TRENCHES

3.4.1

Excavation Method

1

Trial pits and trenches shall be excavated by hand to a maximum depth of 1.2 m or by machine to the required depth to enable visual examination and sampling from outside the pit or trench as required.

2

Where dewatering is required, the pumping equipment used shall be adequate to lower the water table to the required level.

3.4.2

Services

1

The locations, depths and dimensions of all services encountered shall be measured and recorded in the daily report with other designated information.

3.4.3

Sidewall Stability

1

Excavations deeper than 1.2 m shall be braced if necessary.

3.4.4

Trial Pits Examination

1

All recovered materials from the Trial Pits shall be examined in accordance with BS 5930 or ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society Working Party.

2

Disturbed samples shall be obtained from the trial pits for laboratory testing and geological description purposes. The samples shall be taken to be representative of the actual site conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories for examination and testing.

3

Color photographs shall be taken for each excavated trial pit with a metric scale laid into the pit after cleaning it, indicating the pits details such as trial pit number, date and depth.

3.5

OBSERVATION PITS AND TRENCHES

3.5.1

Excavation Method

1

Observation pits and trenches shall be excavated by hand or machine and shall be adequately supported to enable personnel to enter safely and to permit in-situ examination, soil sampling and testing as required. In areas where dewatering is required, the equipment and methods proposed must be approved by the Engineer before beginning the work.

2

All recovered materials from the pit/trench shall be examined in accordance with BS 5930 or ASTM D 2488.

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3.3.3

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Page 5

Disturbed samples shall be obtained for laboratory testing and geological description purposes (if required). The samples shall be taken to be representative of the actual site conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories for examination and testing.

4

Color photographs shall be taken for each excavated pit with a metric scale laid into the pit after cleaning it, indicating the pits details such as trial pit number, date and depth.

3.5.2

Services

1

The locations, depths and dimensions of all services encountered shall be measured and recorded in the daily report with other designated information.

3.5.3

Sidewall Stability

1

Due care shall be exercised to ensure the stability of the sides of the excavation at all times.

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END OF PART

QCS 2014

Section 03: Ground Investigation Part 04: Soil Sampling

Page 1

SOIL SAMPLING ..................................................................................................... 2

4.1 4.1.1 4.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5

SAMPLING GENERALLY ........................................................................................ 2 Sampling and Testing Frequency 2 Recording depths of samples 3 Description of samples 3 Labelling, Protection and Transportation of Samples 3 Retention and Disposal of Samples 3

4.3 4.3.1 4.3.2 4.3.3 4.3.4

SOIL SAMPLES....................................................................................................... 3 Small Disturbed Samples 3 Bulk Disturbed Samples 3 Open Tube and Piston Samples 4 Standard Penetration Test Samples 4

4.4

GROUNDWATER SAMPLES .................................................................................. 4

4.5

SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS ................................................................ 4

4.6

GAS SAMPLING...................................................................................................... 5

4.7

SPECIAL SAMPLING .............................................................................................. 5

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Section 03: Ground Investigation Part 04: Soil Sampling

Page 2

4

SOIL SAMPLING

4.1

GENERAL

4.1.1

Scope

1

Taking of samples of soil, groundwater, gas and contaminants. Sample handling, transportation, storage, retention and disposal.

2

Related Sections and Parts are as follows: This Section

References

1

The following documents are referred to in this Part:

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Part 1, .............. General Part 2, .............. Boreholes Part 3, .............. Pits and Trenches.

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes

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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure) BS 5930 ......................Code of practice for site investigations

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BSI –DD 175 ..............Code of practice for the identification of potentially contaminated land and its investigation (draft for development).

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BS EN 1997--- ............ Ground Investigation and testing

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ICE et al, Soil Investigation Steering Group (SISG) Publication, Soil investigation in construction, Part 4, Guidelines for the safe investigation by drilling of landfills and contaminated land, Thomas Telford, (1993).

SAMPLING GENERALLY

4.2.1

Sampling and Testing Frequency

1

The frequency of sampling and in-situ testing is dependent on the ground conditions. In the absence of designated requirements the intervals observed shall be as follows:

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4.2

(a)

(b)

in boreholes (i)

first open tube sample (generally in clay soils) or standard penetration test (SPT) (generally in granular soils) at 0.5 m depth, the next at 1.0 m depth, thereafter at 1 m intervals to 5 m depth then at 1.5 m intervals.

(ii)

small disturbed samples shall be taken from the topsoil, at each change in soil

(iii)

type or consistency and midway between successive open tube samples or SPT’s.

(iv)

Bulk disturbed samples shall be taken of each soil type.

in pits and trenches

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Section 03: Ground Investigation Part 04: Soil Sampling

Page 3

(i)

Small disturbed samples shall be taken of the topsoil, at each change in soil type or consistency and between successive bulk disturbed samples.

(ii)

Bulk disturbed samples shall be taken at 1 m depth intervals, with at least one large bulk disturbed sample of each soil type.

Recording depths of samples

1

The depths below ground level at which samples are taken shall be recorded. For open tube and piston samples the depth to the top and bottom of the sample, and the length of sample obtained shall be given. For bulk samples the limits of the sampled zone shall be recorded.

4.2.3

Description of samples

1

All samples shall be examined and described by a geotechnical person meeting the requirements of Part 1, Clause 1.3.1, Paragraph 5 Item (c) in accordance with BS 5930. Samples of suspected contaminated ground and leachate shall be described by an environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c) in accordance with DD 175. Descriptions shall include colour and smell with reference to specific inclusions.

4.2.4

Labelling, Protection and Transportation of Samples

1

Samples shall be clearly labelled in accordance with BS 5930. Samples of fill, groundwater, leachate or contaminated ground suspected to be toxic or hazardous shall be tagged with a red label.

2

Samples shall be protected from direct heat and sunlight.

3

Samples shall be transported to the Contractor's premises. Where required by the Engineer, selected samples shall be delivered to the designated address.

4.2.5

Retention and Disposal of Samples

1

Samples shall be kept for the designated period after submission of the approved final report. This period shall not exceed three months, unless specifically designated otherwise. The Contractor shall ultimately dispose of all samples other than those delivered to the designated address.

4.3

SOIL SAMPLES

4.3.1

Small Disturbed Samples

1

Small disturbed samples shall weigh not less than 0.5 kg. They shall be placed immediately in airtight containers, which they should sensibly fill.

4.3.2

Bulk Disturbed Samples

1

Bulk disturbed samples shall be representative of the zone from which they have been taken.

2

Normal bulk disturbed samples shall weigh not less than 10 kg.

3

Large bulk disturbed samples shall weigh not less than 30 kg.

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4.2.2

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Page 4

Open Tube and Piston Samples

1

Open tube and piston samples shall be taken using the sampling equipment and procedures as described in BS 5930. The diameter shall be 100 mm unless otherwise designated.

2

Before an open tube or piston sample is taken, the bottom of the hole shall be carefully cleared of disturb materials and where a casing is being used the sample shall be taken below the bottom of the casing. Following a break in the work exceeding one hour, the borehole shall be advanced by 250 mm before open tube or piston sampling is resumed.

3

Where an attempt to take an open tube or piston sample is unsuccessful the hole shall be cleaned out for the full depth to which the sampling tube has penetrated and the recovered soil saved as a bulk disturbed sample. A fresh attempt shall then be made from the level of the base of the unsuccessful attempt. Should this second attempt also prove unsuccessful the Contractor shall agree with the Engineer as to alternative means of sampling.

4

The samples shall be sealed immediately to preserve their natural moisture content and in such a manner as to prevent the sealant from entering any voids in the sample.

5

Soil from the cutting shoe of an open tube shall be retained as an additional small disturbed sample.

4.3.4

Standard Penetration Test Samples

1

When a standard penetration test (SPT) is made, the sample from the split barrel sampler shall be retained as a small disturbed sample.

4.4

GROUNDWATER SAMPLES

1

Groundwater samples shall be taken from each exploratory hole where groundwater is encountered. Where more than one groundwater level is found, each one shall be sampled separately. Where water has been previously added, the hole shall be bailed out before

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sampling so that only groundwater is present. The sample volume shall be not less than 0.25 l.

SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS

1

Samples of suspected contaminated ground, groundwater and leachate shall be taken in accordance with DD 175 and the SISG publication under the supervision of an environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c).

2

The size and type of sample and container, method of sampling and time limitations for carrying out specific analyses shall be commensurate with the range of analyses to be carried out or as designated.

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Page 5

GAS SAMPLING

1

Samples of gas for chromatographic analysis shall be obtained from exploratory holes or standpipes in accordance with DD 175 and the SISG publication. The sampling method shall relate to the volume of gas available and the type of laboratory analysis. The sampler receptacle shall be airtight and may include lockable syringes, Teflon-lined bags or gas bombs.

4.7

SPECIAL SAMPLING

1

The Engineer may require special sampling. This work will normally require supervision on site by a geotechnical person and shall be carried out in accordance with BS 5930 or as designated.

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END OF PART

QCS 2014

Section 03: Ground Investigation Part 05: In-Situ Testing, Instrumentation and Monitoring

Page 1

IN-SITU TESTING, INSTRUMENTATION AND MONITORING............................... 2

5.1 5.1.1 5.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

5.2 5.2.1 5.2.2

TESTING, INSTRUMENTATION AND MONITORING GENERALLY ...................... 2 Testing 2 Instrumentation and Monitoring 3

5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6

TESTS ..................................................................................................................... 3 Tests in accordance with BS 1377 or BS EN 1997 3 Tests in accordance with BS 5930 4 Geophysical Methods of Investigation 4 Special In-Situ Testing 4 Hand Penetrometer and Hand Vane for Shear Strength 5 Self-boring Pressuremeter 5

5.4 5.4.1 5.4.2 5.4.3

INSTRUMENTATION AND MONITORING .............................................................. 6 Groundwater 6 Installation of Standpipes and Piezometers 6 Installation of Gas Monitoring Standpipes 6

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5

IN-SITU TESTING, INSTRUMENTATION AND MONITORING

5.1

GENERAL

5.1.1

Scope

1

Testing of soils in place, and provision of instrumentation and monitoring of groundwater and subsurface gases.

2

Related Sections and Parts are as follows: This Section

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Part 1 ............... General Part 2 ............... Boreholes Part 3 ............... Pits and Trenches. References

1

The following standards and other documents are referred to in this Part:

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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BS 1377......................Methods of tests for soils for civil engineering purposes BS 5930......................Code of practice for site investigations

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BS 7022......................Geophysical logging of boreholes for hydrogeological purposes

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BS EN 1997................Ground Investigation and testing

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The Geological Society Engineering Group Working Party Report on Engineering Geophysics, Quarterly Journal of Engineering Geology, 21, pp. 207-271, 1988.

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Clarke B.G. and Smith A., A model specification for radial displacement measuring pressuremeters, Ground Engineering, Volume 25, No. 2, March, 1992.

TESTING, INSTRUMENTATION AND MONITORING GENERALLY

5.2.1

Testing

1

The following information shall be submitted for each test record to be included in the daily report, preliminary log and factual report:

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5.2

(a)

Date of test.

(b)

Project name, exploratory hole number and location.

(c)

Depth and location of test or depths covered by test.

(d)

Information on water levels in exploratory hole during testing.

(e)

Original ground level at test site.

(f)

Soil type and description as identified from the sample.

All results shall be reported in SI units.

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Where load, displacement or other measuring equipment is used which necessitates regular calibration, then this shall be carried out in accordance with the relevant standard (the preferred method) or the manufacturer's instructions, by a calibration service approved by the Central Materials Laboratory. Evidence of calibrations and copies of calibration charts shall be supplied to the Engineer prior to commencing work and when otherwise requested.

5.2.2

Instrumentation and Monitoring

1

The top of each standpipe, gas monitoring standpipe and piezometer tube shall be protected by a cover. The type of protective cover shall be approved by the Engineer.

2

When instructed by the Engineer, the Contractor shall install a protective fence around the top of a standpipe or piezometer. The fence shall be constructed of corrosion treated angle iron, galvanised wire, and corrosion resistant wire mesh fencing suitable for use in the climate of Qatar or a fence as a agreed upon with the Engineer.

3

Daily readings of depths to water in groundwater monitoring standpipes and piezometers shall be made by the Contractor, with an instrument approved by the Engineer.

4

Where the presence of gas is suspected or when directed by the Engineer, gas measurements, using an approved in-situ meter, shall be made by the Contractor during construction of exploratory holes and in gas monitoring standpipes. The depth to water and barometric pressure shall be measured immediately after each gas measurement.

5

Unless otherwise designated, piezometers, and standpipes protection shall not be removed from the site.

6

Other instrumentation and monitoring shall be carried out as designated.

5.3

TESTS

5.3.1

Tests in accordance with BS 1377 or BS EN 1997

1

The following in-situ tests shall be carried out and reported in accordance with BS 1377 or BS EN 1997: in-situ density by

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(i)

Small pouring cylinder method.

(ii)

Large pouring cylinder method.

(iii)

Water replacement method.

(iv)

Core cutter method.

(v)

Nuclear method.

(b)

Static cone penetration test (CPT), capacity to suit scheduled depths unless otherwise designated

(c)

Dynamic probing (DPH or DPSH).

(d)

Standard penetration test (SPT).

(e)

Plate loading test.

(f)

Shallow pad maintained load test.

QCS 2014

Section 03: Ground Investigation Part 05: In-Situ Testing, Instrumentation and Monitoring

(g)

California bearing ratio (CBR).

(h)

Vane shear strength.

(i)

Apparent resistivity of soil.

(j)

Redox potential.

(k)

Pressurementer or Self-boring Pressuremeter (PMT)

(l)

Pocket Penetrometer.

Page 4

5.3.2

Tests in accordance with BS 5930

1

The following in-situ tests shall be carried out where applicable and reported in accordance with BS 5930:

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Constant head permeability test. Variable head permeability test. Packer permeability test.

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(a) (b) (c)

Geophysical Methods of Investigation

1

Geophysical testing shall be carried out as designated. The Contractor shall submit to the Engineer a full description of equipment and procedure for each geophysical method required.

2

The equipment and procedure, and information to be submitted for the following geophysical methods of investigation, shall be as described in BS 5930, BS 7022 and the Geological Society Engineering Group Working Party Report on Engineering Geophysics:

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electrical resistivity method

(b)

seismic refraction and reflection method

(c)

magnetic method

(d)

gravity method

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electromagnetic method

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Ground conductivity.

(ii)

Transient electromagnetic.

(iii)

Ground probing radar (optional).

(f)

Borehole geophysical logging.

(g)

Cross-hole seismic method.

(h)

Multi Channel Analysis of Surface Waves (MASW)

(i)

Refraction Microtremor (ReMi)

5.3.4

Special In-Situ Testing

1

Special in-situ testing shall be carried out as designated.

2

The Contractor shall allow for the excavation of boreholes, trenches or trial pits necessary for the execution of inspection tests.

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Section 03: Ground Investigation Part 05: In-Situ Testing, Instrumentation and Monitoring

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Inspection tests shall be decided as directed by the Engineer. These tests shall include but not limited to those in Table 3.2. Table 3.2: Quality Assurance Tests for Completed Work Recommended Test per Layer Deep Fill (boreholes)

In-situ CBR

Field density

Plate load Test

Layer Thickness

Field density

DCP Test

Layer Thickness

SPT

DCP Test

Pressure meter

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1

Hand penetrometer and hand vane tests shall be carried out where required to give a preliminary estimate of undrained shear strength of the soil tested.

2

Hand (or pocket) penetrometer equipment shall be of an approved proprietary make with 2 stainless steel tip of end area 31 mm with an engraved penetration line 6 mm from the tip.

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5.3.5

Hand vane equipment shall be of an approved proprietary make with stainless steel vanes having a length of 19 mm or 33 mm and a length-to-diameter ratio of 2:1. The scale shall be

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The scale shall be suitably graduated. The procedure for the test shall be in accordance with the manufacturer's instructions. Both unconfined compressive strength and estimated shear strength shall be reported for the soil tested.

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suitably graduated. The procedure for test shall be in accordance with BS 5930 and the manufacturer's instructions. Peak shear strength and residual shear strength shall be

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The reported shear strengths for the hand penetrometer and handvane shall be the average of 3 tests in close proximity. Tests giving inconsistent results shall be reported and comments on the relevance of the tests noted.

5.3.6

Self-boring Pressuremeter

1

The equipment shall be of the Cambridge type (soft ground) self-boring pressuremeter (SBP) unless otherwise designated. The instruments, calibration, operator, installation, testing procedure, on-site data processing and analysis, information to be submitted, report data processing and analysis and information to be submitted in the report shall be as described by Clarke and Smith (1992) and as designated..

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5.4

INSTRUMENTATION AND MONITORING

5.4.1

Groundwater

1

When groundwater is encountered in exploratory holes, the depth from ground level of the point of entry shall be recorded together with depth of any casing. Exploratory hole operations shall be stopped and the depth from ground level to water level recorded with an approved instrument at 5 minutes intervals for a period of 20 minutes. If at the end of the

.

period of 20 minutes the water level is still rising, this shall be recorded together with the depth to water below ground level, unless otherwise instructed by the Engineer, and the exploratory hole shall then be continued. If casing is used and this forms a seal against the entry of groundwater, the Contractor shall record the depth of casing at which no further entry or only insignificant infiltration of water occurred. Water levels shall be recorded as required by the Contract and at the beginning and end of each shift. On each occasion when groundwater levels are recorded, the depth of the exploratory hole, the depth of any casing and the time shall also be recorded.

3

Where artesian conditions are encountered, the Contractor shall immediately inform the Engineer and agree a method for dealing with the conditions.

5.4.2

Installation of Standpipes and Piezometers

1

Standpipes for monitoring groundwater levels and changes in groundwater levels shall be installed in exploratory holes, as instructed by the Engineer. They shall be to the designated form and detail, and appropriate dimensions and depths shall be recorded at the time of installation.

2

Standpipe piezometers for monitoring groundwater levels in exploratory holes shall be installed as instructed by the Engineer. They shall be to the designated form and detail, and appropriate dimensions. The installation details of the standpipe piezometers shall be recorded.

3

The Contractor shall install piezometers of the hydraulic, electrical or pneumatic type described in BS 5930 or as designated by the Engineer.

5.4.3

Installation of Gas Monitoring Standpipes

1

Standpipes for monitoring gas concentration in exploratory holes shall be installed as instructed by the Engineer. Warning signs or other safety measures required by the Civil Defence Department of the Government shall be complied with. Standpipes shall be of the designated form and detail. All dimensions and depths shall he recorded at the time of installation.

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END OF PART

QCS 2014

Section 03: Ground Investigation Part 06: Laboratory Testing

Page 1

LABORATORY TESTING ........................................................................................ 2

6.1 6.1.1 6.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

6.2

SCHEDULE OF TESTS ........................................................................................... 2

6.3 6.3.1 6.3.2 6.3.3 6.3.4

TESTING PROCEDURES ....................................................................................... 3 General 3 Geotechnical Testing on Contaminated Samples 3 Soil Testing 3 Rock Testing 3

6.4 6.4.2 6.4.3

CHEMICAL TESTING FOR CONTAMINATED GROUND ....................................... 4 Laboratory Testing On Site 6 Special Laboratory Testing 6

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Section 03: Ground Investigation Part 06: Laboratory Testing

Page 2

6

LABORATORY TESTING

6.1

GENERAL

6.1.1

Scope

1

Geotechnical tests and testing procedures carried out in the laboratory or, when designated, on site.

2

Related Sections and Parts are as follows: This Section

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Part 1, .............. General Part 3, .............. Soil Sampling

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Section 6, ........ Roadworks Section 8, ........ Drainage Works Section 12, ...... Earthworks Related to Buildings References

1

The following standards and other documents are referred to in this Part:

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6.1.2

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes

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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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ASTM SP 402.............Special Technical Publications No. 402

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BS 1377 ......................Methods of tests for soils for civil engineering purposes BS 1881 ......................Analysis of hardened concrete

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BS 812 ........................Testing aggregates

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BS EN 1997--------- .....Ground Investigation and testing

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Brown E.T. (Editor). Rock characterisation testing and monitoring. International Society for Rock Mechanics Suggested Methods. 1981. Pergamon Press. C2 through C25 and C27 through C31, Methods for examination of waters and associated materials, HMSO IRSM Commission on Testing Methods. Suggested method for determining Point Load Strength (revised version). Int. J. Rock Mech. Min. Sci. and Geomech. Abst., 22, 51-60 (1985).

6.2

SCHEDULE OF TESTS

1

The Contractor shall prepare a schedule of tests for approval by the Engineer. It may be necessary to designate additional testing after the results of the original tests are available. Unless otherwise agreed, testing schedules are to be provided within six working days of the receipt by the Engineer of the relevant preliminary logs. The Contractor shall inform the Engineer within six working days from the receipt of the approved testing schedule if a sample referred to in the schedule is not available for testing.

QCS 2014

Section 03: Ground Investigation Part 06: Laboratory Testing

Page 3

TESTING PROCEDURES

6.3.1

General

1

Where applicable, all preparation, testing and reporting shall be in accordance with the relevant Qatar National Standard or British Standards or ASTM Standards. Where tests are not covered by these Standards, they shall be performed in accordance with the procedures in the references or as designated.

2

Calibration of load-displacement or other measuring equipment shall be carried out in accordance with the relevant standard (the preferred method) or the manufacturer’s instructions by a calibration service approved by the Central Materials Laboratory. Evidence of current calibrations shall be supplied to the Engineer.

6.3.2

Geotechnical Testing on Contaminated Samples

1

Where geotechnical testing is required on samples of suspected contaminated material, indicative chemical testing shall be carried out and a safe method of working approved by the Engineer before any such work is started. It should be noted that this may include but is not limited to the safe storage, transportation and handling of all suspect material.

6.3.3

Soil Testing

1

Soil testing shall be carried out and reported in accordance with BS 1377 or ASTM Standards unless otherwise designated.

6.3.4

Rock Testing

1

Rock testing shall be carried out and reported in accordance with the following references and as designated: Classification.

Natural water content - Brown (1981).

(ii)

Porosity/density - Brown (1981).

(iii)

Void index - Brown (1981).

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6.3

(b)

(c)

(d)

(iv)

Carbonate content - BS 1881.

(v)

Petrographic description -Brown (1981).

Durability. (i)

Slake durability index - Brown (1981).

(ii)

Soundness by solution of magnesium sulphate - BS 812.

Hardness. (i)

Shore sclerometer -Brown (1981).

(ii)

Schmidt rebound hardness - Brown (1981).

Aggregates. (i)

Aggregate crushing value - BS 812.

(ii)

Ten percent fines - BS 812.

(iii)

Aggregate impact value - BS 812.

(iv)

Aggregate abrasion value - BS 812.

(v)

Polished stone value - BS 812.

(vi)

Aggregate frost heave - BS 812.

Strength. (i)

Uniaxial compressive strength - Brown (1981).

(ii)

Deformability in uniaxial compression -Brown (1981).

(iii)

Tensile strength-Brown (1981).  

Direct tensile strength. Indirect tensile strength by the Brazilian method.

Undrained triaxial compression without measurement of porewater pressureBrown (1981).

(v)

Direct shear strength - Brown (1981).

(vi)

Swelling pressure - Brown (1981).

(vii)

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Swelling pressure index under conditions of zero volume change. Swelling strain index for a radially confined specimen with axial surcharge. Swelling strain developed in an unconfined rock specimen.

Point load test - IRSM Commission on Testing Methods (1985).

Geophysical. Seismic velocity-Brown (1981).

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(iv)

   (f)

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Section 03: Ground Investigation Part 06: Laboratory Testing

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CHEMICAL TESTING FOR CONTAMINATED GROUND

1

Chemical testing for contaminated ground shall be carried out and reported in accordance with the following references and as designated:

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Primary contaminants in soil. Arsenic total - C4.

(ii)

Cadmium total - C2.

(iii)

Chromium total - C2.

(iv)

hexavalent chromium (undertaken if total chromium content >25 mg/kg dry

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Mass) -C2.

(v)

Lead total - C2.

(vi)

Mercury total - C3.

(vii)

Selenium total - C4.

(viii)

Boron, water-soluble - C5.

(ix)

Copper total - C2.

(x)

Nickel total - C2.

(xi)

Zinc total - C2.

(xii)

Cyanide total (alkali extraction methods) - C6.

(xiii)

Cyanide complex - C6.

(xiv) Cyanide free - C6. (xv)

Thiocyanate - C6.

QCS 2014

Section 03: Ground Investigation Part 06: Laboratory Testing

Page 5

(xvi) (Tests xiii, xiv and xv undertaken if total cyanide >25 mg/kg dry mass. Methods shall follow alkali extraction.) (xvii) Phenols total - C7. (xviii) Sulphide - C8. (xix) Sulphate - total, acid, soluble - C9. (xx)

Sulphate - water soluble, 2 : 1 extract - C9.

(xxi) Sulphur free - C10. (xxii) PH value - C9. (xxiii) Toluene extractable matter - Cl1.

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(xxiv) Coal tar/polyaromatic hydrocarbons (undertaken if toluene extractable matter> 2000 g/kg dry mass of soil) - C12.

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Antimony total - C13.

(ii)

Barium total - C13.

(iii)

Beryllium total - C15.

(iv)

Vanadium total - C13.

(v)

Cyclohexane extractable matter - C14.

(vi)

Freon extractable matter - C15.

(vii)

Mineral oils - C31.

(viii)

Chloride - C9.

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(i)

Contaminants in water.

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(c)

Secondary contaminants in soil.

(i)

Arsenic - C4.

(ii)

Cadmium - C2 and C23. Chromium - C2 and C24.

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(iii)

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(b)

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(xxv) Asbestos. Asbestos content determination shall be carried out by visual examination and polarised light microscopy.

Hexavalent chromium - C2.

(v)

Lead - C2 and C25.

(vi)

Mercury - C3.

(vii)

Selenium - C4.

(viii)

Boron - C5 and C6.

(ix)

Copper - C2 and C27.

(x)

Nickel - C2 and C28.

(xi)

Zinc - C2 and C29.

(xii)

Cyanide total - C6.

(xiii)

Cyanide complex - C6.

(xiv)

Cyanide free - C6.

(xv)

Thiocyanate - C6.

(xvi)

Phenols total - C7.

(xvii)

Sulphide - C8.

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Section 03: Ground Investigation Part 06: Laboratory Testing

Page 6

Sulphate - C9.

(xix)

Sulphur free - C10.

(xx)

PH value - C9.

(xxi)

Polyaromatic hydrocarbons - C 12.

(xxii)

Antimony-C13.

(xxiii)

Barium-C13.

(xxiv)

Beryllium-C15.

(xxv)

Vanadium - C 13.

(xxvi)

Chloride - C9.

(xxvii)

Ammoniacal nitrogen - C16.

(xxviii)

Nitrate nitrogen - Cl7.

(xxix)

Chemical oxygen demand - C18.

(xxx)

Biochemical oxygen demand - C19.

(xxxi)

Total organic carbon - C20.

(xxxii)

Volatile fatty acids - C21.

(xxxiii)

Iron - C22.

(xxxiv)

Manganese - C22.

(xxxv)

Calcium - C31.

(xxxvi)

Sodium - C31.

(xxxvii)

Magnesium - C31.

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(xviii)

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Constituents of gas samples. Carbon dioxide - C30.

(ii)

Hydrogen - C30.

(iii)

Hydrogen sulphide - C30.

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(xxxviii) Potassium - C21.

Methane - C30.

(v)

Nitrogen - C30.

(vi)

Oxygen - C30.

(vii)

Ethane- C30.

(viii)

Propane- C30.

(ix)

Carbon monoxide - C30.

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6.4.2

Laboratory Testing On Site

1

When designated, tests listed under laboratory testing shall be carried out on site.

6.4.3

Special Laboratory Testing

1

When designated, special laboratory testing shall be carried out. END OF PART

QCS 2014

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 1

GENERAL REQUIREMENTS FOR PILING WORK ................................................. 2

1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 General Contract Requirements 2 Submittals 3 Records 3

1.2 1.2.1 1.2.2

GROUND CONDITIONS ......................................................................................... 3 Ground Investigation Reports 3 Unexpected Ground Conditions 4

1.3 1.3.1 1.3.2 1.3.3

MATERIALS AND WORKMANSHIP........................................................................ 4 General 4 Sources of Supply 4 Rejected materials 5

1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6

INSTALLATION TOLERANCES .............................................................................. 5 Setting Out 5 Position 6 Verticality 6 Rake 6 Tolerance Variations 6 Forcible Corrections to Pile 6

1.5 1.5.1 1.5.2 1.5.3 1.5.4

NUISANCE AND DAMAGE ..................................................................................... 6 Noise and Disturbance 6 Damage to Adjacent Structures 7 Damage to Piles 7 Temporary Support 7

1.6 1.6.1 1.6.2 1.6.3

SAFETY .................................................................................................................. 7 General 7 Life-Saving Appliances 7 Driving 7

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QCS 2014

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 2

GENERAL REQUIREMENTS FOR PILING WORK

1.1

GENERAL

1.1.1

Scope

1

This Part is concerned with all works associated with installation of piles by any of the recognised techniques.

1.1.2

References

1

The following standards and codes of practice are referred to in this Part:

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BS 8008......................Safety precautions and procedures for the construction and descent of machine-bored shafts for piling and other purposes

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BS EN 1997................Eurocode 7, Geotechnical Design.

General Contract Requirements

1

The following matters, where appropriate, are described in the contract specific documentation for the Works: general items related to Works Nature of the Works.

(ii)

Classes of loads on piles.

(iii)

Contract drawings.

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(b)

(iv)

Other works proceeding at the same time.

(v)

Working area.

(vi)

Order of the Works.

(vii)

Datum.

(viii)

Offices for the Engineer's Representative.

(ix)

Particular facilities and attendance items where not included in this section.

(x)

Details of soil investigation reports.

specific items related to particular type of pile (i)

Soil sampling, laboratory testing and in-situ soil testing.

(ii)

Designed concrete or grout mixes, grades of concrete or grout, type of cement and aggregate, grout or concrete admixtures, concreting of piles.

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 3

Grades and types of reinforcement and prestressing tendons.

(iv)

Pile dimensions, length and marking of piles.

(v)

Type and quality of pile shoe/splice.

(vi)

Type and quality of permanent casing.

(vii)

Specified working loads.

(viii)

Sections of proprietary types of pile, grades of steel, minimum length to be supplied, thickness of circumferential weld reinforcement.

(ix)

Surface preparation, types and thickness of coatings.

(x)

Test piles, driving resistance or dynamic evaluation and penetration.

(xi)

Detailed requirements for driving records.

(xii)

Acceptance criteria for piles under test.

(xiii)

Disposal of cut-off lengths.

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QCS 2014

(xiv) Preboring. Submittals

1

The Contractor shall supply for approval all relevant details of the method of piling and the plant he proposes to use. Any alternative method to that specified shall be subject to approval.

2

The Contractor shall submit to the Engineer on the first day of each week, or at such longer periods as the Engineer may from time to time direct, a progress report showing the current rate of progress and progress during the previous period on all important items of each section of the Works.

3

The Contractor shall inform the Engineer each day of the intended programme of piling for the following day and shall give adequate notice of his intention to work outside normal hours and at weekends.

1.1.5

Records

1

The Contractor shall keep records, as indicated by an asterisk in Table 1.1, of the installation of each pile and shall submit two signed copies of these records to the Engineer not later than noon of the next working day after the pile is installed. The signed records will form a record of the work. Any unexpected driving or boring conditions shall be noted briefly in the records.

1.2

GROUND CONDITIONS

1.2.1

Ground Investigation Reports

1

Factual information and reports on site investigations for the Works and on the previous known uses of the Site will be provided by the Engineer where they exist as part of the specific contract documentation. However, even if a full report is given, including interpretations, opinions or conclusions, no responsibility is accepted by the Engineer for any opinions or conclusions which may be given in the reports.

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Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 4

Before the start of work the Contractor shall be given a copy of any subsequent information which may have been obtained relating to the ground conditions and previous uses of the Site.

1.2.2

Unexpected Ground Conditions

1

The Contractor shall report immediately to the Engineer any circumstance which indicates that in the Contractor's opinion the ground conditions differ from those reported in or which could have been inferred from the site investigation reports or test pile results.

1.3

MATERIALS AND WORKMANSHIP

1.3.1

General

1

All materials and workmanship shall be in accordance with the appropriate British Standards, codes of practice and other approved standards current at the date of tender except where the requirements of these standards or codes of practice are in conflict with this Section in which case the requirements of this Section shall take precedence.

1.3.2

Sources of Supply

1

The sources of supply of materials shall not be changed without prior approval.

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Table 1.1

Driven segmental concrete piles

Driven cast-in-place concrete piles

Bored cast-in-place concrete piles

Continuous flight auger concrete or grout piles

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

Nominal cross-sectional dimensions or diameter

*

*

*

*

*

Nominal diameter of underream/base

-

-

-

*

-

Length of preformed pile

*

*

-

-

-

Standing groundwater level from direct observation or given site investigation data.

-

-

*

*

*

Date and time of driving, redriving or boring

*

*

*

*

*

Date of concreting

-

-

*

*

*

Ground level/sea bed level at pile position at commencement of installation of pile (commencing surface)

*

*

*

*

*

Working elevation of pile driver

*

*

*

*

*

Depth from ground level at pile position to pile tip

*

*

*

*

*

Tip elevation

*

*

*

*

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Driven steel, precast concrete and steel sheet piles

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Records to be Kept (Indicated by an Asterisk)

Contract

Pile type

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Pile reference number (location)

Bored cast-in-place concrete piles

Continuous flight auger concrete or grout piles

Pile head elevation, as constructed

*

*

*

*

*

Pile cut-off elevation

*

*

*

*

*

Length of temporary casing

-

-

*

*

-

Length of permanent casing

-

-

*

*

-

Type, weight, drop and mechanical condition of hammer and equivalent information for other equipment

*

*

*

-

-

Number and type of packings used and type and condition of dolly used during driving of the pile

*

*

-

-

*

*

-

-

*

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Set of pile or pile tube in millimetres per 10 blows or number of blows per 25 mm of penetration

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Data

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Driven cast-in-place concrete piles

Page 5

Driven segmental concrete piles

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work Driven steel, precast concrete and steel sheet piles

QCS 2014

*

*

*

-

-

If required, temporary compression of ground and pile from time of a marked increase in driving resistance until pile reached its final level

*

*

*

-

-

*

*

*

-

-

Soil samples taken and in-situ tests carried out during pile installation

*

*

*

*

*

Length and details of reinforcements

-

-

*

*

*

Concrete mix

-

-

*

*

*

-

-

*

*

*

*

*

*

*

*

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If required, the sets taken at intervals during the last 3 m of driving

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If required, driving resistance taken at regular intervals over the last 3 m of driving

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Volume of concrete supplied to pile obstructions

delays

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All information regarding interruptions to the work

and

other

1.3.3

Rejected materials

1

Rejected materials are to be removed promptly from the Site.

1.4

INSTALLATION TOLERANCES

1.4.1

Setting Out

1

Setting out of the main grid lines shall be by the Contractor. The installation of marker pins at pile positions, as required by the Contract, shall be located by the Contractor from the main grid lines of the proposed structure. Before installation of the pile, the pile position relative to the main grid lines shall be verified.

QCS 2014

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 6

Position

1

For a pile cut off at or above ground level the maximum permitted deviation of the pile centre from the centre-point shown on the drawings shall be 75 mm in any direction. An additional tolerance for a pile head cut off below ground level will be permitted in accordance with Clauses 1.4.3 and 1.4.4.

1.4.3

Verticality

1

At the commencement of installation, the pile, or pile-forming equipment in the case of a driven pile, or the relevant equipment governing alignment in the case of the bored pile, shall be made vertical to a tolerance of within 1 in 100. The maximum permitted deviation of the finished pile from the vertical is 1 in 75.

1.4.4

Rake

1

As in clause 1.4.3, the pile, or driving or other equipment governing the direction and angle of rake shall be set to give the correct alignment of the pile to within a tolerance of 1 in 50. The piling rig shall be set and maintained to attain the required rake. The maximum permitted deviation of the finished pile from the specified rake is 1 in 25 for piles raking up to 1:6 and 1 in 15 for piles raking more than 1:6.

1.4.5

Tolerance Variations

1

In exceptional circumstances where these tolerances are difficult to achieve, the tolerances of Clauses 1.4.2, 1.4.3 and 1.4.4 may be relaxed by the Engineer, subject to consideration of the implications of such action.

1.4.6

Forcible Corrections to Pile

1

Forcible corrections to concrete piles to overcome errors of position or alignment shall not be made. Forcible corrections may be made to other piles only if approved and where the pile shaft is not fully embedded in the soil.

1.5

NUISANCE AND DAMAGE

1.5.1

Noise and Disturbance

1

The Contractor shall carry out the work in such a manner and at such times as to minimise noise, vibration and other disturbance in order to comply with current environmental legislation.

2

The Contractor shall endeavour to ascertain the nature and levels of noise produced by the mechanical equipment and plant that will be used. He shall than take steps to reduce either the level or the annoying characteristics, or both, of the noise. Reference should be made to BS 5228 Part 1 for prediction of noise level due to different types of mechanical equipment and plant, and to BS 5228 Part 4 for noise and vibration control techniques applicable to piling operations.

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1.4.2

QCS 2014

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 7

Damage to Adjacent Structures

1

If in the opinion of the Contractor, damage will be, or is likely to be, caused to mains, services or adjacent structures, he shall submit to the Engineer his proposals for making preconstruction surveys, monitoring movements or vibrations, and minimising or avoiding such damage.

1.5.3

Damage to Piles

1

The Contractor shall ensure that during the course of the work, displacement or damage which would impair either performance or durability does not occur to completed piles.

2

The Contractor shall submit to the Engineer his proposed sequence and timing for driving or boring piles, having the intent of avoiding damage to adjacent piles.

1.5.4

Temporary Support

1

The Contractor shall ensure that where required, any permanently free-standing piles are temporarily braced or stayed immediately after driving to prevent loosening of the piles in the ground and to ensure that the pile will not be damaged by oscillation, vibration or ground movement.

1.6

SAFETY

1.6.1

General

1

A competent person, properly qualified and experienced, should be appointed to supervise the piling operations. This person should be capable of recognising and assessing any potential dangers as they arise; e.g., unexpected ground conditions that may require a change in construction technique, or unusual smells which may indicate the presence of noxious or dangerous gases.

2

Safety precautions throughout the piling operations shall comply with BS 8008 and BS EN 1997. Refer Section 1 for general safety standards to be adopted at a construction site.

1.6.2

Life-Saving Appliances

1

The Contractor shall provide and maintain on the Site sufficient, proper and efficient lifesaving appliances to the approval of the Engineer. The appliances must be conspicuous and available for use at all times.

2

Site operatives shall be instructed in the use of safety equipment and periodic drills shall be held to ensure that all necessary procedures can be correctly observed.

1.6.3

Driving

1

Before any pile driving is started, the Contractor shall supply the Engineer with two copies of the code of signals to be employed, and shall have a copy of the code prominently displayed adjacent to the driving control station on the craft, structure or site from which the piles will be driven.

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1.5.2

END OF PART

QCS 2014

Section 04: Foundations and Retaining Structures Part 02: Concrete Works for Piling

Page 1

CONCRETE WORKS FOR PILING ......................................................................... 2

2.1 2.1.1 2.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5

MATERIALS ............................................................................................................ 2 Cementitious 2 Aggregate 2 Water 2 Admixtures 2 Steel Reinforcement and Prestressing Steel 2

2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5

CONCRETE MIXES FOR PILING WORK ............................................................... 3 General 3 Grade Designation 3 Designed Mix 3 Durability 3 Exposure Classes 3

2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7

PLACING CONCRETE ............................................................................................ 3 General 3 Inspection 4 Cleanliness of Pile Bases 4 Workability of Concrete 4 Compaction 4 Placing Concrete in Dry Borings 5 Placing Concrete under Water or Drilling Fluid 5

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QCS 2014

Section 04: Foundations and Retaining Structures Part 02: Concrete Works for Piling

CONCRETE WORKS FOR PILING

2.1

GENERAL

2.1.1

Scope

1

This part applies to cast in-situ as well as precast concrete work.

2

Related Sections and Parts are as follows:

Section 5

Concrete.

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This Section Part 1, Part 3 Part 4 Part 5

.

2

Page 2

References

1

The following Standards are referred to in this Part:

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All Standards mentioned in Section 5

MATERIALS

2.2.1

Cementitious

1

All cementitious materials shall comply with the requirements of Section 5, Part 3.

2

All cementitious materials shall be stored in separate containers according to type in waterproof stores or silos.

2.2.2

Aggregate

1

Aggregates shall comply with the requirements of Section 5, Part 2.

2.2.3

Water

1

If water for the Works is not available from a public supply, approval shall be obtained regarding the source of water. For quality of water refer to Section 5, Part 4.

2.2.4

Admixtures

1

Admixtures shall comply with the requirements of Section 5, Part 5

2.2.5

Steel Reinforcement and Prestressing Steel

1

Steel reinforcement shall be stored in clean and dry conditions. It shall be clean, and free from loose rust and loose mill scale when installed in the Works. For requirements of steel reinforcement refer to Section 5, Part 11.

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The number of joints in longitudinal steel bars shall be kept to a minimum. Joints in reinforcement shall be such that the full strength of each bar is effective across the joint and shall be made so that there is no detrimental displacement of the reinforcement during the construction of the pile.

3

For requirements of prestressing steel refer to Section 5, Part 18.

2.3

CONCRETE MIXES FOR PILING WORK

2.3.1

General

1

For general requirements of concrete mixes, trial mixes, batching, mixing and transportation of fresh concrete and testing of hardened concrete refer to Section 5.

2.3.2

Grade Designation

1

Grades of concrete shall be as given in Section 5, Part 6.

2.3.3

Designed Mix

1

The Contractor shall be responsible for selecting the mix proportions to achieve the required strength and workability..

2

Complete information on the mix and sources of aggregate for each grade of concrete and the water/cementitious ratio and the proposed degree of workability shall be approved before work commences.

3

Where low-alkali, sulphate-resisting cement to BS EN 197 is specified, the alkali content (equivalent sodium oxide) of the cement shall not exceed 0.6 % by weight.

4

The Contractor shall submit the slump value for approval before work commences.

2.3.4

Durability

1

For piles exposed to aggressive ground or groundwater, approved measures shall be taken to ensure durability. Reference shall be made to Section 5, Part 6.

2.3.5

Exposure Classes

1

The minimum cementitious content and type and the concrete grades shall be specified based on the exposure classes as given in Table 6.8, Section 5, Part 6.

2.4

PLACING CONCRETE

2.4.1

General

1

The workability and method of placing and vibrating the concrete shall be such that a continuous monolithic concrete shaft of the full cross-section is formed.

2

The concrete shall be placed without such interruption as would produce a cold joint in the pile. The method of placing shall be approved.

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3

The Contractor shall take all precautions in the design of the mix and placing of the concrete to avoid arching of the concrete in a temporary casing. No soil, liquid or other foreign matter which would adversely affect the performance of the pile shall be permitted to contaminate the concrete.

2.4.2

Inspection

1

Each pile bore which does not contain standing water or drilling fluid shall be inspected directly or indirectly before to concrete is placed in it. This inspection shall be carried out from the ground surface in the case of piles of less than 750 mm diameter. Torches or other approved means of lighting, measuring tapes, and a means of measuring verticality shall be provided. For piles of 750 mm diameter or larger, equipment shall be provided by the

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Contractor to enable his representatives and the Engineer to descend into the bore for the purpose of inspection. Any method of descent and the equipment used shall comply with the requirements of BS 8008. Cleanliness of Pile Bases

1

On completion of boring and where inspection of a dry pile bore indicates the necessity, loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain water or drilling fluid, a cleaning process shall be employed before concrete is placed, or the concrete shall be placed by tremie method. Large debris or accumulated sediment, or both of them, shall be removed using appropriate approved methods, which shall be designed to clean while at the same time minimising ground disturbance below the pile bases. Water or drilling fluid shall be maintained at such levels throughout and following the cleaning operation that stability of the bore is preserved.

2.4.4

Workability of Concrete

1

Slump measured at the time of discharge into the pile bore shall be in accordance with the standards shown in Table 2.1.

2.4.5

Compaction

1

Internal vibrators may be used to compact concrete, with the approval of the Engineer obtained in advance for each specific use.

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Piling mix workability

Table 2.1 Standards for Concrete Slump Slump Minimum

Range

mm

mm

Typical conditions of use

A

75

75-150

Placed into water-free unlined or permanently lined bore of 600 mm diameter or over, or where concrete is placed below temporary casing, and where reinforcement is widely spaced leaving ample room for free movement of concrete between bars.

B

100

100-200

Where reinforcement is not spaced widely, where concrete is placed within temporary casings, where pile bore is water-free, and the diameter less than 600 mm

C

150

150 or more

Where concrete is to be placed by tremie under water or drilling mud, or by pumping

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Placing Concrete in Dry Borings

1

Approved measures shall be taken to ensure that the structural strength of the concrete placed in all piles is not impaired through grout loss, segregation or bleeding.

2

Concrete shall be placed by “elephant trunk”, and the free fall shall not exceed 1.2 m.

2.4.7

Placing Concrete under Water or Drilling Fluid

1

Before placing concrete, measures shall be taken in accordance with Clause 2.4.3 to ensure that there is no accumulation of silt or other material at the base of the boring, and the Contractor shall ensure that heavily contaminated bentonite suspension, which could impair the free flow of concrete from the tremie pipe, has not accumulated in the bottom of the hole.

2

Concrete to be placed under water or drilling fluid shall be placed by tremie and shall not be discharged freely into the water or drilling fluid. Pumping of concrete may be approved where appropriate.

3

A sample of the bentonite suspension shall be taken from the base of the boring using an approved sampling device. If the specific gravity of the suspension exceeds 1.20 the placing of concrete shall not proceed. In this event the Contractor shall modify or replace the bentonite as approved to meet the specification.

4

The concrete shall be a rich, coherent mix and highly workable, and cement content shall be in accordance with Clause 2.3.5.

5

The concrete shall be placed in such a manner that segregation does not occur.

6

The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall extend to the base of the bore and a sliding plug or barrier shall be placed in the pipe to prevent direct contact between the first charge of concrete in the tremie and the water or drilling fluid. The pipe shall at all times penetrate the concrete which has previously been placed and shall be withdrawn at a rate such that there shall be a minimum concrete cover of 2 m over the end of the tremie pipe, until completion of concreting. A sufficient quantity of

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concrete shall be maintained within the pipe to ensure that the pressure from it exceeds that from the water or drilling fluid. The internal diameter of the tremie pipe shall be not less than 150 mm, and the maximum sized aggregate shall be 20 mm. It shall be so designed that external projections are minimised, allowing the tremie to pass within reinforcing cages without causing damage. The internal face of the pipe of the tremie shall be free from projections. END OF PART

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Page 1

SHALLOW FOUNDATIONS .................................................................................... 2

3.1 3.1.1 3.1.2 3.1.3 3.1.4

GENERAL ............................................................................................................... 2 Scope 2 Definition 2 References 2 Limit States Considerations 2

3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

DESIGN CONSIDERATIONS .................................................................................. 3 General 3 Allowable Bearing Pressure 3 Selection of Types of Shallow Foundation 3 Pad foundations 4 Strip foundations 4 Raft foundations 5

3.3 3.3.1 3.3.2 3.3.3

BASIS OF GEOTECHNICAL DESIGN .................................................................... 5 Design Requirements 5 Design Situations 7 Durability 8

3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11

GEOTECHNICAL DESIGN BY CALCULATION ...................................................... 9 General 9 Actions 10 Ground Properties 12 Geometrical Data 13 Characteristic and Representative Values of Actions 13 Characteristic Values of Geotechnical Parameters 13 Characteristic Values of Geometrical Data 14 Geotechnical Design Report 14 Actions and Design Situations 15 Design and Construction Considerations 15 Foundations on Rock; Additional Design Considerations 16

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SHALLOW FOUNDATIONS

3.1

GENERAL

3.1.1

Scope

1

The provisions of this Section apply to shallow foundations including isolated, pads, strips and rafts.

3.1.2

Definition

1

Shallow foundations are taken to be those where the depth below finished ground level is less than 3 m and include isolated, pad, strip and raft foundations. The choice of 3 m is arbitrary; shallow foundations where the depth/breadth ratio is high may need to be designed as deep foundations.

3.1.3

References

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BS 8004,.....................Code of practice for foundations.

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BS EN 1990................Eurocode 0: Basis of Structural Design BS EN 1991................Eurocode 1: Actions on structures BS EN 1992................Eurocode 2: Design of concrete structures -

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BS EN 1993................Eurocode 3: Design of steel structures

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BS EN 1994................Eurocode 4: Design of composite steel and concrete structures BS EN 1995................Eurocode 5: Design of timber structures

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BS EN 1996................Eurocode 6: Design of masonry structures

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BS EN 1997-1 ............Eurocode 7, Geotechnical design Part 1: General Rules BS EN 1997-2 ............Eurocode 7, Geotechnical design Part 2: Ground investigation and testing

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BS EN 1998................Eurocode 8: Design of structures for earthquake resistance

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BS 5930......................Code of Practice for Site Investigation Limit States Considerations

1

The following limit states shall be considered and an appropriate list shall be compiled:

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3.1.4

(a)

Loss of overall stability;

(b)

Bearing resistance failure, punching failure, squeezing;

(c)

Failure by sliding;

(d)

Combined failure in the ground and in the structure;

(e)

Structural failure due to foundation movement;

(f)

Excessive settlements;

(g)

Excessive heave due to swelling, frost and other causes;

(h)

Unacceptable vibrations.

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3.2

DESIGN CONSIDERATIONS

3.2.1

General

1

The depth to which foundations should be carried depends on two principal factors: (a)

Reaching an adequate bearing stratum;

(b)

Penetration below the zone in which trouble may be expected from seasonal weather changes.

Other factors such as ground movements, changes in groundwater conditions, long-term stability and heat transmitted from structures to the supporting ground may be important.

3

Shallow foundations are particularly vulnerable to certain soil conditions, e.g. loose waterbearing sands and soils that change structure when loaded. Specialist advice should be sought where such conditions are indicated by ground investigation.

3.2.2

Allowable Bearing Pressure

1

The center of area of a foundation or group of foundations should be arranged vertically under the centre of gravity of the imposed loading. If this is not possible, the effects on the structure of rotation and settlement of the foundation need to be considered.

2

Where foundation support is provided by a number of separate bases these should, as far as practicable, be proportioned so that differential settlement is minimal.

3.2.3

Selection of Types of Shallow Foundation

1

The selection of the appropriate type of shallow foundation will normally depend on the magnitude and disposition of the structural loads, the bearing capacity and settlement characteristics of the ground and the need to found in stable soil.

2

A pad foundation is used for the purpose of distributing concentrated loads. Unless special conditions control the design, relatively heavy column loads make it advantageous to use pad foundations.

3

Strip foundations may be more appropriate where column loads are comparatively small and closely spaced or where walls are heavy or heavily loaded.

4

Adjacent pad foundations can be combined or joined together with ground beams to support eccentric loads, to resist overturning or to oppose horizontal forces. Walls between columns may be carried on ground beams spanning between the pad foundations.

5

Where the allowable bearing pressure would result in large isolated foundations occupying the majority of the available area, it may be logical to join them to form a raft and spread the loads over the entire area. The combination of isolated foundations to form a raft sometimes results in a complex design and a large increase in the reinforcement requirement.

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In connection with the provision of foundations to an extension of an existing building, allowance should be made for differential movement of the foundations between the new and existing structure; such movement affects the structure above foundations. Where a degree of cracking and subsequent remedial work is not acceptable, provision for a joint between the extension and existing building should be considered. Where the foundations of an extension about the foundations of the existing building, the stability of the existing foundations should be ensured.

3.2.4

Pad foundations

1

For buildings such as low rise dwellings and lightly framed structures, pad foundations may be of unreinforced concrete provided that the angle of spread of load from the pier or base plate to the outer edge of the ground bearing does not exceed one (vertical) in one (horizontal) and that the stresses in the concrete due to bending and shear do not exceed tolerable limits. For buildings other than low rise and lightly framed structures, it is customary to use reinforced concrete foundations.

2

The thickness of the foundation should under no circumstances be less than 150 mm and will generally be greater than this to maintain cover to reinforcement where provided.

3

Where concrete foundations are used they should be designed in accordance with the design method appropriate to the loading assumptions.

3.2.5

Strip foundations

1

Similar considerations to those for pad foundations apply to strip foundations. On sloping sites strip foundations should be on a horizontal bearing, stepped where necessary to maintain adequate depth.

2

In continuous wall foundations it is recommended that reinforcement be provided wherever an abrupt change in magnitude of load or variation in ground support occurs. Continuous wall foundations will normally be constructed in mass concrete provided that the angle of spread of load from the edge of the wall base to the outer edge of the ground bearing does not exceed one (vertical) in one (horizontal). Foundations on sloping ground, and where regarding is likely to take place, may require to be designed as retaining walls to accommodate steps between adjacent ground floor slabs or finished ground levels. At all changes of level unreinforced foundations should be lapped at the steps for a distance at least equal to the thickness of the foundation or a minimum of 300mm. Where the height of the step exceeds the thickness of the foundation, special precautions should be taken. The thickness of reinforced strip foundations should be not less than 150mm, and care should be taken with the excavation levels to ensure that this minimum thickness is maintained. For the longitudinal spread of loads, sufficient reinforcement should be provided to withstand the tensions induced. It will sometimes be desirable to make strip foundations of inverted tee beam sections, in order to provide adequate stiffness in the longitudinal direction. At corners and junctions the longitudinal reinforcement of each wall foundation should be lapped.

3

Where the use of ordinary strip foundations would overstress the bearing strata, wide strip foundations designed to transmit the foundation loads across the full width of the strip may be used. The depth below the finished ground level should be the same as for ordinary strip foundations.

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Where the nature of the ground is such that narrow trenches can be neatly cut down to the bearing stratum, an economical foundation may be achieved by filling the trenches with concrete. When deciding the trench width, account should be taken of normal building tolerances in relation to setting out dimensions. Where the thickness of such a foundation is 500mm or more, any step should be not greater than the concrete thickness and the lap at such a step should be at least 1 m or twice the step height, whichever is the greater?

5

Where fill or other loose materials occur above the bearing stratum adequate support is required to any excavation. Consideration may be given to the use of lean mix mass concrete replacement under ordinary strip footings placed at shallow depth. This mass concrete can be poured against either permanent or recoverable shuttering. This form of foundation provides a method of dealing with local areas where deeper foundations are required.

3.2.6

Raft foundations

1

General. Suitably designed raft foundations may be used in the following circumstances.

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For lightly loaded structures on soft natural ground where it is necessary to spread the load, or where there is variable support due to natural variations, made ground or weaker zones. In this case the function of the raft is to act as a bridge across the weaker zones. Rafts may form part of compensated foundations.

(b)

Where differential settlements are likely to be significant. The raft will require special design, involving an assessment of the disposition and distribution of loads, contact pressures and stiffness of the soil and raft.

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(a)

BASIS OF GEOTECHNICAL DESIGN

3.3.1

Design Requirements

1

For each geotechnical design situation it shall be verified that no relevant limit state is exceeded.

2

When defining the design situations and the limit states, the following factors should be considered: Site conditions with respect to overall stability and ground movements;

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3

(b)

Nature and size of the structure and its elements, including any special requirements such as the design life;

(c)

Conditions with regard to its surroundings (e.g.: neighboring structures, traffic, utilities, vegetation, hazardous chemicals);

(d)

Ground conditions;

(e)

Ground-water conditions;

(f)

Regional seismicity;

(g)

Influence of the environment (hydrology, surface water, subsidence, seasonal changes of temperature and moisture).

Limit states can occur either in the ground or in the structure or by combined failure in the structure and the ground.

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Page 6

Limit states should be verified by any appropriate method such as calculation method as described in 3.4;

5

In practice, experience will often show which type of limit state will govern the design and the avoidance of other limit states may be verified by a control check.

6

Buildings should normally be protected against the penetration of ground-water or the transmission of vapor or gases to their interiors.

7

If practicable, the design results should be checked against comparable experience.

8

In order to establish minimum requirements for the extent and content of geotechnical investigations, calculations and construction control checks, the complexity of each geotechnical design shall be identified together with the associated risks. In particular, a distinction shall be made between:

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L ight and simple structures and small earthworks for which it is possible to ensure that the minimum requirements will be satisfied by experience and qualitative geotechnical investigations, with negligible risk;

(b)

Other geotechnical structures.

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(a)

For structures and earthworks of low geotechnical complexity and risk, such as defined above, simplified design procedures may be applied.

10

To establish geotechnical design requirements, three Geotechnical Categories, 1, 2 and 3, may be introduced.

11

A preliminary classification of a structure according to Geotechnical Category should normally be performed prior to the geotechnical investigations. The category should be checked and changed, if necessary, at each stage of the design and construction process.

12

The procedures of higher categories may be used to justify more economic designs, or if the designer considers them to be appropriate.

13

The various design aspects of a project can require treatment in different Geotechnical Categories. It is not required to treat the whole of the project according to the highest of these categories.

14

Geotechnical Category 1 should only include small and relatively simple structures:

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(a)

For which it is possible to ensure that the fundamental requirements will be satisfied on the basis of experience and qualitative geotechnical investigations;

(b)

With negligible risk.

15

Geotechnical Category 1 procedures should be used only where there is negligible risk in terms of overall stability or ground movements and in ground conditions, which are known from comparable local experience to be sufficiently straightforward. In these cases the procedures may consist of routine methods for foundation design and construction.

16

Geotechnical Category 1 procedures should be used only if there is no excavation below the water table or if comparable local experience indicates that a proposed excavation below the water table will be straightforward.

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17

Geotechnical Category 2 should include conventional types of structure and foundation with no exceptional risk or difficult soil or loading conditions

18

Designs for structures in Geotechnical Category 2 should normally include quantitative geotechnical data and analysis to ensure that the fundamental requirements are satisfied.

19

Routine procedures for field and laboratory testing and for design and execution may be used for Geotechnical Category 2 designs. the following are examples of conventional structures or parts of structures complying with Geotechnical Category 2: Shallow foundations;

(ii)

Pile foundations;

(iii)

Walls and other structures retaining or supporting soil or water;

(iv)

Excavations;

(v)

Bridge piers and abutments;

(vi)

Embankments and earthworks;

(vii)

Ground anchors and other tie-back systems;

(viii)

Tunnels in hard, non-fractured rock and not subjected to special water tightness or other requirements.

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Geotechnical Category 3 should include structures or parts of structures, which fall outside the limits of Geotechnical Categories 1 and 2.

21

Geotechnical Category 3 should normally include alternative provisions and rules to those in this standard. Geotechnical Category 3 includes the following examples: Very large or unusual structures;

(ii)

Structures involving abnormal risks, or unusual or exceptionally difficult ground or loading conditions;

(iii)

Structures in highly seismic areas;

(iv)

Structures in areas of probable site instability or persistent ground movements that require separate investigation or special measures.

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3.3.2

Design Situations

1

Both short-term and long-term design situations shall be considered.

2

In geotechnical design, the detailed specifications of design situations should include, as appropriate: (a)

The actions, their combinations and load cases;

(b)

The general suitability of the ground on which the structure is located with respect to overall stability and ground movements;

(c)

The disposition and classification of the various zones of soil, rock and elements of construction, which are involved in any calculation model;

QCS 2014

Section 04: Foundations and Retaining Structures Part 03: Shallow Foundations

(d)

Dipping bedding planes;

(e)

Mine workings, caves or other underground structures;

(f)

In the case of structures resting on or near rock: (i)

inter bedded hard and soft strata;

(ii)

faults, joints and fissures;

(iii)

possible instability of rock blocks;

(iv)

solution cavities, such as swallow holes or fissures filled with soft material, and continuing solution processes;

The environment within which the design is set, including the following: (i)

effects of scour, erosion and excavation, leading to changes in the geometry of the ground surface;

(ii)

effects of chemical corrosion;

(iii)

effects of weathering;

(iv)

effects of long duration droughts;

(v)

variations in ground-water levels, including, e.g. the effects of dewatering, possible flooding, failure of drainage systems, water exploitation;

(vi)

the presence of gases emerging from the ground;

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Earthquakes;

(i)

Ground movements caused by subsidence due to mining or other activities;

(j)

The sensitivity of the structure to deformations;

(k)

The effect of the new structure on existing structures, services and the local environment.

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Durability

1

At the geotechnical design stage, the significance of environmental conditions shall be assessed in relation to durability and to enable provisions to be made for the protection or adequate resistance of the materials.

2

In designing for durability of materials used in the ground, the following should be considered:

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3.3.3

(a)

For concrete: (i)

(b)

Aggressive agents in the ground-water or in the ground or fill material, such as acids or sulfate salts;

For steel: (i)

Chemical attack where foundation elements are buried in ground that is sufficiently permeable to allow the percolation of ground-water and oxygen;

(ii)

Corrosion on the faces of sheet pile walls exposed to free water, particularly in the mean water level zone;

(iii)

The pitting type of corrosive attack on steel embedded in fissured or porous concrete, particularly for rolled steel where the mill scale, acting as a cathode, promotes electrolytic action with the scale-free surface acting as an anode;

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Section 04: Foundations and Retaining Structures Part 03: Shallow Foundations For timber: (i)

(d)

Page 9

Fungi and aerobic bacteria in the presence of oxygen;

For synthetic fabrics: (i)

The ageing effects of UV exposure or ozone degradation or the combined effects of temperature and stress, and secondary effects due to chemical degradation.

Reference should be made to durability provisions in construction materials standards.

3.4

GEOTECHNICAL DESIGN BY CALCULATION

3.4.1

General

1

Design by calculation shall be in accordance with the fundamental requirements of EN 1990 and with the particular rules of this specification. Design by calculation involves:

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Actions, which may be either imposed loads or imposed displacements, e.g. from ground movements;

(b)

Properties of soils, rocks and other materials;

(c)

Geometrical data;

(d)

Limiting values of deformations, crack widths, vibrations etc;

(e)

Calculation models.

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(a)

It should be considered that knowledge of the ground conditions depends on the extent and quality of the geotechnical investigations. Such knowledge and the control of workmanship are usually more significant to fulfilling the fundamental requirements than is precision in the calculation models and partial factors.

3

The calculation model shall describe the assumed behavior of the ground for the limit state under consideration.

4

If no reliable calculation model is available for a specific limit state, analysis of another limit state shall be carried out using factors to ensure that exceeding the specific limit state considered is sufficiently improbable. Alternatively, design by prescriptive measures, experimental models and load tests, or the observational method, shall be performed.

5

The calculation model may consist of any of the following:

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(a)

An analytical model;

(b)

A semi-empirical model;

(c)

A numerical model.

6

Any calculation model shall be either accurate or err on the side of safety.

7

A calculation model may include simplifications.

8

If needed, a modification of the results from the model may be used to ensure that the design calculation is either accurate or errs on the side of safety.

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If the modification of the results makes use of a model factor, it should take account of the following: (a)

The range of uncertainty in the results of the method of analysis;

(b)

Any systematic errors known to be associated with the method of analysis.

10

If an empirical relationship is used in the analysis, it shall be clearly established that it is relevant for the prevailing ground conditions.

11

Limit states involving the formation of a mechanism in the ground should be readily checked using a calculation model. For limit states defined by deformation considerations, the deformations should be evaluated by calculation or otherwise assessed.

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NOTE: many calculation models are based on the assumption of a sufficiently ductile performance of the ground/structure system. A lack of ductility, however, will lead to an ultimate limit state characterized by sudden collapse. Numerical methods can be appropriate if compatibility of strains or the interaction between the structure and the soil at a limit state are considered.

13

Compatibility of strains at a limit state should be considered. Detailed analysis, allowing for the relative stiffness of structure and ground, may be needed in cases where a combined failure of structural members and the ground could occur. Examples include raft foundations, laterally loaded piles and flexible retaining walls. Particular attention should be paid to strain compatibility for materials that are brittle or that have strain-softening properties.

14

In some problems, such as excavations supported by anchored or strutted flexible walls, the magnitude and distribution of earth pressures, internal structural forces and bending moments depend to a great extent on the stiffness of the structure, the stiffness and strength of the ground and the state of stress in the ground.

15

In these problems of ground-structure interaction, analyses should use stress-strain relationships for ground and structural materials and stress states in the ground that are sufficiently representative, for the limit state considered, to give a safe result.

3.4.2

Actions

1

The definition of actions shall be taken as:

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(a)

Set of forces (loads) applied to the structure (direct action);

(b)

Set of imposed deformations or accelerations caused for example, by temperature changes, moisture variation, uneven settlement or earthquakes (indirect action).

The values of actions shall be taken from EN 1991 or equivalent international standard, where relevant. 2

The values of geotechnical actions to be used shall be selected, since they are known before a calculation is performed; they may change during that calculation. NOTE: Values of geotechnical actions may change during the course of calculation. In such cases they will be introduced as a first estimate to start the calculation with a preliminary, known value.

3

Any interaction between the structure and the ground shall be taken into account when determining the actions to be adopted in the design.

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In geotechnical design, the following should be considered for inclusion as actions: the weight of soil, rock and water;

(b)

stresses in the ground;

(c)

earth pressures and ground-water pressure;

(d)

free water pressures, including wave pressures;

(e)

ground-water pressures;

(f)

seepage forces;

(g)

dead and imposed loads from structures;

(h)

surcharges;

(i)

mooring forces;

(j)

removal of load or excavation of ground;

(k)

traffic loads;

(l)

movements caused by mining or other caving or tunneling activities;

(m)

swelling and shrinkage caused by vegetation, climate or moisture changes;

(n)

movements due to creeping or sliding or settling ground masses;

(o)

movements due to degradation, dispersion, decomposition, self-compaction and solution;

(p)

movements and accelerations caused by earthquakes, explosions, vibrations and dynamic loads;

(q)

temperature effects, including frost action;

(r)

imposed pre-stress in ground anchors or struts;

(s)

down drag.

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Section 04: Foundations and Retaining Structures Part 03: Shallow Foundations

Consideration shall be given to the possibility of variable actions occurring both jointly and separately.

6

The duration of actions shall be considered with reference to time effects in the material properties of the soil, especially the drainage properties and compressibility of fine-grained soils.

7

Actions, which are applied repeatedly, and actions with variable intensity shall be identified for special consideration with regard to, e.g. continuing movements, liquefaction of soils, change of ground stiffness and strength.

8

Actions that produce a dynamic response in the structure and the ground shall be identified for special consideration.

9

Actions in which ground- and free-water forces predominate shall be identified for special consideration with regard to deformations, fissuring, variable permeability and erosion.

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NOTE Unfavorable (or destabilizing) and favorable (or stabilizing) permanent actions may in some situations be considered as coming from a single source. If they are considered so, a single partial factor may be applied to the sum of these actions or to the sum of their effects.

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Page 12

Ground Properties

1

Properties of soil and rock masses, as quantified for design calculations by geotechnical parameters, shall be obtained from test results, either directly or through correlation, theory or empiricism, and from other relevant data.

2

Values obtained from test results and other data shall be interpreted appropriately for the limit state considered.

3

Account shall be taken of the possible differences between the ground properties and geotechnical parameters obtained from test results and those governing the behavior of the geotechnical structure.

4

The above differences can be due to the following factors: many geotechnical parameters are not true constants but depend on stress level and mode of deformation;

(b)

soil and rock structure (e.g. fissures, laminations, or large particles) that may play a different role in the test and in the geotechnical structure;

(c)

time effects;

(d)

the softening effect of percolating water on soil or rock strength;

(e)

the softening effect of dynamic actions;

(f)

the brittleness or ductility of the soil and rock tested;

(g)

the method of installation of the geotechnical structure;

(h)

the influence of workmanship on artificially placed or improved ground;

(i)

the effect of construction activities on the properties of the ground.

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(a)

When establishing values of geotechnical parameters, the following should be considered:

the value of each geotechnical parameter compared with relevant published data and local and general experience;

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(b)

published and well recognized information relevant to the use of each type of test in the appropriate ground conditions;

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3.4.3

6

(c)

the variation of the geotechnical parameters that are relevant to the design;

(d)

the results of any large scale field trials and measurements from neighboring constructions;

(e)

any correlations between the results from more than one type of test;

(f)

any significant deterioration in ground material properties that may occur during the lifetime of the structure.

Calibration factors shall be applied where necessary to convert laboratory or field test results according to EN 1997-2 into values that represent the behavior of the soil and rock in the ground, for the actual limit state, or to take account of correlations used to obtain derived values from the test results.

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Geometrical Data

1

The level and slope of the ground surface, water levels, levels of interfaces between strata, excavation levels and the dimensions of the geotechnical structure shall be treated as geometrical data.

3.4.5

Characteristic and Representative Values of Actions

1

Characteristic and representative values of actions shall be derived in accordance with EN 1990:2002 and the various parts of EN 1991.

3.4.6

Characteristic Values of Geotechnical Parameters

1

The selection of characteristic values for geotechnical parameters shall be based on results and derived values from laboratory and field tests, complemented by well-established experience.

2

The characteristic value of a geotechnical parameter shall be selected as a cautious estimate of the value affecting the occurrence of the limit state.

3

The selection of characteristic values for geotechnical parameters shall take account of the following:

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3.4.4

geological and other background information, such as data from previous projects;

(b)

the variability of the measured property values and other relevant information, e.g. from existing knowledge;

(c)

the extent of the field and laboratory investigation;

(d)

the type and number of samples;

(e)

the extent of the zone of ground governing the behavior of the geotechnical structure at the limit state being considered;

(f)

the ability of the geotechnical structure to transfer loads from weak to strong zones in the ground.

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Characteristic values can be lower values, which are less than the most probable values, or upper values, which are greater.

5

For each calculation, the most unfavorable combination of lower and upper values of independent parameters shall be used.

6

The zone of ground governing the behavior of a geotechnical structure at a limit state is usually much larger than a test sample or the zone of ground affected in an in situ test. Consequently the value of the governing parameter is often the mean of a range of values covering a large surface or volume of the ground. The characteristic value should be a cautious estimate of this mean value.

7

If the behavior of the geotechnical structure at the limit state considered is governed by the lowest or highest value of the ground property, the characteristic value should be a cautious estimate of the lowest or highest value occurring in the zone governing the behavior.

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Page 14

When selecting the zone of ground governing the behavior of a geotechnical structure at a limit state, it should be considered that this limit state may depend on the behavior of the supported structure. For instance, when considering a bearing resistance ultimate limit state for a building resting on several footings, the governing parameter should be the mean strength over each individual zone of ground under a footing, if the building is unable to resist a local failure. If, however, the building is stiff and strong enough, the governing parameter should be the mean of these mean values over the entire zone or part of the zone of ground under the building.

9

If statistical methods are employed in the selection of characteristic values for ground properties, such methods should differentiate between local and regional sampling and should allow the use of a prior knowledge of comparable ground properties.

10

If statistical methods are used, the characteristic value should be derived such that the calculated probability of a worse value governing the occurrence of the limit state under consideration is not greater than 5%.

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NOTE : In this respect, a cautious estimate of the mean value is a selection of the mean value of the limited set of geotechnical parameter values, with a confidence level of 95%; where local failure is concerned, a cautious estimate of the low value is a 5% fractal. When using standard tables of characteristic values related to soil investigation parameters, the characteristic value shall be selected as a very cautious value.

3.4.7

Characteristic Values of Geometrical Data

1

Characteristic values of the levels of ground and ground-water or free water shall be measured, nominal or estimated upper or lower levels.

2

Characteristic values of levels of ground and dimensions of geotechnical structures or elements should usually be nominal values.

3.4.8

Geotechnical Design Report

1

The assumptions, data, methods of calculation and results of the verification of safety and serviceability shall be recorded in the Geotechnical Design Report.

2

The level of detail of the Geotechnical Design Reports will vary greatly, depending on the type of design. For simple designs, a single sheet may be sufficient.

3

The Geotechnical Design Report should normally include the following items, with crossreference to the Ground Investigation Report :

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(a)

a description of the site and surroundings;

(b)

a description of the ground conditions;

(c)

a description of the proposed construction, including actions;

(d)

design values of soil and rock properties, including justification, as appropriate;

(e)

statements on the codes and standards applied;

(f)

statements on the suitability of the site with respect to the proposed construction and the level of acceptable risks;

(g)

geotechnical design calculations and drawings;

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(h)

foundation design recommendations;

(i)

a note of items to be checked during construction or requiring maintenance or monitoring.

4

The Geotechnical Design Report shall include a plan of supervision and monitoring, as appropriate. Items, which require checking during construction or, which require maintenance after construction shall be clearly identified. When the required checks have been carried out during construction, they shall be recorded in an addendum to the Report.

5

In relation to supervision and monitoring the Geotechnical Design Report should state: the purpose of each set of observations or measurements;

(b)

the parts of the structure, which are to be monitored and the locations at which observations are to be made;

(c)

the frequency with which readings is to be taken;

(d)

the ways in which the results are to be evaluated;

(e)

the range of values within which the results are to be expected;

(f)

the period of time for which monitoring is to continue after construction is complete;

(g)

the parties responsible for making measurements and observations, for interpreting the results obtained and for maintaining the instruments.

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An extract from the Geotechnical Design Report, containing the supervision, monitoring and maintenance requirements for the completed structure, shall be provided to the owner/client.

3.4.9

Actions and Design Situations

1

Design situations shall be selected in accordance with 3.3.2.

2

The actions listed in 3.4.2(4) should be considered when selecting the limit states for calculation.

3

If structural stiffness is significant, an analysis of the interaction between the structure and the ground should be performed in order to determine the distribution of actions.

3.4.10

Design and Construction Considerations

1

When choosing the depth of a shallow foundation the following shall be considered:

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(a)

reaching an adequate bearing stratum;

(b)

the depth above which shrinkage and swelling of clay soils, due to seasonal weather changes, or to trees and shrubs, may cause appreciable movements;

(c)

the level of the water table in the ground and the problems, which may occur if excavation for the foundation is required below this level;

(d)

possible ground movements and reductions in the strength of the bearing stratum by seepage or climatic effects or by construction procedures;

(e)

the effects of excavations on nearby foundations and structures;

(f)

anticipated excavations for services close to the foundation;

(g)

high or low temperatures transmitted from the building;

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Section 04: Foundations and Retaining Structures Part 03: Shallow Foundations

Page 16

(h)

the possibility of scour;

(i)

the effects of variation of water content due to long periods of drought, and subsequent periods of rain, on the properties of volume-unstable soils in arid climatic areas;

(j)

the presence of soluble materials, e.g. limestone, clay stone, gypsum, salt rocks;

2

In addition to fulfilling the performance requirements, the design foundation width shall take account of practical considerations such as economic excavation, setting out tolerances, working space requirements and the dimensions of the wall or column supported by the foundation.

3

One of the following design methods shall be used for shallow foundations: a direct method, in which separate analyses are carried out for each limit state. When checking against an ultimate limit state, the calculation shall model as closely as possible the failure mechanism, which is envisaged. When checking against a serviceability limit state, a settlement calculation shall be used;

(b)

an indirect method using comparable experience and the results of field or laboratory measurements or observations, and chosen in relation to serviceability limit state loads so as to satisfy the requirements of all relevant limit states;

(c)

a prescriptive method in which a presumed bearing resistance is used.

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Foundations on Rock; Additional Design Considerations

1

The design of shallow foundations on rock shall take account of the following features: the deformability and strength of the rock mass and the permissible settlement of the supported structure;

(b)

the presence of any weak layers, for example solution features or fault zones, beneath the foundation;

(c)

the presence of bedding joints and other discontinuities and their characteristics (for example filling, continuity, width, spacing);

(d)

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disturbance of the natural state of the rock caused by construction activities, such as, for example, underground works or slope excavation, being near to the foundation.

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(e)

the state of weathering, decomposition and fracturing of the rock;

2

Shallow foundations on rock may normally be designed using the method of presumed bearing pressures. For strong intact igneous rocks, gneissic rocks, limestone and sandstones, the presumed bearing pressure are limited by the compressive strength of the concrete foundation.

3

The settlement of a foundation may be assessed on the basis of comparable experience related to rock mass classification. END OF PART

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Page 1

DEEP FOUNDATIONS ............................................................................................ 4

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9

PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES .................... 4 General 4 Limit States Considerations 4 Precast Reinforced and Prestressed Concrete Piles 4 Materials and components 5 Prestressing 7 Driving Piles 8 Risen Piles 10 Repair and lengthening of piles 10 Cutting off pile heads 10

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.2.10 4.2.11

PRECAST REINFORCED CONCRETE SEGMENTAL PILES............................... 10 Scope 10 References 11 Submittals 11 Quality Assurance 11 Tolerances in Pile Dimensions 11 Handling, Transportation, Storage and Acceptance of Piles 12 Materials and components 12 Driving piles 13 Risen Piles 14 Repair and lengthening of piles 15 Cutting off pile heads 15

4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6

BORED CAST IN PLACE PILES ........................................................................... 15 Scope 15 References 16 Quality Assurance 16 Materials 16 Boring 17 Extraction of casing 19

4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5

BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS ....... 21 Scope 21 Materials 21 Boring 22 Placing of concrete or grout 23 Cutting off pile heads 23

4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6

DRIVEN CAST IN PLACES PILES ........................................................................ 23 Scope 23 Submittals 24 Quality Assurance 24 Materials 24 Driving piles 25 Risen Piles 26

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Page 2

Extraction of casing

26

4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.6.8 4.6.9 4.6.10 4.6.11

STEEL PILES ........................................................................................................ 28 Scope 28 References 28 Submittals 28 Quality Assurance 28 Delivery, Storage and Handling 29 Materials 29 Acceptance Standards For Welds 30 Acceptability and inspection of coatings 31 Driving of piles 31 Risen Piles 33 Preparation of pile heads 33

4.7

MICROPILES (TO BE ADDED LATER) ................................................................. 33

4.8 4.8.1 4.8.2 4.8.3 4.8.4 4.8.5

REDUCTION OF FRICTION ON PILES ................................................................ 33 Scope 33 Submittals 33 Friction Reducing Methods 33 Inspection 34 Driving resistance 35

4.9 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5 4.9.6 4.9.7 4.9.8

PILE LOAD TESTING ........................................................................................... 35 Static Load Testing of Piles 35 Presentation of results 45 Low strain Integrity test 47 Grosshole Sonic Logging Test 48 Calliper Logging Test 48 Axial Tensile Load Test 48 Lateral Load Test 48 Alternative Methods for Testing Piles 48

4.10 4.10.1 4.10.2 4.10.3

DESIGN METHODS AND DESIGN CONSIDERATIONS ...................................... 51 Design method 51 Verification of Resistance for Structural and Ground Limit States in Persistent and Transient Situations 51 Design Considerations 51

4.11 4.11.1 4.11.2 4.11.3 4.11.4 4.11.5 4.11.6 4.11.7 4.11.8 4.11.9 4.11.10

AXIALLY LOADED PILES ..................................................................................... 52 Limit state design 52 Compressive Ground Resistance 53 Ultimate compressive resistance from static load tests 54 Ultimate compressive resistance from ground test results 55 Ultimate compressive resistance from dynamic impact tests 56 Ultimate compressive resistance by applying pile driving formulae 56 Ultimate compressive resistance from wave equation analysis 56 Ground tensile resistance 57 Ultimate tensile resistance from pile load tests 57 Ultimate tensile resistance from ground test results 57

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4.5.7

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Page 3

4.11.11 Vertical displacements of pile foundations 4.11.12 Pile foundations in compression 4.11.13 Pile foundations in tension

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TRANSVERSELY LOADED PILES ....................................................................... 58 Design method 58 Transverse load resistance from pile load tests 59 Transverse load resistance from ground test results and pile strength parameters 59 Transverse displacement 60

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4.12 4.12.1 4.12.2 4.12.3 4.12.4

58 58 58

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Page 4

DEEP FOUNDATIONS

4.1

PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES

4.1.1

General

1

The provisions of this Part apply to end-bearing piles, friction piles, tension piles and transversely loaded piles installed by driving, by jacking, and by screwing or boring with or without grouting.

4.1.2

Limit States Considerations

1

The following limit states shall be considered and an appropriate list shall be compiled:

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Loss of overall stability;

(b)

bearing resistance failure of the pile foundation;

(c)

Uplift or insufficient tensile resistance of the pile foundation;

(d)

Failure in the ground due to transverse loading of the pile foundation;

(e)

Structural failure of the pile in compression, tension, bending, buckling or shear;

(f)

combined failure in the ground and in the pile foundation;

(g)

combined failure in the ground and in the structure;

(h)

Excessive settlement;

(i)

Excessive heave;

(j)

Excessive lateral movement;

(k)

Unacceptable vibrations.

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(a)

Precast Reinforced and Prestressed Concrete Piles

1

Scope

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This Part applies to precast concrete driven piles usually supplied for use in a single length without facility for joining lengths together.

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4.1.3

(b) 2

Related Sections and Parts are as follows:

References (a)

The following Standards are referred to in this Part:

BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates BS 3100,.....................Steel castings for general engineering purposes BS 2789,.....................Spheroidal graphite or nodular graphite cast iron BS 8110,.....................Structural use of concrete. 3

Submittals (a)

The Contractor shall order the piles to suit the construction programme and seek the Engineer's approval before placing the order. When preliminary piles are specified, the approval of the piles for the main work will not necessarily be given until the results of the driving and loading tests on preliminary piles have been received and evaluated.

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Page 5

Quality Assurance (a)

5

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

After a pile has been cast, the date of casting, reference number, length and, where appropriate, the prestressing force shall be clearly inscribed on the top surface of the pile and also clearly and indelibly marked on the head of the pile. Lifting positions shall be marked at the proper locations on each pile.

Tolerances in Pile Dimensions (a)

The cross-sectional dimensions of the pile shall be not less than those specified and shall not exceed them by more than 6 mm. Each face of a pile shall not deviate by more than 6 mm from any straight line 3 m long joining two points on that face, nor shall the centre of area of the pile at any cross section along its length deviate by more

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than 1/500 of the pile length from a line joining the centres of area at the ends of the pile. Where a pile is less than 3 m long, the permitted deviation from straightness shall

Handling, Transportation and Storage of Piles

The method and sequence of lifting, handling, and storage of piles transporting and storing piles shall be such as to avoid shock loading and to ensure that the piles are not damaged. Only the designated lifting and support points shall be used. During transport and storage, piles shall be appropriately supported under the marked lifting points or fully supported along their length.

(b)

All piles within a stack shall be in groups of the same length. Packing of uniform thickness shall be provided between piles at the lifting points.

(c)

Concrete shall at no time be subjected to loading, including its own weight, which will induce a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the specified strength, whichever is the lesser. For this purpose the assessment of the strength of the concrete and of the stresses produced by the loads shall be subject to the agreement of the Engineer.

(d)

Pile may be rejected when the width of any transverse crack exceeds 0.3 mm. The

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be reduced below 6 mm on a pro rata basis in accordance with actual length.

measurement shall be made with the pile in its working attitude.

Materials and components

1

Fabricated Steel Components

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4.1.4

(a)

2

Pile Toes (a)

3

In the manufacture of precast concrete piles, fabricated steel components shall comply with BS 7613 grades 43A or 50B, cast steel components with BS 3100 grade A, and ductile iron components with BS 2789.

Pile toes shall be constructed so as to ensure that damage is not caused to the pile during installation. Where positional fixity is required on an inclined rock surface or in other circumstances, an approved shoe may be required.

Pile Head Reinforcement (a)

The head of each pile shall be so reinforced or banded as to prevent bursting of the pile under driving conditions.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 6

Main Reinforcement (a)

The main longitudinal reinforcing bars in piles not exceeding 12 m in length shall be in one continuous length unless otherwise specified. In piles more than 12 m long, lap splicing will be permitted in main longitudinal bars at 12 m nominal intervals, with no more than 25 % of the bars lapped at one location, and laps staggered by a minimum of 1.2 m. Laps in reinforcement shall be such that the full strength of the bar is effective across the joint. Lap or splice joints shall be provided with sufficient link bars to resist eccentric forces.

(c)

Sufficient reinforcement shall be provided for lifting and handling purposes.

Unless otherwise agreed by the Engineer, concrete shall be compacted with the assistance of vibrators. Internal vibrators shall be capable of producing not less than 150 Hz and external vibrators not less than 50 Hz. Internal vibrators shall operate not

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closer than 75 mm to shuttering.

Vibrators shall be operated in such a manner that neither segregation of the concrete mix constituents nor displacement of reinforcement occurs.

(c)

Immediately after compaction, concrete shall he adequately protected from the harmful effects of the weather, including wind, rain, rapid temperature changes and frost. It shall be protected from drying out by an approved method of curing.

(d)

Piles shall not be removed from formwork until a sufficient pile concrete strength has been achieved to allow the pile to be handled without damage.

(e)

The period of curing at an ambient temperature of 10 °C shall not be less than that

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(b)

shown in Table 4.1. If the temperature is greater or less than 10 °C, the periods given

When steam or accelerated curing is used the curing procedure shall be approved. Four hours must elapse from the completion of placing concrete before the temperature is raised. The rise in temperature within any period of 30 min shall not exceed 10 °C and the maximum temperature attained shall not exceed 70 °C. The rate

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shall be adjusted accordingly and shall be approved.

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(b)

of subsequent cooling shall not exceed the rate of heating. Table 4.1 Period of Curing at 10 °C Type of cement

Wet curing time after completion of placing concrete, d

Ordinary Portland

4

Sulphate-resisting Portland

4

Portland blast-furnace

4

Super-sulphated

4

Rapid-hardening Portland

3

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 7

Formwork (a)

shaped point or shoe, then the end of the pile shall be symmetrical about the longitudinal axis of the pile. Holes for handling or pitching, where provided in the pile, shall be lined with steel tubes; alternatively, approved inserts may be cast in.

(b)

Formwork shall be robust, clean and so constructed as to prevent loss of grout or aggregate from the wet concrete and ensure the production of uniform pile sections, free from defects. The piles are to be removed from the formwork carefully so as to prevent damage.

4.1.5

Prestressing

1

General Tensioning shall be carried out only when the Engineer is present, unless otherwise approved. In cases where piles are manufactured off site, the Contractor shall ensure that the Engineer is given adequate notice and every facility for inspecting the manufacturing process.

(b)

Prestressing operations shall be carried out only under the direction of an experienced and competent supervisor. All personnel operating the stressing equipment shall have been trained in its use.

(c)

The calculated extensions and total forces, including allowance for losses, shall be agreed with the Engineer before stressing is commenced.

(d)

Stressing of tendons and transfer of prestress shall be carried out at a gradual and steady rate. The force in the tendons shall be obtained from readings on a recently calibrated load cell or pressure gauge incorporated in the equipment. The extension of the tendons under the agreed total forces shall be within 5 % of the agreed calculated extension.

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Concrete Strength

The Contractor shall cast sufficient cubes, cured in the same manner as the piles, to be able to demonstrate by testing two cubes at a time, with approved intervals between pairs of cubes, that the specified transfer strength of the concrete has been reached.

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Post-Tensioned Piles (a)

4

Unless otherwise permitted, concrete shall not be stressed until two test cubes attain the specified transfer strength.

Ducts and vents in post-tensioned piles shall be grouted after the transfer of prestress.

Grouting Procedure (a)

Grout shall be mixed for a minimum of 2 min and until a uniform consistency is obtained.

(b)

Ducts shall not be grouted when the air temperature in the shade is lower than 3 °C.

(c)

Before grouting is started all ducts shall be thoroughly cleaned by means of compressed air.

(d)

Grout shall be injected near the lowest point in the duct in one continuous operation and allowed to flow from the outlet until the consistency is equivalent to that of the grout being injected.

(e)

Vents in ducts shall be provided in accordance with Clause 8.9.2 of BS 8110.

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Page 8

Grout (a)

Unless otherwise directed or agreed by the Engineer (i)

the grout shall consist only of ordinary Portland cement, water and approved admixtures; admixtures containing chlorides or nitrates shall not be used

(ii)

the grout shall have a water/cement ratio as low as possible consistent with the necessary workability, and the water/cement ratio shall not exceed 0.45 unless an approved mix containing an expanding agent is used

(iii)

the grout shall not be subject to bleeding in excess of 2 % after 3 h, or in excess of 4% maximum, when measured at 18 C in a covered glass cylinder approximately 100 mm in diameter with a height of grout of approximately 100 mm, and the water shall be reabsorbed after 24 h.

Records

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

The Contractor shall keep detailed records of times of tensioning, measured extensions, pressure gauge readings or load cell readings and the amount of pull-in at each anchorage. Copies of these records shall be supplied to the Engineer within such reasonable time from completion of each tensioning operation as may be required, and in any case not later than noon on the following working day.

(b)

The Contractor shall keep records of grouting, including the date, the proportions of the grout and any admixtures used, the pressure, details of interruption and topping up required. Copies of these records shall be supplied to the Engineer within such reasonable time after completion of each grouting operation as may be required, and in any case not later than noon on the following working day.

Driving Piles

1

Strength of Piles (a)

Piles shall not be driven until the concrete has achieved the specified strength.

At all stages during driving and until incorporation into the substructure, the pile shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling. These arrangements shall be such that damage to the pile does not occur.

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Leaders and Trestles

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2

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4.1.6

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as

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ta

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(a)

3

4

Performance of Driving Equipment (a)

The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where designated, dynamic evaluation and analysis shall be provided.

(b)

Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile unless otherwise approved by the Engineer. For other types of hammer the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft or damage to the pile.

Length of Piles (a)

The length of pile to be driven in any location shall be approved prior to the commencement of driving.

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Page 9

Driving Procedure and Redrive Checks (a)

The driving of each pile shall be continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can subsequently be driven to the specified depth or resistance (set), or both, without damage. A follower shall not be used unless approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(b)

The Contractor shall inform the Engineer without delay if an unexpected change in driving characteristics is noted. A detailed record of the driving resistance over the full length of the nearest available pile shall be taken if required.

(c)

At the start of the work in a new area or section, a detailed driving record shall be made over the full length of the first pile and during the last 3 m of subsequent piles

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until consistency of behaviour is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the locations of such piles being

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specified by the Engineer.

The Contractor shall give adequate notice and provide all necessary facilities to enable the Engineer to check driving resistance. A set or resistance measurement shall be taken only in the presence of the Engineer unless otherwise approved.

(e)

Redrive checks, if required, shall be carried out to an approved procedure.

as

Final Set (a)

When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per 10 blows or as the number of blows required to produce a penetration of 25 mm.

(b)

When a final set is being measured, the following requirements shall be met:

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6

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(d)

The exposed part of the pile shall be in good condition without damage or distortion.

(ii)

The helmet, dolly and any packing shall be in sound condition.

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(i)

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(iii)

7

(iv)

The hammer shall be in good condition, delivering adequate energy per blow, and operating correctly.

(v)

The temporary compression of the pile shall be recorded, if required.

Preboring (a)

8

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis, and the head of the pile protected against damage from hammer impact.

If preboring is specified, the diameter and depth of prebore shall be as designated.

Jetting (a)

Jetting shall be carried out only when the Contractor's detailed proposals have been approved.

QCS 2014

Page 10

Risen Piles Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral displacement of the ground.

(b)

When required, levels and measurements shall be taken to determine the movement of the ground or of any pile resulting from the driving process.

(c)

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile is unimpaired. If required, the Contractor shall make proposals for correcting detrimentally affected piles and for avoidance or control of heave effects in subsequent work.

4.1.8

Repair and lengthening of piles

1

Repair of Damaged Pile Heads

rw

If it is necessary to repair the head of a pile during driving, the Contractor shall carry out such repair in an approved way which allows the pile-driving to be completed without further damage. If the driving of a pile has been accepted but sound concrete of the pile is below the required cut-off level, the pile shall be made good to the cut-off level, using an approved method so that it will safely withstand the imposed design load.

as

Lengthening of Reinforced and Prestressed Concrete Piles Any provision for lengthening piles incorporated at the time of manufacture shall be as designed or approved.

(b)

If no provision for lengthening piles was incorporated at the time of manufacture, any method for lengthening shall be such that splices are capable of safely resisting the stresses during driving and under service load and shall be subject to approval.

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(a)

Driving Repaired or Lengthened Piles Repaired or lengthened piles shall not be driven until the added concrete has reached the specified strength of the concrete of the pile.

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4.1.7

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Cutting off pile heads

1

Unless otherwise directed by the Engineer, when the driving of a pile has been approved the concrete of the head of the pile shall be cut off to the designated level. The length of splice reinforcing bars projecting above this level shall be as designated.

2

Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section at the cut-off level.

4.2

PRECAST REINFORCED CONCRETE SEGMENTAL PILES

4.2.1

Scope

1

This Part applies to piles made of elements cast at a precasting works away from the site, where work cannot normally be closely supervised by the Engineer. The elements are joined together as necessary on site during driving using special proven steel joints incorporated into the pile elements when cast.

m

4.1.9

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2

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 11

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 5,

Concrete.

4.2.2

References

1

The following Standards are referred to in this Part: Eurocode 7, EN1997-1, Section 7 Pile foundation BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates BS 3100,.....................Steel castings for general engineering purposes

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BS 2789,.....................Spheroidal graphite or nodular graphite cast iron

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BS 8110,.....................Structural use of concrete. Submittals

1

The Contractor shall order the piles to suit the construction programme and seek the Engineer's approval before placing the order. When preliminary piles are specified the approval for the piles for the main work will not necessarily be given until the results of the driving and tests on preliminary piles have been received and evaluated.

4.2.4

Quality Assurance

1

A certificate of quality from the pile manufacturer shall be provided to the Engineer when required stating that the designated requirements have been fulfilled during manufacture.

2

Each pile element shall be marked in such a manner that it can be identified with the records of manufacture, which shall state the date of casting, the cement type, concrete grade, element length and any other relevant data. On delivery, the pile elements shall be accompanied by records of manufacture.

4.2.5

Tolerances in Pile Dimensions

1

The cross-sectional dimensions of the pile shall be not less than those designated.

2

The head of a pile element or the end of the pile upon which the hammer acts shall be square to the pile axis within a tolerance of 1 in 50.

3

Each pile joint shall be square to the axis of the pile within a tolerance of 1 in 150. The centroid of the pile joint shall lie within 5 mm of the true axis of the pile element.

4

Each face of a pile element shall not deviate by more than 6 mm from any straight line 3 m long joining two points on that face, nor shall the centre of area of the pile at any crosssection along its length deviate by more than 1/500 of the pile length from a line joining the centres of area at the ends of the element. Where a pile element is less than 3 m long the permitted deviation from straightness shall be reduced below 6 mm on a pro rata basis in accordance with actual length.

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4.2.3

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Page 12

Handling, Transportation, Storage and Acceptance of Piles

1

The method and sequence of lifting, handling, transporting and storing piles shall be such as to avoid shock loading and to ensure that the piles are not damaged. Only designed lifting and support points shall be used. During transport and storage, piles shall be appropriately supported under the marked lifting points or fully supported along their length.

2

All pile elements within a stack shall be in groups of the same length. Packing of uniform thickness shall be provided between piles at the lifting points.

3

Concrete shall at no time be subjected to loading, including its own weight, which will induce a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the specified strength, whichever is the less. For this purpose the assessment of the strength of the concrete and of the stresses produced by the loads shall be subject to the approval of the Engineer.

4

A pile element shall be rejected when the width of any transverse crack exceeds 0.3 mm. The measurement shall be made with the pile in its working attitude.

4.2.7

Materials and components

1

Fabricated Steel Components

ta qa

In the manufacture of jointed precast concrete segmental piles, fabricated steel components shall comply with BS 7613 grades 43A or 50A, cast steel components with BS 3100 grade A, and ductile iron components with BS 2789.

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Pile Splices (a)

The splice joints shall be close-fitting face to face and the locking method shall be such as to hold the faces in intimate contact. The design and manufacture of the splicing system shall be approved by the Engineer prior to the commencement of the Contract.

(b)

A spliced pile shall be capable of withstanding the same driving stresses or service axial loads, moments and shear stresses as a single unspliced pile of the same crosssectional dimensions and materials.

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4.2.6

(c)

3

Pile Toes (a)

4

Pile toes shall be constructed so as to ensure that damage is not caused to the pile during installation. Where fixity is required or socketing into rock, or in other circumstances, an approved shoe may be required.

Pile Head Reinforcement (a)

5

The welding of a joint to main reinforcement in lieu of a lapped connection with projecting bars affixed to the joint will not be permitted.

Where the pile head is not furnished with a joint, it shall be so reinforced or banded as to prevent bursting of the pile under driving conditions.

Main Reinforcement (a)

The main longitudinal reinforcing bars shall be in one continuous length. Splicing of bars will not be permitted except at element ends.

QCS 2014

Page 13

(b)

Concrete cover to steel reinforcement shall be in accordance with the requirements of BS 8110.

(c)

In very aggressive ground or exposure conditions, cover greater than 25 mm may be required, but alternative protection methods may be approved.

Formwork (a)

If a pile is constructed with a shaped point or shoe, then the end of the pile shall be symmetrical about the longitudinal axis of the pile.

(b)

Holes for handling or pitching, where provided in the pile, shall be lined with steel tubes; alternatively, approved inserts may be cast in.

(c)

Formwork shall be robust, clean and so constructed as to prevent loss of grout or aggregate from the wet concrete and ensure the production of uniform pile sections. The piles are to be removed from the formwork carefully so as to prevent damage.

Driving piles

1

Strength of Piles

Leaders and Trestles

At all stages during driving and until incorporation into the substructure, the pile shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling. These arrangements shall be such that damage to the pile does not occur.

Performance of Driving Equipment

The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where required in the particular specification, dynamic evaluation and analysis shall be provided. Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile at the moment of driving unless otherwise approved by the Engineer. For other types of hammer, the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft or damage to the pile.

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(b)

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(a)

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(a)

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2

Piles shall not be driven until the concrete has achieved the specified characteristic strength.

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(a)

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4.2.8

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4

Length of Piles (a)

The length of pile supplied to be driven in any location and any additional lengths to be added during driving shall he approved prior to the commencement of pile-driving. During the execution of the Works, any changes to the supplied lengths shall be approved.

QCS 2014

Page 14

Driving Procedure and Redrive Checks (a)

Except when making field splices, the driving of each pile shall he continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can subsequently be driven to the specified depth or resistance (set), or both, without damage. A follower shall only be used when approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(b)

The Contractor shall inform the Engineer without delay if an unexpected change in driving characteristics is noted. A detailed record of the driving resistance over the full length of the nearest available pile shall be taken if required.

(c)

At the start of the work in a new area or section a detailed driving record shall be made over the full length of the first pile and during the last 3 m of subsequent piles until consistency of behaviour is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the positions of such piles being specified by the Engineer.

(d)

The Contractor shall give adequate notice and provide all necessary facilities to enable the Engineer to check driving resistance. A set or resistance measurement shall be taken only in the presence of the Engineer unless otherwise approved.

(e)

Redrive checks, if required, shall be carried out to an approved procedure.

as

Final Set

When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm.

(b)

When a final set is being measured, the following requirements shall be met:

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(a)

The exposed part of the pile shall be in good condition, without damage or distortion.

(ii)

The helmet, dolly and any packing shall be in sound condition.

(iii)

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis.

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(i)

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

7

(v)

The temporary compression of the pile shall be recorded if required.

If preboring is specified, the diameter and depth of prebore shall be as designated.

Jetting (a)

4.2.9

The hammer shall be in good condition, delivering adequate energy per blow, and operating correctly.

Preboring (a)

8

(iv)

Jetting shall be carried out only when the Contractor's detailed proposals have been approved.

Risen Piles (a)

Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral displacement of the ground.

QCS 2014

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 15

(b)

When required, levels and measurements shall be taken to determine the movement of the ground or of any pile resulting from the driving process.

(c)

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile is unimpaired. If required, the Contractor shall make proposals for correcting piles detrimentally affected and for avoidance or control of heave effects in subsequent work.

4.2.10

Repair and lengthening of piles

1

Repair of Damaged Pile Heads If it is necessary to repair the head of a pile during driving, the Contractor shall carry out such repair in an approved way which allows the driving of the pile to be completed without further damage. If the driving of a pile has been accepted but sound concrete of the pile is below the required cut-off level, the pile shall be made good to the cut-off level, using an approved method so that it will safely withstand the imposed design load.

Where piles are required to be driven to depths exceeding those expected, leaving insufficient projection for bonding into the following works, the piles shall be extended or replaced as required by the Engineer using approved materials and methods.

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(a)

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Lengthening of Piles

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(a)

Cutting off pile heads

1

Unless otherwise specified, when the driving of a pile has been approved the concrete of the head of the pile shall be cut off to the designated level. The length of splice reinforcing bars projecting above this level shall be as designated.

2

Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section at the cut-off level.

4.3

BORED CAST IN PLACE PILES

4.3.1

Scope

1

This Part applies to bored piles in which the pile bore is excavated by rotary or percussive means, or both, using short augers, buckets, grabs or other boring tools to advance the open bore. Where the open bore is unstable, temporary or permanent casing or bentonite suspension may be used to support the wall of the bore prior to concreting.

2

Related Sections and Parts are as follows:

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4.2.11

This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 3, Ground Investigation Section 5, Concrete

QCS 2014

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4.3.2

References

1

The following codes of practice are referred to in this Part:

Page 16

BS 5573,.....................Code of practice for safety precautions in the construction of large diameter boreholes for piling and other purposes BS 5930,.....................Code of practice for site investigation. 4.3.3

Quality Assurance

1

Inspection Each pile bore which does not contain standing water or drilling fluid shall be inspected directly or indirectly prior to concrete being placed in it. This inspection shall be carried out from the ground surface in the case of piles of less than 750 mm diameter. Torches or other approved means of lighting, measuring tapes, and a means of measuring verticality shall be provided. For piles of 750 mm diameter or larger, equipment shall be provided, by the Contractor to enable his representatives and the Engineer to descend into the bore for the purpose of inspection. Any method of descent and the equipment used shall comply with the requirements of BS 5573.

Cleanliness of pile bases

On completion of boring and where inspection of a dry pile bore indicates the necessity, loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain water or drilling fluid, a cleaning process shall be employed before concrete is placed. Large debris and accumulated sediment shall be removed using appropriate approved methods, which shall be designed to clean while at the same time minimising ground disturbance below the pile bases. Water or drilling fluid shall be maintained at such levels throughout and following the cleaning operation that stability of the bore is preserved.

Samples and Testing

The taking of samples and all subsequent handling, transporting and testing shall be carried out in accordance with Section 3, Ground Investigation.

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(b)

If required in the Contract, soil, rock or groundwater samples shall be taken or soil tests carried out in-situ while the pile is being bored. The samples shall be taken to an approved laboratory for testing as specified.

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(a)

4.3.4

Materials

1

Permanent Casings (a)

2

Permanent casings shall be as specified.

Drilling Fluid Supply (a)

A certificate shall be obtained by the Contractor from the manufacturer of the bentonite powder showing the properties of each consignment delivered to the Site. This certificate shall be made available to the Engineer on request. The properties to be given by the manufacturer are the apparent viscosity range (in Pascal seconds) and the gel strength range (in Pascal) for solids in water.

QCS 2014

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Page 17

Drilling Fluid Mixing (a)

Bentonite shall be mixed thoroughly with clean fresh water to make a suspension which will maintain the stability of the pile bore for the period necessary to place concrete and complete construction. The temperature of the water used in mixing the bentonite suspension, and of the suspension when supplied to the borehole, shall be not lower than 5 C.

(b)

Where saline or chemically contaminated groundwater occurs, special precautions shall be taken to modify the bentonite suspension or prehydrate the bentonite in fresh water so as to render it suitable in all respects for the construction of piles.

Drilling Fluid Tests (a)

The frequency of testing drilling fluid and the method and procedure of sampling shall be proposed by the Contractor for approval prior to the commencement of the work. The frequency may subsequently be varied as required, depending on the consistency of the results obtained, subject to approval.

(b)

Control tests shall be carried out on the bentonite suspension, using suitable apparatus. The density of freshly mixed bentonite suspension shall be measured daily as a check on the quality of the suspension being formed. The measuring device shall be calibrated to read to within 0.005 g/ml. Tests to determine density, viscosity, shear strength and pH value shall be applied to bentonite supplied to the pile bore. For average soil conditions the results shall generally be within the ranges in Table 4.2.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Table 4.2.Tests on Bentonite

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Viscosity

Less than 1.10 g/ml

Mud density balance

30 - 90 s or less than 0.020 Pa • s

Marsh cone method

1.4-10 Pa Or 4-40 Pa

Shear meter

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9.5 - 12

Fann viscometer*

Fann viscometer pH indicator paper strips or electrical pH meter

Where the Fann viscometer is specified, the fluid sample should be screened by a number 52 sieve (300 m) prior to testing.

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*

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Shear strength (10 minute gel strength) pH

Test method

se

Density

Range of results at 20 C

as

Property to be measured

(c)

The tests shall be carried out until a consistent working pattern has been established account being taken of the mixing process, any blending of freshly mixed bentonite suspension and previously used bentonite suspension, and any process which may be used to remove impurities from previously used bentonite suspension. When the results show consistent behaviour, the tests for shear strength and pH value may be discontinued, and tests to determine density and viscosity shall be carried out as agreed with the Engineer. In the event of a change in the established working pattern, tests for shear strength and pH value shall be reintroduced for a period if required.

4.3.5

Boring

1

Boring Near Recently Cast Piles (a)

Piles shall not be bored so close to other recently completed piles as to damage them.

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Page 18

Temporary Casings (a)

Temporary casing of approved quality or an approved alternative method shall be used to maintain the stability of a pile bore which might otherwise collapse.

(b)

Temporary casings shall be free from significant distortion. They shall be of uniform cross-section throughout each continuous length. During concreting they shall be free from internal projections and encrusted concrete which might adversely affect the proper formation of piles.

(c)

The use of a vibrator to insert and withdraw temporary casing may be permitted by the Engineer subject to compliance with Noise and Disturbance and Damage to Adjacent Structures of this section and to the method not causing disturbance of the ground which would adversely affect the construction or the capacity of piles.

(d)

Where piles are bored under water or bentonite suspension in an unlined state, the insertion of a full-length loosely fitting casing to the bottom of the bore prior to placing concrete will not be permitted.

(e)

Where permanent casing is specified to ensure the integrity of a pile, the Contractor shall submit for approval his proposals regarding the method of installation.

ta qa

Stability of Pile

Where boring takes place through unstable water-bearing strata, the process of excavation and the depth of temporary casing employed shall be such that soil from outside the area of the pile is not drawn into the pile section and cavities are not created outside the temporary casing as it is advanced.

(b)

Where the use of drilling fluid is specified or approved for maintaining the stability of a bore, an adequate temporary casing shall be used in conjunction with the method so as to ensure stability of the strata near ground level until concrete has been placed. During construction the level of drilling fluid in the pile excavation shall be maintained within the cased or stable bore so that it is not less than 1.0 m above the level of external standing groundwater at all times.

(c)

In the event of a rapid loss of drilling fluid from a pile excavation, the bore shall be backfilled without delay and the instructions of the Engineer shall be obtained before boring at that location is resumed.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Spillage and Disposal of Drilling Fluid (a)

5

Pumping from Pile Bores (a)

6

All reasonable steps shall be taken to prevent the spillage of bentonite suspension on the Site in areas outside the immediate vicinity of boring. Discarded bentonite shall be removed from the Site without undue delay. Any disposal of bentonite shall comply with the regulations of the local controlling authority.

Pumping from pile bores shall not be permitted unless the bore has been sealed against further water entry by casing or unless the soil is stable and will allow pumping to take place without ground disturbance below or around the pile.

Continuity of Construction (a)

For a pile constructed in a stable cohesive soil without the use of temporary casing or other form of support, the pile shall be bored and the concrete shall be placed without such delay as would lead to significant impairment of the soil strength.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Enlarged Pile Bases (a)

A mechanically formed enlarged base shall be no smaller than the dimensions specified and shall be concentric with the pile shaft to within a tolerance of 10 % of the shaft diameter. The sloping surface of the frustum forming the enlargement shall make an angle to the axis of the pile of not more than 35 .

4.3.6

Extraction of casing

1

Workability of Concrete (a)

Temporary casings shall be extracted while the concrete within them remains sufficiently workable to ensure that the concrete is not lifted. During extraction the motion of the casing shall be maintained in an axial direction relative to the pile.

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Concrete Level

When the casing is being extracted, a sufficient quantity of concrete shall be maintained within it to ensure that pressure from external water, drilling fluid or soil is exceeded and that the pile is neither reduced in section nor contaminated.

(b)

The concrete level within a temporary casing shall be topped up where necessary during the course of casing extraction in such a way that the base of the casing is always below the concrete surface until the casting of the pile has been completed.

(c)

Adequate precautions shall be taken in all cases where excess heads of water or drilling fluid could occur as the casing is withdrawn because of the displacement of water or fluid by the concrete as it flows into its final position against the walls of the pile bore. Where two or more discontinuous lengths of casing (double casing) are used in the construction the proposed method of working shall be approved.

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(a)

For piles cast in dry bores using temporary casing and without the use of a permanent lining, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.3, but shall not be above the original ground level. No pile shall be cast with its head below standing water level unless approved measures are taken to prevent inflow of water causing segregation of the concrete as temporary casing is extracted, and, where approved by the Engineer, the groundwater level for each pile shall be treated as the cut-off level for the purpose of calculating tolerance.

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Pile Head Casting Level Tolerances

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(b)

For piles cast in dry bores within permanent lining tubes or permanent casings, or where their cut-off levels are in stable ground below the base of any casing used, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.4, but shall not be above the original ground level.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 20

(c)

For piles cast under water or drilling fluid, the pile heads shall be cast to a level above the specified cut-off so that, after trimming to remove all debris and contaminated concrete, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.4, but shall not be above the commencing surface level. Cut-off levels may be specified below the standing groundwater level, and where this condition applies the borehole fluid level shall not be reduced below the standing groundwater level until the concrete has set.

(d)

Where the cut-off level of piles lies at depths greater than 10 m below the original ground level, then the tolerances given in Tables 4.3, 4.4 and 4.5 will be varied after discussion with the Contractor and before the commencement of the piling to take account of the special conditions which apply. Table 4.3

Casting tolerance above cut-off level, m

rw

Cut-off distance below commencing surface, H, m

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Casting Tolerance above Cut-off Level for Piles Cast In Dry Bores Using Temporary Casing and Without the Use of a Permanent Lining

ta

0.3 + H/12 + C/8 where C = length of temporary casing below the commencing surface*

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0.15-10.00 *

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If H is greater than C, then this tolerance is no longer applicable and the tolerances in Table 4.4 will apply.

Table 4.4

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Casting Tolerance above Cut-off Level for Piles Cast in Dry Bores within Permanent Lining Tubes or Permanent Casings, or Where Their Cut-Off Levels is in Stable Ground below the Base of Any Casing Used

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Cut-off distance below commencing surface, H, m

0.3 + H/10

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0.15-10.00

Casting tolerance above cut-off level, m

m

Table 4.5 Casting Tolerance above Cut-off Level for Piles Cast Under Water or Drilling Fluid** Cut-off distance below commencing surface, H, m

0.15-10.00

** 4

Casting tolerance above cut-off level, m

1.0 + H /12 + C/8 where C = length of temporary casing below the commencing surface

In cases where a pile is cast so that the cut-off is within a permanent lining tube, the appropriate tolerance is given by deletion of the casing term C/8 in the table.

Water levels (a)

During extraction of temporary casings, where circumstances are such that newly placed unset concrete is brought into contact with external groundwater, precautions shall be taken to ensure that the internal concrete pressure at all levels within the pile exceeds the external groundwater pressure.

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5

After each pile has been cast, any empty bore remaining shall be protected and shall be carefully backfilled as soon as possible with approved materials.

Disposal of excavated material (a)

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Temporary backfilling above pile casting level (a)

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Disposal of excavated material shall be carried out by the Contractor as necessary to facilitate the Works and to the satisfaction of the Engineer.

Cutting off pile heads (a)

When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section at the cut-off level

BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS

4.4.1

Scope

1

This Part applies to bored piles which employ a continuous flight auger for both advancing the bore and maintaining its stability. The spoil-laden auger is not removed from the ground until concrete or grout is pumped into the pile bore from the base of the hollow-stemmed auger to replace the excavated soil.

2

Related Sections and Parts are as follows:

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This Section

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Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling

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Section 3, Ground Investigation. Section 5, Concrete Materials

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Concrete Mix Design and Workability

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4.4.2

(a)

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Where not otherwise stated in this Part, the concrete shall comply with Section 5. The design and workability of concrete to be used in the formation of a pile shall produce a mix which is suitable for pumping. It shall have a minimum slump of 150 mm unless 3 otherwise approved and a minimum cement content of 340 kg/m . The mix shall be designed so that segregation does not occur during the placing process, and bleeding of the mix shall be minimised.

Grout Mix Design and Workability (a)

Mix design of grout shall be subject to approval. Cement, water and aggregates for grout shall be according to Section 5. Course aggregate to be used shall be of 6 mm nominal size and shall be rounded and evenly graded.

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(b)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

The workability of grout mixes, where used, shall be measured by a suitable and approved means. The procedure for monitoring the suitability of grout throughout the Works shall be stated in writing to the Engineer before beginning of the Works and shall be subject to approval.

(c)

Additives to the grout shall require prior approval of the Engineer.

Reinforcement All reinforcement shall be placed with the minimum delay after the completion of the concreting or grouting operation. It shall be designed and fabricated in cages to permit it to be placed in the correct position and to the depth specified through the concrete or grout of the pile. Suitable approved spacers shall be provided to maintain the specified concrete or grout cover to steel.

(b)

The transverse reinforcement of any reinforcing cage shall be approved and may consist of either spirals, hoops or links.

(c)

Longitudinal main steel reinforcement shall be continuous over the specified length. Where splices are necessary, the number of laps shall be kept to a minimum and bars shall be welded or joined together in an approved manner.

(d)

Reinforcement shall be supported and centred so that it will provide the required projection above the cut-off level, and the proper concrete cover.

Boring

1

General

During uncased boring with continuous flight auger, the feed forward and speed (revolutions per minute) are to be adjusted according to the soil conditions in a way that the excavation of soil will be limited to a quantity that the lateral support of the uncased borehole wall will be ensured.

Boring Near Recently Cast Piles

Removal of Augers from the Ground

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Piles shall not be bored so close to other piles which have recently been cast as to damage them.

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(a)

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Depth of Piles (a)

5

Augers shall not be extracted from the ground during the boring or construction of a pile in such a way that an open unsupported bore or inflow of water into the pile section would result. While withdrawing the continuous flight auger, the auger shall be rotated in the same direction as during drilling into the soil or shall be withdrawn without rotation.

Any failure of a pile to reach the designated depth shall be reported to the Engineer without delay and a full statement of the reasons given.

Suitability of Boring Equipment (a)

The piles shall be bored using approved and suitable equipment capable of penetrating the ground without drawing surrounding soils laterally into the pile bore.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4.4.4

Placing of concrete or grout

1

Equipment for Supply of Concrete or Grout to Piles (a)

Grout or concrete shall be supplied to the pile through suitable tubing and the hollow auger stem. All pipe fitments and connections shall be so constructed that grout does not leak during the injection process.

Commencement of Concrete or Grout Supply to Each Pile (a)

The base of the auger stem shall be fitted with a suitable means of sealing it against ingress of water and soil until concrete or grout placing begins.

(b)

At the beginning of concrete or grout placement this sealing device shall be removed by the application of concrete or grout pressure. Care shall be taken to ensure that the auger is lifted only sufficiently to initiate the flow of concrete or grout, and that water inflow and soil movement at the base of the auger are minimised. The technique and equipment used to initiate and maintain the concrete or grout flow shall be such that a pile of the full specified cross-section is obtained from the maximum depth of boring to the final pile cut-off level.

The concrete or grout shall be supplied to the pile at a sufficient rate during auger withdrawal to ensure that a continuous monolithic shaft of the full specified crosssection is formed, free from debris or any segregated concrete or grout.

(b)

The rate of withdrawal of the auger, the injection pressures and the rate of supply of concrete or grout shall be measured and recorded throughout the phase of auger withdrawal for each pile.

(c)

The Contractor shall submit proposals for his method of monitoring construction for approval before beginning the Works.

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Completion of Piles

If the concrete or grout placing in any pile cannot be completed in the normal manner, then the pile shall be rebored before concrete has hardened and shall be completely replaced.

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Rate of Supply of Concrete or Grout

Casting Level of Pile Head Concrete or grout shall be cast to the original ground level in all cases, and the reinforcing cage set, as appropriate.

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4.4.5

Cutting off pile heads

1

When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any laitance, or contaminated, cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section up to the cut-off level.

4.5

DRIVEN CAST IN PLACES PILES

4.5.1

Scope

1

This Part applies to piles for which a permanent casing of steel or concrete is driven, reinforcement placed within it if required, and the casing filled with concrete. It also applies to piles in which a temporary casing is driven, reinforcement placed within it and the pile formed in the ground by filling the temporary casing with concrete before and during its extraction.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 24

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 5, Concrete Section 3, Ground Investigation. Submittals

1

Where the Contractor wishes to form a pile with an enlarged base, details of the proposed method of forming the base and the materials to be used shall be submitted at the time of tendering.

4.5.3

Quality Assurance

1

Before placing concrete in a pile casing, the Contractor shall check in an approved manner that the casing is undamaged, and free from water or other foreign matter. In the event of water or foreign matter having entered the pile casing, either the casing shall be withdrawn, repaired if necessary and re-driven, or other action shall be taken as may be approved to continue the construction of the pile.

4.5.4

Materials

1

Permanent Casings

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Permanent casings shall be as specified. Where a permanent casing is to be made from a series of short sections it shall be designed and placed so as to produce a continuous water-free shaft. The dimensions and quality of the casing shall be adequate to withstand the stresses caused by handling and driving without damage or distortion.

Temporary casings shall be free from significant distortion. They shall be of uniform external cross-section throughout each continuous length. During concreting they shall be free from internal projections and encrusted concrete which might prevent the proper formation of piles.

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Pile Shoes (a)

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Pile shoes shall be manufactured from durable material capable of withstanding the stresses caused by driving without damage, and shall be designed to give a watertight joint during construction.

Reinforcement (a)

This type of pile shall normally be reinforced over its full length unless permanently cased. The use of shorter reinforcement in piles which are not permanently cased shall be subject to the approval of the Engineer.

(b)

The number of splices in longitudinal steel bars shall be kept to a minimum. The full strength of each bar shall be effective across each splice, which shall be made so that there is no detrimental displacement of the reinforcement during the construction of the pile.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4.5.5

Driving piles

1

Piling Near Recently Cast Piles (a)

2

Casings shall not be driven or piles formed so close to other piles which have recently been cast as to damage them.

Performance of Driving Equipment (a)

The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment

(b)

Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft.

Length of Piles

Driving Procedure (a)

Each pile casing shall be driven continuously until the specified or approved depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided on resumption the casing can be driven to the specified depth or resistance (set), or both, without damage.

(b)

The Contractor shall inform the Engineer without delay if an unexpected change in driving characteristics is encountered. A detailed record of the driving resistance over the full length of the nearest available subsequent pile shall be taken if required.

(c)

At the start of the work in a new area or section a detailed driving record shall be made over the full length of the first pile to be installed and over the last 3 m of the driving of subsequent piles until consistency of behaviour is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the positions of such piles being specified by the Engineer.

(d)

The Contractor shall give adequate notice and provide all facilities to enable the Engineer to check driving resistance. A set shall be taken only in the presence of the Engineer unless otherwise approved.

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Final Set

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The length of pile to be driven in any location shall be approved.

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(a)

Where piles are driven to a set, the final set of each pile, pile shell or casing shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm.

(b)

When a final set is being measured, the following requirements shall be met: (i)

The exposed part of the pile casing shall be in good condition, without damage or distortion.

(ii)

The dolly, helmet and packing, if any, shall be in sound condition.

(iii)

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis.

(iv)

The hammer shall be in good condition, delivering adequate energy per blow, and operating correctly.

(v)

Temporary compression of the pile casing shall be recorded if required.

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6

If preboring is specified the pile casing shall be pitched after preboring to the designated depth and diameter.

Jetting (a)

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Preboring (a)

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Jetting shall be carried out only when the Contractor's detailed proposals have been approved by the Engineer

Internal Drop Hammer Where a casing for a pile without an enlarged base is to be driven by an internal drop hammer, a plug consisting of concrete grade 20 with a water/cement ratio not exceeding 0.25 shall be placed in the pile. This plug shall have a compacted height of not less than 2.5 times the diameter of the pile. Fresh concrete shall be added to ensure that this height of driving plug is maintained in the casing throughout the period of driving, and in any event a plug of fresh concrete shall be added after 1.5 h of normal driving or after 45 min of hard driving, or, should the driving of a pile be interrupted for 30 min or longer, fresh concrete shall be added prior to driving being resumed.

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Risen Piles

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Piles shall be driven in an approved sequence to minimise any detrimental effects of heave and lateral displacement of the ground.

2

When required, levels and measurements shall be taken to determine the movement of the ground or any pile resulting from the driving process.

3

When a pile has risen with detrimental effects as a result of adjacent piles being driven the Contractor shall, if required, submit to the Engineer his proposals for correcting or compensating for this and for avoidance or control of heave effects in subsequent work.

4.5.7

Extraction of casing

1

Workability of Concrete

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(a)

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3

Temporary casings shall be extracted while the concrete within them remains sufficiently workable to ensure that the concrete is not lifted.

Concrete Level (a)

When the casing is being extracted, a sufficient quantity of concrete shall be maintained within it to ensure that pressure from external water or soil is exceeded and that the pile is neither reduced in section nor contaminated.

(b)

Concrete shall be topped up as necessary while the casing is extracted until the required head of concrete to complete the pile in a sound and proper manner has been provided. No concrete is to be placed once the bottom of the casing has been lifted above the top of the concrete.

Vibrating Extractors (a)

The use of vibrating casing extractors will be permitted subject to Part 1 (Noise and Disturbance) and (Damage to Adjacent Structures).

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Page 27

Concrete Casting Tolerances (a)

For piles constructed without the use of a rigid permanent lining, pile concrete shall be cast to the original ground level.

(b)

Where piles are constructed inside rigid permanent lining tubes or permanent casings, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. In this case, the tolerance of casting above the cut-off level shall be determined according to Table 4.6. Table 4.6

Casting Tolerance above Cut-off Level for Piles Constructed Inside Rigid Permanent Lining Tubes or Permanent Casings Cut-off distance below original ground, H, (m)

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Casting tolerance above cut-off level (m)

2.2 + H/10

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Repair of damaged pile heads and making-up of piles to the correct level When repairing or extending the head of a pile, the head shall be cut off square in sound concrete, and all loose particles shall be removed by wire brushing, followed by washing with water.

(b)

If the driving of a pile has been accepted but sound concrete of the pile is below the cut-off level, the pile shall be made good to the cut-off level with concrete of a grade not inferior to that of the concrete of the pile.

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Lengthening of cast-in- place piles after driving When it is required to extend a cast-in-place driven pile above ground, the materials to be used and procedures to be adopted shall be subject to the approval of the Engineer.

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Lengthening of permanent pile casings during construction The lengthening of permanent steel pile casings by adding an additional length of the same steel casing during construction shall be carried out in accordance with the relevant clauses of this Section or by other approved methods. The use of casing extension materials and methods other than those specified shall be subject to approval.

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Temporary backfilling above pile casting level (a)

9

After each pile has been cast, any hole remaining shall be protected and shall be carefully backfilled as soon as possible with approved materials.

Cutting off pile heads (a)

When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section to the cut-off level.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 28

4.6

STEEL PILES

4.6.1

Scope

1

This Part applies to driven steel piles designed to act as bearing piles.

2

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling

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Section 3, Ground Investigation. Section 5, Concrete References

1

The following standards and other documents are referred to in this Part:

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BS 4, ..........................Structural steel sections

BS 3100, ....................Steel casting for general engineering purposes.

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BS 5135, ....................Process of arc-welding of carbon and carbon manganese steels BS 6265, ....................Resistance steam welding of uncoated and coated low carbon steel

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BS 7613, ....................Hot rolled quenched and tempered weldable structural steel plates

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API 5L,........................Interpretation of non-destructive testing. Submittals

1

Where coatings are specified, the Contractor shall submit for approval full details of the coating procedure and surface preparation according to relevant British or Swedish Standards.

4.6.4

Quality Assurance

1

The Contractor shall provide the Engineer with Works test certificates, analyses, and mill sheets, together with a tube manufacturer's certificate showing details of the pile number, cast number of the steel and a record of all tests and inspections carried out. The Engineer has the right to inspect any stage of the manufacturing processes and shall be given adequate notice by the Contractor of such processes and production tests, provided that, once he has been notified, any delay in his attendance does not cause delay to, or disrupt, the manufacturing process. The Contractor shall provide the Engineer with samples for independent testing when requested.

2

The Contractor shall submit for approval full details of the welding procedures and electrodes, with drawings and schedules as may be necessary. Tests shall be undertaken as may be required by the relevant British Standard or as may be required by the Engineer. Only welders who are qualified in the approved welding procedure in accordance with the tests laid down in the relevant British Standard, or who have a proven record over the previous six months, or who have attained a similar standard, shall be employed on the Works. Proof of welders' proficiency shall be made available to the Engineer on request.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4.6.5

Delivery, Storage and Handling

1

The Contractor shall (a)

Order the piles to suit the construction programme.

(b)

Obtain the Engineer's approval before placing the order.

Page 29

When preliminary piles are specified, the approval for the piles for the main work will not necessarily be given until the results of the driving and tests on preliminary piles have been received and evaluated.

3

Each pile shall be clearly numbered and its length shown near the pile head using white paint. In addition, before being driven, each pile shall be graduated at appropriate intervals along its length and at intervals of 250 mm along the top 3 m.

4

All piles within a stack shall be in groups of the same length and on approved supports. All operations such as handling, transporting and storing of piles shall be carried out in a manner such that damage to piles and their coatings is minimised.

4.6.6

Materials

1

Pile Shoes

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Cast steel shoes shall be of steel to BS 3100, grade Al. Flat plate and welded fabricated steel shoes shall be grade 43A or 50A, conforming to BS 7613 and related standards.

Strengthening of Piles

The strengthening to the toe of a pile in lieu of a shoe or the strengthening of the head of a pile shall be made using material of the same grade as the pile unless otherwise approved.

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Manufacturing Tolerance All piles shall be of the type and cross-sectional dimensions specified. For standard rolled sections the dimensional tolerances and weight shall comply with the relevant standard. The tolerance on length shall be -0 and +75 mm unless otherwise specified. For proprietary sections the dimensional tolerances shall comply with the manufacturer's standards. The rolling or manufacturing tolerances for proprietary sections shall be such that the actual weight of section does not differ from the theoretical weight by more than +4 % or -2½ % unless otherwise agreed. The rolling or manufacturing tolerances for steel tubular piles shall be such that the actual weight of section does not differ from the theoretical weight by more than ±5 %.

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Straightness of Piles (a)

For standard rolled sections the deviation from straightness shall be within the compliance provisions of BS 4, Part 1. When two or more rolled lengths are joined by butt-jointing, the deviation from straightness shall not exceed 1/600 of the overall length of the pile.

(b)

For proprietary sections made up from rolled sections, and for tubular piles, the deviation from straightness on any longitudinal face shall not exceed 1/600 of the length of the pile nor 5 mm in any 3 m length.

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Fabrication of Piles (a)

For tubular piles where the load will be carried by the wall of the pile, and if the pile will be subject to loads that induce reversal of stress during or after construction, the external diameter at any section as measured by using a steel tape on the circumference shall not differ from the theoretical diameter by more than ±1.

(b)

The ends of all tubular piles as manufactured shall be within a tolerance on ovality of ±1 % as measured by a ring gauge for a distance of 100 mm at each end of the pile length.

(c)

The root edges or root faces of lengths of piles that are to be shop butt-welded shall not differ by more than 25 % of the thickness of pile walls not exceeding 12 mm thick or by more than 3 mm for piles where the wall is thicker than 12 mm. When piles of unequal wall thickness are to be butt-welded, the thickness of the thinner material shall be the criterion.

Matching of Pile Lengths

Longitudinal seam welds and spiral seam welds of two lengths of tubular piles being joined shall, whenever possible, be evenly staggered at the butt. However, if in order to obtain a satisfactory match of the ends of piles or to meet specified straightness, the seams cannot be staggered evenly, then they shall be staggered by at least 100 mm.

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Welding

Welding of H-piles and piles that will be subjected to stress reversal, during or after construction, shall be in accordance with BS 5135.

(b)

For a tubular pile where the load will be compressive and non-reversible and will be carried by the wall of the pile or by composite action with a concrete core, the welding shall be to BS 5135 or BS 6265.

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(a)

Coating Piles for Protection against Corrosion Where coatings are specified they shall be provided in accordance with the Particular Specification. In general, coatings will not be called for where piles are fully in contact with undisturbed natural soils or below the standing water table. Cathodic protection may be called for when there is a possibility of stray electrical current from the supported structure flowing to earth through the piles.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4.6.7

Acceptance Standards For Welds

1

Acceptance Standards for Shop Welds (a)

Longitudinal or spiral welds made in the manufacture of tubular piles are subject to the acceptance standard for interpretation of non-destructive testing specified in latest edition of API 5L. The maximum projecting height of weld reinforcement shall not exceed 3 mm for wall thicknesses not exceeding 13 mm and 5 mm for wall thicknesses greater than 13 mm.

(b)

Longitudinal welds joining the constituent parts of the box or proprietary section shall be in accordance with the manufacturer's specification.

(c)

The maximum projecting height of weld reinforcement for circumferential welds in tubular piles shall be the same as specified above for longitudinal welds in tubular piles.

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Acceptance Standards for Site Butt Welds (a)

Welds shall comply with the requirements of the Weld Quality Acceptance Standards for Site Butt Welds in Steel Bearing Piles published by British Steel Corporation, General Steels Group.

Acceptability and inspection of coatings

1

The finished coating shall be generally of smooth and uniform texture and free from sharp protuberances or pin holes. Excessive sags, dimpling or curtaining will not be acceptable.

2

Any coat damaged by subsequent processes, or which has deteriorated to an extent such that proper adhesion of the coating is in doubt, shall be removed and the surface shall be cleaned to the original standard and recoated with the specified number and thicknesses of coats.

3

The completed coating shall be checked for thickness by an approved magnetic thickness gauge. Areas where the thickness is less than that specified shall receive approved additional coating.

4

Average measured thickness should be equal to or greater than the specified thickness and no single reading should be less than 85 % of the specified thickness. The completed coating shall also be checked for adhesion by the cross-hatching method with lines spaced at ten times the thickness of the coating. Adhesion tests should not be carried out prior to seven days after coating.

5

The tests shall be made on 10 % of the piles. Areas where the adhesion is not approved shall be sand blasted and recoated. The coating shall be approved before pitching and driving of the piles.

4.6.9

Driving of piles

1

Leaders and Trestles

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At all stages during driving and until incorporation in the superstructure, the free length of the pile shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling. In marine works, lengths which remain unsupported after driving shall be adequately restrained until incorporated into the permanent Works. These constraint arrangements shall be such that damage to piles and their coatings is minimised.

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4.6.8

2

Performance of Driving Equipment (a)

The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where required in the Contract, dynamic evaluation and analysis shall be provided.

(b)

Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile unless otherwise approved by the Engineer. For other types of hammer the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft.

QCS 2014

Length of Piles (a)

The length of pile to be driven and any additional lengths of pile to be added during driving shall be approved by the Engineer.

Driving Procedure and Redrive Checks The driving of each pile shall be continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can be driven to the specified depth or resistance (set), or both, without damage.

(b)

A follower shall not be used unless approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(c)

The Contractor shall inform the Engineer as soon as an unexpected change in driving characteristics is noted. A detailed record of the driving resistance over the full length of the nearest subsequent pile shall be taken, if required by the Engineer.

(d)

At the start of the work in a new area or section a detailed record shall be made over the full driving length of the first pile, and during the last 3 m of the driving of subsequent piles, to establish the driving behaviour. Where required, detailed driving records shall also be made for 5 % of the piles driven, the locations of such piles being specified by the Engineer.

(e)

The Contractor shall give adequate notice and provide all necessary facilities to enable the Engineer to check driving resistance. A set or resistance measurement shall be taken only in the presence of the Engineer unless otherwise approved.

(f)

Redrive checks, if required, shall be carried out in accordance with an approved procedure.

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When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm. When a final set or resistance is being measured, the following requirements shall be met:

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6

(i)

The exposed part of the pile shall be in good condition, without damage or distortion.

(ii)

The dolly and packing, if any, shall be in sound condition.

(iii)

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis.

(iv)

The hammer shall be in good condition, delivering adequate energy per blow and operating correctly.

(v)

The temporary compression of the pile shall be recorded, if required by the Engineer.

Preboring (a)

If preboring is specified the pile shall be pitched after preboring to the designated depth and diameter.

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Jetting (a)

Jetting shall be carried out only when the Contractor's detailed proposals have been approved.

Risen Piles

1

Piles shall be driven in an approved sequence to minimise any detrimental effects of heave and lateral displacement of the ground.

2

When required by the Engineer, levels and measurements shall be taken to determine the movement of the ground or any pile resulting from the driving of adjacent piles.

3

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile under load is unimpaired. If required, the Contractor shall make proposals for correcting detrimentally affected piles and for avoidance or control of heave in subsequent work.

4.6.11

Preparation of pile heads

1

If a steel superstructure is to be welded to piles, the pile cut-off shall be square and to within 5 mm of the elevations shown on the Drawings. If pile heads are to be encased in concrete they shall be cut to that same tolerance and protective coatings shall be removed from the surfaces of the pile heads down to a level 100 mm above the soffit of the concrete.

4.7

MICROPILES (TO BE ADDED LATER)

4.8

REDUCTION OF FRICTION ON PILES

4.8.1

Scope

1

This Part includes preapplied bituminous or other proprietary friction-reducing coating, preapplied low-friction sleeving, formed-in-place low-friction surround, and preinstalled lowfriction sleeving.

2

Related Parts are as follows:

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4.6.10

This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 3, Ground Investigation. 4.8.2

Submittals

1

Where the particular method of reducing friction is not specified, the Contractor shall submit full details of the method which he proposes.

4.8.3

Friction Reducing Methods

1

General (a)

Where a means of reducing friction on any specified length of pile is required by the Contract, the Contractor shall provide a suitable interface between pile and soil by one of the following, or other approved, methods

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(i)

Preapplied bituminous or other proprietary friction-reducing coating.

(ii)

Preapplied low-friction sleeving.

(iii)

Formed-in-place low-friction surrounds.

(iv)

Preinstalled low-friction sleeving.

Preapplied Bituminous or other Friction-Reducing Coating Materials (a)

Where a proprietary product is specified, the process of cleaning pile surfaces, and the conditions and methods of application shall conform to the manufacturer's current instructions. All materials shall conform to the manufacturer's specification, which shall be given to the Engineer before any coating is applied.

(b)

Where a friction-reducing material has been applied to a preformed pile prior to installation, it shall be protected from damage during handling and transportation. In the event of inadvertent damage to the coating, it shall be repaired on site, prior to the pile being driven, to the same specification as the original coating. Where bituminous materials are involved, precautions shall be taken as necessary in hot weather to prevent excessive flow or displacement of the coating. The coated piles shall be adequately protected against direct sunlight and, if stacked, they shall be separated to prevent their coatings sticking together.

(c)

In the case of applied coatings, the piles shall not be driven when the air temperature is such that the coating will crack, flake or otherwise be damaged prior to entry into the ground. Where bituminous materials are involved, driving shall be carried out while the temperature is at or above 5 °C unless otherwise approved or called for in the manufacturer's instructions.

Formed-In-Place Low-Friction Surround Where a hole is bored in the ground and filled with low-friction material through which a pile is subsequently driven or placed, the method and the properties of the low-friction material both above and below standing groundwater level, together with the dimensions of the prebored hole in relation to the pile, shall be approved by the Engineer.

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Piles may be driven with a preapplied low-friction sleeving subject to the approval of the detailed design and method by the Engineer.

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Preinstalled Low-Friction Sleeving (a)

Where a system is employed involving placing a low-friction sleeve in the ground prior to pile installation, the detailed materials and method of installation of the sleeving shall be approved by the Engineer.

4.8.4

Inspection

1

The Engineer may call for piles to be partially exposed or extracted at the commencement of a contract in order to demonstrate that the method of installation does not impair the effectiveness of the system in the circumstances of use on the particular site. Where damage is found to have occurred, or is likely to occur in the opinion of the Engineer, additional measures or variation of the method may be called for. At the discretion of the Engineer, further inspections shall be carried out to ascertain the effectiveness of the additional measures.

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4.8.5

Driving resistance

1

Allowance shall be made in driving piles to a required resistance or set for any differences between the short-term driving resistance and the long-term static resistance of the coating or surrounding low-friction material which is in use.

4.9

PILE LOAD TESTING

4.9.1

Static Load Testing of Piles

1

Scope This Part deals with the testing of a pile by the controlled application of an axial load. It covers vertical and raking piles tested in compression (i.e. subjected to loads or forces in a direction such as would cause the piles to penetrate further into the ground) and vertical or raking piles tested in tension (i.e., subjected to forces in a direction such as would cause the piles to be extracted from the ground).

References The following standard is referred to in this Part:

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Allowable pile capacity: a load which is not less than the specified working load and which takes into account the pile's ultimate bearing capacity, the materials from which the pile is made, the required factor of safety, settlement, pile spacing, downdrag, the overall bearing capacity of the ground beneath the piles and any other relevant factors. The allowable pile capacity indicates the ability of a pile to meet the specified loading requirements.

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Definitions

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When required, the design and full details of the proposed load application system shall be submitted to the Engineer prior to the commencement of testing. The load application system shall be satisfactory for the required test.

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(b)

Compression pile: a pile which is designed to resist compressive (downward) axial load.

(c)

Constant rate of penetration (CRP) test: a test in which the pile is made to penetrate the soil at a constant controlled speed, while the loads applied at the top of the pile in order to maintain the constant rate of penetration are continuously measured. The purpose of the test is to derive the ultimate bearing capacity of a pile and not its load settlement characteristics.

(d)

Constant rate of uplift (CRU) test: the same in principle as the CRP test, but the pile is subject to tension rather than compression. The purpose of the test is to determine the 'pull-out' capacity of a pile.

(e)

Design verification load (DVL): a test load, in lieu of a specified working load, applied to a single pile at the time of testing to determine that site conditions conform to design assumptions. This load will be peculiar to each preliminary (test) pile and should equal the maximum specified working load for a pile of the same dimensions and material, plus allowances for soil-induced forces and any other particular conditions of the test.

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Kentledge: ballast used in a loading test.

(g)

Maintained load test: a loading test in which each increment of load is held constant either for a defined period of time or until the rate of settlement falls to a specified value.

(h)

Preliminary pile: a test pile installed before the commencement of the main piling works or a specific part of the Works for the purpose of establishing the suitability of the chosen type of pile and for confirming its design, dimensions and bearing capacity.

(i)

Proof load: a load applied to a selected working pile to confirm that it is suitable for the load at the settlement specified. A proof load should not normally exceed the design verification load plus 50 % of the specified working load.

(j)

Raking pile: a batter pile, installed at an inclination to the vertical.

(k)

Reaction system: the arrangement of kentledge, piles, anchors or rafts that provides a resistance against which the pile is tested.

(l)

Specified working load (SWL): the designated load on the head of a pile.

(m)

Tension pile: a pile which is designed to resist a tensile (upward) axial force.

(n)

Test pile: any pile, preliminary or part of the works, to which a test is applied.

(o)

Ultimate bearing capacity: the load at which the resistance of the soil becomes fully mobilised through friction, end bearing or a combination thereof.

(p)

Working pile: one of the piles forming the foundation of a structure.

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Notice of Construction

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The Contractor shall give the Engineer at least 48 hours' notice of the commencement of construction of any preliminary pile which is to be testloaded.

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Method of Construction Each preliminary test pile shall be constructed in a manner similar to that to be used for the construction of the working piles, and by the use of similar equipment and materials. Any variation will be permitted only with prior approval.

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(c)

Boring or Driving Record (i)

(d)

For each preliminary pile to be tested, a detailed record of the conditions experienced during boring and of the progress during driving, shall be made and submitted to the Engineer daily, not later than noon on the next working day. Where the Engineer requires soil samples to be taken or in-situ tests to be made, the Contractor shall include that in the daily report, as well as the test results.

Concrete Test Cubes (i)

In the case of concrete piles, four test cubes shall be made from the concrete 3 used in the manufacturer of each preliminary test pile and from each 50 m of the concrete used in the manufacture of working piles. If a concrete pile is extended or capped for the purpose of testing, an additional four cubes shall be made from the corresponding batch of concrete. The cubes shall be made and tested in accordance with BS 1881.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations (ii)

(e)

If a test is required on a working pile the Contractor shall cut off or otherwise prepare the pile for testing as required by the Engineer.

Cut-off Level (i)

The cut-off level for a preliminary test pile shall be approved by the Engineer.

.

Supervision The setting-up of pile testing equipment shall be carried out under competent supervision and the equipment shall be checked to ensure that the set-up is satisfactory before the commencement of load application.

(b)

All tests shall be carried out only under the direction of an experienced and competent supervisor experienced with the test equipment and test procedure. All personnel operating the test equipment shall have been trained in its use.

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Safety precautions General

Design, erection and dismantling of the pile test reaction system and the application of load shall be carried out according to the requirements of the various applicable statutory regulations concerned with lifting and handling heavy equipment and shall safeguard operators and others who may from time to time be in the vicinity of a test from all avoidable hazards.

Kentledge

Where kentledge is used, the Contractor shall construct the foundations for the kentledge and any cribwork, beams or other supporting structure in such a manner that there will not be differential settlement, bending or deflexion of an amount that constitutes a hazard to safety or impairs the efficiency of the operation. The kentledge shall be adequately bonded, tied or otherwise held together to prevent it becoming unstable because of deflexion of the supports or for any other reason.

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The pile test shall not be started until the strength of the cubes taken from the pile exceeds twice the average direct stress in any pile section under the maximum required test load, and the strength of the cubes taken from the cap exceeds twice the average stress at any point in the cap under the same load. Variation of procedure will be permitted only if approved by the Engineer.

Preparation of a Working Pile to be Tested (i)

(f)

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(ii)

When kentledge constitutes the principal component of a reaction system, its weight for each test shall be at least 25% greater than the maximum test load for that test. The weight may be determined by scale or the density and volume of the constituent materials. In adding kentledge, care shall be taken to properly position the centre of gravity of the stack.

QCS 2014

(c)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Tension Piles, Reaction Piles and Ground Anchorages (i)

Where tension piles, reaction piles or ground anchorages constitute the principal components of a reaction system, they shall be so designed that they will resist the forces applied to them safely and without excessive deformation which could cause a safety hazard during the work. Such piles (which, unless approved, will not be working piles) or anchorages shall be driven in the specified locations, and all bars, tendons or links shall be aligned to provide a stable reaction in the direction required. Any welding employed to extend or to fix anchorages to a reaction frame shall be carried out so that the full strength of the system is adequate and unimpaired.

Testing Equipment (i)

In all cases the Contractor shall ensure that when the hydraulic jack and loadmeasuring device are mounted on the pile head the whole system will be stable up to the maximum load to be applied.

(ii)

If in the course of carrying out a test any unforeseen occurrence should take place, further loading shall not be applied until a proper engineering assessment of the condition has been made and steps have been taken to rectify any fault. Reading of gauges should, however, be continued where possible and if it is safe to do so.

(iii)

Where an inadequacy in any part of the system might constitute a hazard, means shall be provided to enable the test to he controlled from a position remote from of the kentledge stack or test frame.

(iv)

The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be operated under hydraulic pressure shall be capable of withstanding a pressure of 1.5 times the maximum pressure used in the test without leaking. The maximum test load expressed as a reading on the gauge in use shall be displayed and all operators shall be made aware of this limit.

Pile Head for Compression Test For a pile that is tested in compression, the pile head or cap shall be formed to give a plane surface which is normal to the axis of the pile, sufficiently large to accommodate the loading and settlement measuring equipment and adequately reinforced or protected to prevent damage from the concentrated load applied by the loading equipment.

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(f)

(ii)

Any test pile cap shall be concentric with the test pile; the joint between the cap and the pile shall have a strength equivalent to that of the pile.

(iii)

Sufficient clear space shall be made under any part of the cap projecting beyond the section of the pile so that, at the maximum expected settlement, load is not transmitted to the ground by the cap.

Pile Connection for Tension Test (i)

For a pile that is tested in tension, means shall be provided for transmitting the test load axially without inducing moment in the pile. The connection between the pile and the loading equipment shall be constructed in such a manner as to provide strength equal to 1.5 times the maximum load which is to be applied to the pile during the test.

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Reaction systems

(i)

The reaction for compression tests shall be provided by kentledge, tension piles or specially constructed anchorages. Kentledge shall not be used for tests on raking piles except where the test set-up has been specifically designed to conform to Item 7(g). and has been approved by the Engineer.

(ii)

Where kentledge is to be used, it shall be supported on cribwork and positioned so that the centre of gravity of the load is as close as possible to the axis of the pile. The bearing pressure under supporting cribs shall be such as to ensure stability of the kentledge stack.

Tension Tests (i)

The reaction for tension tests shall be provided by compression piles, rafts or grillages constructed on the ground. In all cases the resultant force of the reaction system shall be coaxial with the test pile.

(ii)

Where inclined piles or reactions are proposed, full details shall be submitted for approval prior to the commencement of testing.

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Working piles shall not be used as reaction piles without approval from the Engineer.

(ii)

Where working piles are used as reaction piles their movement shall be measured and recorded to with an accuracy of 0.5 mm, and recorded.

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Spacing

Where kentledge is used for loading vertical piles in compression, the distance from the edge of the test pile to the nearest part of the crib supporting the kentledge stack in contact with the ground shall be not less than 1.3 m.

(ii)

The centre-to-centre spacing of vertical reaction piles from a test pile shall conform to Paragraph 1 above, but shall be not less than three times the diameter of the test pile or the reaction piles or 2 m, whichever is the greatest, except in the case of piles of 300 mm diameter (or equivalent) or less, where the distance may be reduced to 1.5 m. Where a pile to be tested has an enlarged pile cap, the same criterion shall apply with regard to the pile shaft, with the additional requirement that no surface of a reaction pile shall be closer to the pile cap of the test pile than one half of the pile cap plan dimension.

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(iii)

(e)

Where ground anchorages are used to provide a test reaction for loading in compression, no section of fixed anchor length transferring load to the ground shall be closer to the test pile than three times the diameter of the test pile. Where the pile to be tested has an enlarged pile cap, the same criterion shall apply with regard to the pile shaft, with the additional requirement that no section of the fixed anchor transferring load to the ground shall be closer to the pile cap than a distance equal to one half the pile cap plan dimension.

Adequate Reaction (i)

The reaction frame support system shall be adequate to transmit the maximum test load in a safe manner without excessive movement or influence on the test pile. Calculations shall be provided to the Engineer when required to justify the design of the reaction system.

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(f)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Care of Piles (i)

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The method employed in the installation of the reaction system shall be such as to prevent damage to any test pile or working pile.

Equipment for applying load The equipment used for applying load shall consist of a hydraulic ram or jack. The jack shall be arranged in conjunction with the reaction system to deliver an axial load to the test pile. Proposals to use more than one ram or jack will be subject to approval by the Engineer of the detailed arrangement. The complete system shall be capable of safely transferring the maximum load required for the test. The length of stroke of a ram shall be sufficient to account for deflexion of the reaction system under load plus a deflection of the pile head by up to 15 % of the pile shaft diameter unless otherwise specified or agreed prior to commencement of test loading.

Measurement of load

A load measuring device shall be used and in addition a calibrated pressure gauge included in the hydraulic system. Readings of both the load measuring device and the pressure gauge shall be recorded. In interpreting the test data the values given by the load measuring device shall normally be used; the pressure gauge readings are required as a check for gross error.

(b)

The load measuring device may consist of a load measuring column, pressure cell or other appropriate system. A spherical seating of appropriate size shall he used to avoid eccentric loading. Care shall be taken to avoid any risk of buckling of the load application and measuring system. Load measuring and application devices shall be short in axial length in order to secure stability. The Contractor shall ensure that axial loading is maintained.

(c)

The load measuring device shall be calibrated before and after each series of tests, whenever adjustments are made to the device or at intervals appropriate to the type of equipment. The pressure gauge and hydraulic jack shall be calibrated together. Certificates of calibration shall be supplied to the Engineer.

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Control of loading

The loading equipment shall enable the load to be increased or decreased smoothly or to be held constant at any required value.

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Measuring pile head movement (a)

Maintained Load Test (i)

(b)

In a maintained load test, movement of the pile head shall he measured by one of the methods in Items 11 (d), (e), (f), (g) in the case of vertical piles, or by one of the methods in 11 (d), (f), (g) in the case of the raking piles, as required.

CRP and CRU Tests (i)

In a CRP or a CRU test, the method in Item 11 (d) shall be used. Checklevelling of the reference frame or the pile head shall not be required. The dial gauge shall be graduated in divisions of 0.02 mm or less.

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

(c)

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Reference Beams and Dial Gauges (i)

An independent reference beam or beams shall be set up to enable measurement of the movement of the pile to be made to the required accuracy. The supports for a beam shall be founded in such a manner and at such a distance from the test pile and reaction system that movements of the ground do not cause movement of the reference beam or beams which will affect the accuracy of the test. The supports of the beam or beams shall be at least three test pile diameters or 2 m from the centre of the test pile, whichever distance is the greater.

(ii)

Check observations of any movements of the reference beam or beams shall be made and a check shall be made of the movement of the pile head relative to a remote reference datum at suitable intervals during the progress of the test.

(iii)

The measurement of pile movement shall be made by four dial gauges rigidly mounted on the reference beam or beams, bearing on prepared flat surfaces fixed to the pile cap or head and normal to the pile axis. Alternatively, the gauges may be fixed to the pile and bear on prepared surfaces on the reference beam or beams. The dial gauges shall be placed equidistant from the pile axis and from each other. The dial gauges shall enable readings to be made to an accuracy of at least 0.1 mm and have a stem travel of at least 25 mm. Machined spacer blocks may be used to extend the range of reading. Equivalent electrical displacement-measuring devices may be substituted.

Optical Levelling Method

An optical levelling method by reference to a remote datum may be used.

(ii)

Where a level and staff are used, the level and scale of the staff shall be chosen to enable readings to be made to within an accuracy of 0.5 mm. A scale attached to the pile or pile cap may be used instead of a levelling staff. At least two reliable independent datum points shall be established. Each datum point shall be so situated as to permit a single setting-up position of the level for all readings.

(iii)

No datum point shall be located where it can be affected by the test loading or other operations on the Site.

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(i)

Two parallel reference wires, one on either side of the pile, shall be held under constant tension at right angles to the test pile axis between supports formed as in the method in Item 11 (d). The wires shall be positioned against scales fixed to the test pile head in an axial direction and the movements of the scales relative to the wires shall be determined.

(ii)

Check observations of any movements of the supports of the wires shall be made and a check shall be made on the movement of the pile head at approved time intervals. Readings shall be taken to within an accuracy of 0.5 mm.

Other Methods (i)

The Contractor may submit for approval any other method of measuring the movement of the test pile head.

QCS 2014

Protection of testing equipment (a)

Protection from Weather (i)

(b)

Throughout the test period all equipment for measuring load and shall be protected from exposure to adverse effect of weather.

movement

Prevention of Disturbance (i)

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Construction activity and persons who are not involved in the testing process shall be kept at a sufficient distance from the test to avoid disturbance to the measuring apparatus. Full records shall be kept of any intermittent unavoidable activity that might affect the test set-up.

Notice of test The Contractor shall give the Engineer at least 24 hours' notice of the commencement of the test. No load shall be applied to the test pile before the commencement of the specified test procedure.

Test procedure

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Proof Load Test Procedure (working compression piles)

The maximum load which shall be applied in a proof test shall normally be the sum of the design verification load (DVL) plus 50 % of the specified working load (SWL). The loading and unloading shall be carried out in stages as shown in Table 4.7. Any particular requirements given in the particular contract documentation shall be complied with.

(ii)

Following each application of an increment of load, the load shall be maintained at the specified value for not less than the period shown in Table 4.7 and until the rate of settlement is less than 0.25 mm/h and decreasing. The rate of settlement shall be calculated from the slope of the line obtained by plotting values of settlement versus time and drawing a smooth curve through the points.

(iii)

Each decrement of unloading shall proceed after the expiry of the period shown in Table 4.7.

(iv)

For any period when the load is constant, time and settlement shall be recorded immediately on reaching the load, at not more than 5 min intervals up to 15 min; at approximately 15 min intervals up to 1 h; at 30 min intervals between 1 h and 4 h; and 1 h intervals between 4 h and 12 h after the application of the increment of load.

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(v)

Where the methods of measuring pile head movement given in Item 11 is used, the periods of time for which loads must be held constant to achieve the specified rates of settlement shall be extended as necessary to take into account the lower levels of accuracy available from these methods and to allow correct assessment of the settlement rate.

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Table 4.7 Minimum time of holding load

25% DVL 50% DVL 75% DVL 100% DVL 75% DVL 50% DVL 25% DVL 0 100% DVL 100% DVL + 25% SWL 100% DVL + 50% SWL 100% DVL + 25% SWL 100% DVL 75% DVL 50% DVL 25% DVL 0 100% DVL 100% DVL + 50% SWL 100% DVL + 75% SWL 100% DVL + 100% SWL 100% DVL + 75% SWL 100% DVL + 50% SW 100% DVL + 25% SW 100% DVL 75% DVL 50% DVL 25% DVL 0

1h 1h 1h 1h 10 min 10 min 10 min 1h 6h 1h 6h 10 min 10 min 10 min 10 min 10 min 1h 6h 6h 1h 6h 10 min 10 min 10 min 10 min 10 min 10 min 10 min 1h

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Applicable to tests on Preliminary Pile only

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(i)

The procedure to be adopted for carrying out load tests on preliminary compression piles shall be either the extended proof load test procedure or the constant rate of penetration testing procedure given below. A normal proof load test will constitute the first stage of such a test unless otherwise specified.

(ii)

Extended proof load test procedure. Where test pile is to be loaded up to the sum of design verification load (DVL) plus 100 % of the specified working load, the loading procedure may be carried out as a continuation of the proof load testing procedure given in Item 14 (a).

(iii)

Following the completion of the proof load test, the load shall be restored in two stages (DVL, DVL +50 % SWL), and shall subsequently be increased by stages of 25 % of the specified working load. Following each application of an increment of load, the load shall be maintained at the specified value for the period shown in Table 4.7 and until the rate of settlement is decreasing and is less than 0.25 mm/h.

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(iv)

Where verification of required minimum factor of safety is called for or the pile is to be tested to failure, the loading procedure shall be continued after reaching DVL +100 % SWL stage by increasing the load in increments of 25 % of the specified working load or other specified amount until the maximum specified load of the test is reached. Following each application of increment of load, the load shall be maintained at the specified value for not less than 1 h and until the rate of settlement is decreasing and is less than 0.25 mm/h, or other approved rate appropriate to the stage of loading and its proximity to a failure condition. Permissible settlement at the load corresponding to the required minimum factor of safety called for in the design will not normally be specified.

(v)

The rate of settlement shall be calculated from the slope of the line obtained by plotting values of settlement versus time and drawing a smooth curve through the points. Reduction of load at the end of the test shall be gradual as required by Item 14 (a).and the final rebound of the pile head shall be recorded.

(vi)

Constant rate of penetration (CRP) testing procedure. Where it is required to determine the ultimate load of a preliminary compression pile, and particularly where piles are largely embedded in and bearing on clay soils, the CRP testing procedure will normally be specified.

(vii)

The rate of movement of the pile head shall be maintained constant in so far as is practicable and shall be approximately 0.01 mm/s.

(viii)

Readings of loads, penetration and time shall be made simultaneously at regular intervals; the interval chosen shall be such that a curve of load versus penetration can be plotted without ambiguity.

(ix)

Loading shall be continued until one of the following results is obtained

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The maximum required test load.

2.

A constant or reducing load has been recorded for an interval of penetration of 10 mm.

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The load shall then be reduced in five approximately equal stages to zero load, penetration and load being recorded at each stage.

Testing of Piles Designed to Carry Load in Tension (i)

The testing of piles designed to carry load in tension shall follow the same procedure as specified in 4.9.1

(ii)

In testing by the constant rate of uplift method, overall movements of the pile head will normally be less than those expected in a constant rate of penetration test. The rate of movement of the pile head shall be maintained at approximately 0.005 mm/s in so far as is practicable.

Completion of a test (a)

Removal of Test Equipment

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(i)

On completion of a test and subject to the approval of the Engineer, all measuring equipment and load application devices shall be dismantled and checked. All other test equipment, including kentledge, beams and supporting structures shall be removed from the test pile location. Measuring and other demountable equipment shall be stored in a safe manner so that it is available for further tests, or removed from the Site as approved by the Engineer.

(ii)

Temporary tension piles and ground anchorages shall be cut off below ground level, and off-cut materials removed from the Site. The ground shall be restored to the original contours.

Preliminary Test Pile Cap Unless otherwise specified, the head of each preliminary test pile shall be cut off below ground level, off-cut material shall be removed from the Site and the ground restored to the original contours.

Proof Test Pile Cap

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On completion of a test on a proof pile, the test pile cap shall be prepared as specified and left in a state ready for incorporation into the Permanent Works. Any resulting off-cut materials shall be removed from the Site.

Presentation of results

1

Results to be submitted

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4.9.2

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(i)

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(c)

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(i)

During the progress of a test, all records taken shall be available for inspection by the Engineer.

(b)

Results shall be submitted as

Preliminary report of the test results to the Engineer, unless otherwise directed, within 24 hours of the completion of the test, which shall show. For a test by maintained load: for each stage of loading, the period for which the load was held, the load and the maximum pile movement at the end of the stage.

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1.

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(i)

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(a)

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2.

(ii)

2

For a CRP or CRU test: the maximum load reached and a graph of load against penetration or load against uplift.

The final report of recorded data as prescribed in Item 15 (b).within ten days of the completion of the test.

Schedule of Recorded Data (a)

The Contractor shall provide information about the test pile in accordance with the following schedule where applicable. (i)

General. 1.

site location contract identification

2.

proposed structure

3.

main contractor

4.

piling contractor

5.

engineer client/employer

6.

date and time of test

QCS 2014

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Pile details. 1.

all types of pile

2.

identification (number and location)

3.

specified working load (SWL)

4.

design verification load (DVL)

5.

original ground level at pile location

6.

head level at which test load was applied

7.

type of pile

8.

vertical or raking, compression or tension

9.

shape and size of cross-section of pile, and position of any change in cross-section

10.

shoe or base details

11.

head details

12.

length in ground

13.

tip Elevation

14.

dimensions of any permanent casing

15.

concrete piles

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(ii)

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concrete mix/grade



aggregate type and source



cement type and cement replacement and type where used

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admixtures

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(iii)

16.



slump



cube test results for pile and cap



date of casting of precast pile



reinforcement

steel piles 

steel quality



coating



filling or core materials type and quality, if applicable

Installation details. 1.

2.

all piles 

dates and times of boring, driving and concreting of test pile



difficulties and delays encountered



date and time of casting concrete pile cap

bored piles 

type of equipment used and method of boring



temporary casing - diameter, type and length

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full log of pile borehole



method of placing concrete



Volume of concrete placed



driven preformed and driven cast-in-place piles



Method of support of hammer and pile driven length of pile or temporary casing at final set



Hammer type, and size or weight



Dolly and packing, type and condition



Driving log (depth, hammer drop, blows per 250 mm, interruptions or breaks in driving)



Final set in number of blows to produce penetration of 25 mm



Redrive check, time interval and set in number of blows to produce penetration of 25 mm or other agreed amount at final set and at redrive set, for a drop hammer or for a single acting hammer the length of the drop or stroke, for a diesel hammer the length of the stroke and the blows per minute, for a double acting hammer the operating pressure and the number of blows per minute



condition of pile head or temporary casing after driving



use of a follower



use of preboring



use of jetting



lengthening

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(iv)

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method of placing concrete

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Test procedure.

mass of kentledge

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1.

tension pile, ground anchorage or compression pile details

3.

plan of test arrangement showing position and distances of kentledge supports, rafts, tension or compression piles or ground anchorages, and supports to pile movement reference system

4.

jack capacity

5.

method of load measurement

6.

method(s) of penetration or uplift measurement

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2.

(v)

Test results. 1.

in tabular form

2.

in graphical form: load plotted against pile head movement

3.

ambient temperature records during test.

4.9.3

Low strain Integrity test

1

This test shall be carried out in accordance with ASTM D5882 in a frequency as mentioned in Section 2

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Grosshole Sonic Logging Test

1

This test shall be carried out in accordance with ASTM D4428, D6760 in a frequency as mentioned in Section 2

4.9.5

Calliper Logging Test

1

This test shall be carried out in accordance with ASTM D6167 in a frequency as mentioned in Section 2

4.9.6

Axial Tensile Load Test

1

This test shall be carried out in accordance with ASTM D3689 in a frequency as mentioned in Section 2

4.9.7

Lateral Load Test

1

This test shall be carried out in accordance with ASTM D3966 in a frequency as mentioned in Section 2

4.9.8

Alternative Methods for Testing Piles

1

Scope

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4.9.4

This Part outlines the alternative methods for testing piles. A significant advance in identifying the existence of defects in construction of piles has been the development and adoption of modern integrity testing systems which may be employed to check the quality of construction when required by the Engineer.

(b)

Dynamic pile-testing is normally used to evaluate the pile capacity, soil resistance distribution, and immediate settlement characteristics, hammer transfer energy (efficiency), and pile stresses during driving. The results obtained relate directly to dynamic loading conditions.

(c)

Related Sections and Parts are as follows:

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This Section Section 2

2

3

Quality Assurance (a)

The testing shall be carried out by an approved firm.

(b)

The interpretation of tests shall be carried out by persons competent in the test procedure, and the full test results and findings shall normally be given to the Engineer within 10 d of the completion of each phase of testing. Full details of the ground conditions, pile dimensions and construction method shall be made available to the specialist firm when required in order to facilitate interpretation of the tests.

Integrity-testing of piles (a)

General

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(i)

Integrity-testing of piles is designed to give information about the physical dimensions, continuity and consistency of materials used in piles, and not to give direct information about the performance of piles under the conditions of loading. The methods available are normally applied to preformed concrete piles made in a single length, to steel piles and to cast-in-place concrete piles.

(ii)

This type of testing will not be regarded as a replacement for static load testing, but as a source of supplementary information.

(iii)

There is normally a limit to the length: diameter ratio of pile which can be successfully and fully investigated in this way, depending on the ground conditions.

(iv)

In the event that any anomaly is found in the results of such testing, the Engineer may call for further testing to be carried out in order to investigate the cause, nature and extent of the anomaly and whether the pile is satisfactory for its intended use.

Method of Testing

Where integrity-testing is called for but the method is not specified, the method to be adopted shall be approved by the Engineer and shall be one of the following

3.

The sonic logging method.

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The vibration method.

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Other methods may be adopted subject to the approval of the Engineer and subject to satisfactory evidence of performance.

In the case of cast-in-place concrete piles, integrity tests shall not be carried out until 7 d or more have elapsed after pile-casting, unless otherwise approved by the Engineer.

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Preparation of Pile Heads

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(i)

4

2.

Age of Piles at Time of Testing (i)

(d)

The sonic method.

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(b)

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Where the method of testing requires the positioning of sensing equipment on the pile head, the head shall be clean, free from water, laitance and loose concrete and readily accessible for the purpose of testing.

Dynamic pile-testing (a)

General (i)

Dynamic pile-testing involves monitoring the response of a pile to a heavy impact applied at the pile head. The impact is often provided by the pile-driving hammer and response is normally measured in terms of force and acceleration or displacement close to the pile head.

(ii)

The results directly obtained refer to dynamic loading conditions. Interpretation in terms of static loading requires soil- and pile-dependent adjustments, and corroboration from experience may be required to correlate dynamic testing with normal static load tests as specified in clause 4.9.1 of this Section.

(iii)

Details of the equipment to be used and of the method of analysis of test results shall be provided to the Engineer before the commencement of testing.

QCS 2014

(b)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Measuring Instruments (i)

(c)

All instruments affixed to the pile for the purpose of measuring stress and movement, and all equipment for receiving and processing data shall be suitable for the purpose. The equipment required to be attached to the pile shall be appropriately positioned and fixed to the approval of the Engineer.

Hammer (i)

(d)

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The hammer and all other equipment used shall be capable of delivering an impact force sufficient to mobilise the equivalent specified test load without damaging the pile.

Preparation of the Pile Head The preparation of the pile head for the application of the dynamic test load shall involve, where appropriate, trimming the head, cleaning and building up the pile using materials which will at the time of testing safely withstand the impact stresses. The impact surface shall be flat and normal to the axis of the pile.

(e)

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(i)

Time of Testing

Dynamic load tests shall be carried out at appropriate and approved times after pile installation. The time between the completion of installation and testing for a preformed pile shall normally be more than 12 h, and in the case of a cast-inplace concrete piles shall be after the concrete has reached 75 % of its specified 28 day strength so that the pile is not damaged under the impact stresses.

Set Measurements

(g)

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Where required and appropriate, the permanent penetration per blow and temporary compression of the pile and soil system shall be measured independently of the instruments being used to record the dynamic test data.

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(i)

Results

Initial the results shall be provided to the Engineer within 24 hours of the completion of a test. These shall include

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(i)

The maximum force applied to the pile head.

2.

The maximum pile head velocity.

3.

The maximum energy imparted to the pile.

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1.

(ii)

Normally within 10 d of the completion of testing final report shall be given to the Engineer which includes: 1.

Date of pile installation.

2.

Date of test.

3.

Pile identification number and location.

4.

Length of pile below ground surface.

5.

Total pile length, including projection above commencing surface at time of test.

6.

Length of pile from instrumentation position to tip.

7.

Hammer type, drop and other relevant details.

8.

Blow selected for analysis.

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9.

Test load achieved (i.e. total mobilised deduced static load).

10.

Pile head movement at equivalent design verification load.

11.

Pile head movement at equivalent design verification load plus 50 % of specified working load.

12.

Pile head movement at maximum applied test load.

13.

Permanent residual movement of pile head after each blow.

14.

Temporary compression.

DESIGN METHODS AND DESIGN CONSIDERATIONS

4.10.1

Design method

1

The design shall be based on one of the following approaches:

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4.10

The results of static load tests, which have been demonstrated, by means of calculations or otherwise, to be consistent with other relevant experience;

(b)

Empirical or analytical calculation methods whose validity has been demonstrated by static load tests in comparable situations;

(c)

The results of dynamic load tests whose validity has been demonstrated by static load tests in comparable situations;

(d)

The observed performance of a comparable piles foundation, provided that this approach is supported by the results of site investigation and ground testing.

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(a)

Design values for parameters used in the calculations should be in general accordance with design parameters from geotechnical investigations report, but the results of load tests may also be taken into account in selecting parameter values.

3

Static load tests may be carried out on trial piles, installed for test purposes only, before the design is finalized, or on working piles, which form part of the foundation.

4.10.2

Verification of Resistance for Structural and Ground Limit States in Persistent and Transient Situations

1

When considering a limit state of rupture or excessive deformation of a structural element or section of the ground (Structural and Geotechnical), it shall be verified in accordance with (Eurocode1997-1) or equivalent.

4.10.3

Design Considerations

1

The behavior of individual piles and pile groups and the stiffness and strength of the structure connecting the piles shall be considered.

2

In selecting calculation methods and parameter values and in using load test results, the duration and variation in time of the loading shall be considered.

3

Planned future placement or removal of overburden or potential changes in the ground-water regime shall be considered, both in calculations and in the interpretation of load test results.

4

The choice of type of pile, including the quality of the pile material and the method of installation, shall take into account:

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the ground and ground-water conditions on the site, including the presence or possibility of obstructions in the ground;

(b)

the stresses generated in the pile during installation;

(c)

the possibility of preserving and checking the integrity of the pile being installed;

(d)

the effect of the method and sequence of pile installation on piles, which have already been installed and on adjacent structures or services;

(e)

the tolerances within, which the pile can be installed reliably;

(f)

the deleterious effects of chemicals in the ground;

(g)

the possibility of connecting different ground-water regimes;

(h)

the handling and transportation of piles;

(i)

the effects of pile construction on neighboring buildings.

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(a)

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In considering the aspects listed above, the following items should receive attention: the spacing of the piles in pile groups;

(b)

displacement or vibration of adjacent structures due to pile installation;

(c)

the type of hammer or vibrator used;

(d)

the dynamic stresses in the pile during driving;

(e)

for those types of bored pile where a fluid is used inside the borehole, the need to keep the pressure of the fluid at a level to ensure that the borehole will not collapse and that hydraulic failure of the base will not occur;

(f)

cleaning of the base and sometimes the shaft of the borehole, especially under bentonite, to remove remolded materials;

(g)

local instability of a shaft during concreting, which may cause a soil inclusion within the pile;

(h)

ingress of soil or water into the section of a cast-in-situ pile and possible disturbance of wet concrete by the flow of water through it;

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the effect of unsaturated sand layers around a pile extracting water from the concrete;

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(i)

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(a)

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

(j)

the retarding influence of chemicals in the soil;

(k)

soil compaction due to the driving of displacement piles;

(l)

soil disturbance due to the boring of a pile shaft.

4.11

AXIALLY LOADED PILES

4.11.1

Limit state design

1

The design shall demonstrate that exceeding the following limit states is sufficiently improbable: (a)

ultimate limit states of compressive or tensile resistance failure of a single pile;

(b)

ultimate limit states of compressive or tensile resistance failure of the pile foundation as a whole;

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(c)

ultimate limit states of collapse or severe damage to a supported structure caused by excessive displacement or differential displacements of the pile foundation;

(d)

serviceability limit states in the supported structure caused by displacement of the piles.

Normally the design should consider the margin of safety with respect to compressive or tensile resistance failure, which is the state in which the pile foundation displaces significantly downwards or upwards with negligible increase or decrease of resistance.

3

For piles in compression it is often difficult to define an ultimate limit state from a load settlement plot showing a continuous curvature. In these cases, settlement of the pile top equal to 10% of the pile base diameter should be adopted as the "failure" criterion.

4

For piles that undergo significant settlements, ultimate limit states may occur in supported structures before the resistance of the piles is fully mobilized. In these cases a cautious estimate of the possible range of the settlements shall be adopted in design.

4.11.2

Compressive Ground Resistance

1

To demonstrate that the pile foundation will support the design load with adequate safety against compressive failure, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations:

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2

as

Fc ≤ Rc

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Where

er

Fc: design axial compression load on a pile or a group of piles

In principle Fc should include the weight of the pile itself and Rc should include the overburden pressure of the soil at the foundation base. However these two items may be disregarded if they cancel approximately. They need not cancel if: (a)

downdrag is significant; the soil is very light,

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(b)

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2

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Rc: design value

(c) 3

the pile extends above the surface of the ground.

For piles in groups, two failure mechanisms shall be taken into account: (a)

compressive resistance failure of the piles individually;

(b)

compressive resistance failure of the piles and the soil contained between them acting as a block.

NOTE: The design resistance shall be taken as the lower value caused by these two

mechanisms. 4

The compressive resistance of the pile group acting as a block may be calculated by treating the block as a single pile of large diameter.

5

The stiffness and strength of the structure connecting the piles in the group shall be considered when deriving the design resistance of the foundation.

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If the piles support a stiff structure, advantage may be taken of the ability of the structure to redistribute load between the piles. A limit state will occur only if a significant numbe r of piles fail together; therefore a failure mode involving only one pile need not be considered.

7

If the piles support a flexible structure, it should be assumed that the compressive resistance of the weakest pile governs the occurrence of a limit state.

8

Special attention should be given to possible failure of edge piles caused by inclined or eccentric loads from the supported structure.

9

If the layer in which the piles bear overlies a layer of weak soil, the effect of the weak layer on the compressive resistance of the foundation shall be considered.

10

The strength of a zone of ground above and below the pile base shall be taken into account when calculating the pile base resistance.

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NOTE: This zone may extend several diameters above and below the pile base. Any weak ground in this zone has a relatively large influence on the base resistance.

Punching failure should be considered if weak ground is present at a depth of less than 4 times the base diameter below the base of the pile.

12

Where the pile base diameter exceeds the shaft diameter, the possible adverse effect shall be considered.

13

For open-ended driven tube or box-section piles with openings of more than 500 mm in any direction, and without special devices inside the pile to induce plugging, the base resistance should be limited to the smaller of:

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11

the shearing resistance between the soil plug and the inside face of the pile;

(b)

the base resistance derived using the cross-sectional area of the base.

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(a)

Ultimate compressive resistance from static load tests

1

The manner in which load tests are carried out shall be in accordance with 4.11.2 and shall be specified in the Geotechnical Design Report.

2

Trial piles to be tested in advance shall be installed in the same manner as the piles that will form the foundation and shall be founded in the same stratum.

3

If the diameter of the trial pile differs from that of the working piles, the possible difference in performance of piles of different diameters should be considered in assessing the compressive resistance to be adopted.

4

In the case of a very large diameter pile, it is often impractical to carry out a load test on a full size trial pile. Load tests on smaller diameter trial piles may be considered provided that:

m

4.11.3

(a)

the ratio of the trial pile diameter/working pile diameter is not less than 0,5;

(b)

the smaller diameter trial pile is fabricated and installed in the same way as the piles used for the foundation;

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the trial pile is instrumented in such a manner that the base and shaft resistance can be derived separately from the measurements.

NOTE: This approach should be used with caution for open-ended driven piles because of the influence of the diameter on the mobilisation of the compressive resistance of a soil plug in the pile. In the case of a pile foundation subjected to downdrag, the pile resistance at failure, or at a displacement that equals the criterion for the verification of the ultimate limit state determined from the load test results, shall be corrected. The correction shall be achieved by subtracting the measured, or the most unfavorable, positive shaft resistance in the compressible stratum and in the strata above, where negative skin friction develops, from the loads measured at the pile head.

6

During the load test of a pile subject to downdrag, positive shaft friction will develop along the total length of the pile. The maximum test load applied to the working pile should be in excess of the sum of the design external load plus twice the downdrag force.

7

When deriving the ultimate characteristic compressive resistance from values measured in one or several pile load tests, an allowance shall be made for the variability of the ground and the variability of the effect of pile installation.

8

The systematic and random components of the variations in the ground shall be recognized in the interpretation of pile load tests.

9

The records of the installation of the test pile(s) shall be checked and any deviation from the normal execution conditions shall be accounted for.

10

The characteristic compressive resistance of the ground may be derived from the characteristic values of the base resistance and of the shaft resistance in accordance with Eurocode1997-1.

4.11.4

Ultimate compressive resistance from ground test results

1

Methods for assessing the compressive resistance of a pile foundation from ground test results shall have been established from pile load tests and from comparable experience.

2

A model factor may be introduced as described as following to ensure that the predicted compressive resistance is sufficiently safe :

3

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5

(a)

the range of uncertainty in the results of the method of analysis;

(b)

any systematic errors known to be associated with the method of analysis

In assessing the validity of a model based on ground test results, the following items should be considered: (a)

soil type, including grading, mineralogy, angularity, density, pre-consolidation, compressibility and permeability;

(b)

method of installation of the pile, including method of boring or driving;

(c)

length, diameter, material and shape of the shaft and of the base of the pile (e.g. enlarged base);

(d)

method of ground testing.

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4.11.5

Ultimate compressive resistance from dynamic impact tests

1

Where a dynamic impact (hammer blow) pile test [measurement of strain and acceleration versus time during the impact event is used to assess the resistance of individual compression piles, the validity of the result shall have been demonstrated by previous evidence of acceptable performance in static load tests on the same pile type of similar length and cross-section and in similar ground conditions.

2

When using a dynamic impact load test, the driving resistance of the pile should be measured directly on the site in question.

.

NOTE A load test of this type can also include a process of signal matching to measured stress wave figures. Signal matching enables an approximate evaluation of shaft and base resistance of the pile as well as a simulation of its load-settlement behaviour. The impact energy shall be high enough to allow for an appropriate interpretation of the pile capacity at a correspondingly high enough strain level.

4

The design value of the compressive resistance of the pile could be calculated and verified according to Eurocode1997-1.

4.11.6

Ultimate compressive resistance by applying pile driving formulae

1

Pile driving formulae shall only be used if the stratification of the ground has been determined.

2

If pile driving formulae are used to assess the ultimate compressive resistance of individual piles in a foundation, the validity of the formulae shall have been demonstrated by previous experimental evidence of acceptable performance in static load tests on the same type of pile, of similar length and cross-section, and in similar ground conditions.

3

For end-bearing piles driven into non-cohesive soil, the design value of the compressive resistance shall be assessed by the same procedure as in 4.11.5.

4

When a pile driving formula is applied to verify the compression resistance of a pile, the pile driving test should have been carried out on at least 5 piles distributed at sufficient spacing in the piling area in order to check a suitable blow count for the final series of blows.

5

The penetration of the pile point for the final series of blows should be recorded for each pile.

4.11.7

Ultimate compressive resistance from wave equation analysis

1

Wave equation analysis shall only be used where stratification of the ground has been determined by borings and field tests.

2

Where wave equation analysis is used to assess the resistance of individual compression piles, the validity of the analysis shall have been demonstrated by previous evidence of acceptable performance in static load tests on the same pile type, of similar length and cross- section, and in similar ground conditions.

3

The design value of the compressive resistance derived from the results of wave equation analysis of a number of representative piles, shall be assessed by the same procedure as in 4.11.3.

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NOTE Wave equation analysis is based on a mathematical model of soil, pile and driving equipment without stress wave measurements on site. The method is usually applied to study hammer performance, dynamic soil parameters and stresses in the pile during driving. It is also, on the basis of the models, possible to determine the required driving resistance (blow count) that is usually related to the expected compressive resistance of the pile. Ground tensile resistance

1

The design of piles in tension shall be consistent with the design rules given in 4.11.2, where applicable. Design rules that are specific for foundations involving piles in tension are presented below.

2

To verify that the foundation will support the design load with adequate safety against a failure in tension, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations in accordance with Eurocode1997-1.

3

For isolated tensile piles or a group of tensile piles, the failure mechanism may be governed by the pull-out resistance of a cone of ground, especially for piles with an enlarged base or rock socket.

4

When considering the uplift of the block of ground containing the piles the shear resistance along the sides of the block may be added to the resisting forces.

5

Normally the block effect will govern the design tensile resistance if the distance between the piles is equal to or less than the square root of the product of the pile diameter and the pile penetration into the main resisting stratum.

6

The group effect, which may reduce the effective vertical stresses in the soil and hence the shaft resistances of individual piles in the group, shall be considered when assessing the tensile resistance of a group of piles.

7

The severe adverse effect of cyclic loading and reversals of load on the tensile resistance shall be considered.

8

Comparable experience based on pile load tests should be applied to appraise this effect.

4.11.9

Ultimate tensile resistance from pile load tests

1

Pile load tests to determine the ultimate tensile resistance of an isolated pile shall be carried out in accordance with 4.9.1 and with regard to 4.11.3.

2

The design tensile resistance could be calculated and verified according to Eurocode1997-1.

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4.11.8

4.11.10 Ultimate tensile resistance from ground test results 1

Methods for assessing the tensile resistance of a pile foundation from ground test results shall have been established from pile load tests and from comparable experience.

2

A model factor may be introduced as following to ensure that the predicted tensile resistance is sufficiently safe. (a)

the range of uncertainty in the results of the method of analysis;

(b)

any systematic errors known to be associated with the method of analys is

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The design value of tensile resistance of a pile could be calculated and verified according to Eurocode1997-1.

4.11.11 Vertical displacements of pile foundations 1

Vertical displacements under serviceability limit state conditions shall be assessed and checked.

2

When calculating the vertical displacements of a pile foundation, the uncertainties involved in the calculation model and in determining the relevant ground properties should be taken into account. Hence it should not be overlooked that in most cases calculations will provide only an approximate estimate of the displacements of the pile foundation.

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NOTE For piles bearing in medium-to-dense soils and for tension piles, the safety requirements for the ultimate limit state design are normally sufficient to prevent a serviceability limit state in the supported structure.

The occurrence of a serviceability limit state in the supported structure due to pile settlements shall be checked, taking into account downdrag, where probable.

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4.11.12 Pile foundations in compression

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NOTE When the pile toe is placed in a medium-dense or firm layer overlying rock or very hard soil, the partial safety factors for ultimate limit state conditions are normally sufficient to satisfy serviceability limit state conditions. Assessment of settlements shall include both the settlement of individual piles and the settlement due to group action.

3

The settlement analysis should include an estimate of the differential settlements that may occur.

4

When no load test results are available for an analysis of the interaction of the piled foundation with the superstructure, the load-settlement performance of individual piles should be assessed on empirically established safe assumptions.

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4.11.13 Pile foundations in tension The assessment of upward displacements shall be done and Particular attention should be paid to the elongation of the pile material.

2

When very severe criteria are set for the serviceability limit state, a separate check of the upward displacements shall be carried out.

4.12

TRANSVERSELY LOADED PILES

4.12.1

Design method

1

The design of piles subjected to transverse loading shall be consistent with the design rules given in 4.10, where applicable. Design rules specifically for foundations involving piles subjected to transverse loading are presented below.

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To demonstrate that a pile will support the design transverse load with adequate safety against failure, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations: Ftr ≤ Rtr Where; Ftr: design value of the transverse load on a pile or a pile foundation Rtr : design resistance of transversally loaded pile One of the following failure mechanisms should be considered: for short piles, rotation or translation as a rigid body;

(b)

for long slender piles, bending failure of the pile, accompanied by local yielding and displacement of the soil near the top of the pile.

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The group effect shall be considered when assessing the resistance of transversely loaded piles.

5

It should be considered that a transverse load applied to a group of piles may result in a combination of compression, tension and transverse forces in the individual piles.

4.12.2

Transverse load resistance from pile load tests

1

Transverse pile load tests shall be carried out in accordance with 4.9.6.

2

Contrary to the load test procedure described in 4.9 tests on transversely loaded piles need not normally be continued to a state of failure. The magnitude and line of action of the test load should simulate the design loading of the pile.

3

An allowance shall be made for the variability of the ground, particularly over the top few meters of the pile, when choosing the number of piles for testing and when deriving the design transverse resistance from load test results.

4

Records of the installation of the test pile(s) should be checked, and any deviation from the normal construction conditions should be accounted for in the interpretation of the pile load test results. For pile groups, the effects of interaction and head fixity should be accounted for when deriving the transverse resistance from the results of load tests on individual test piles.

4.12.3

Transverse load resistance from ground test results and pile strength parameters

1

The transverse resistance of a pile or pile group shall be calculated using a compatible set of structural effects of actions, ground reactions and displacements.

2

The analysis of a transversely loaded pile shall include the possibility of structural failure of the pile in the ground.

3

The calculation of the transverse resistance of a long slender pile may be carried out using the theory of a beam loaded at the top and supported by a deformable medium characterized by a horizontal modulus of subgrade reaction.

4

The degree of freedom of rotation of the piles at the connection with the structure shall be taken into account when assessing the foundation’s transverse resistance.

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4.12.4

Transverse displacement

1

The assessment of the transverse displacement of a pile foundation shall take into account: the stiffness of the ground and its variation with strain level;

(b)

the flexural stiffness of the individual piles;

(c)

the moment fixity of the piles at the connection with the structure;

(d)

the group effect;

(e)

the effect of load reversals or of cyclic loading

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END OF PART

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RETAINING STRUCTURES ---------------------------------------------------------------------------------- 2

5.1

GENERAL---------------------------------------------------------------------------------------------------------- 2

5.2

LIMIT STATES ---------------------------------------------------------------------------------------------------- 2

5.2.2 5.2.3

Ultimate Limit State ---------------------------------------------------------------------------------------------- 2 Serviceability Limit State ---------------------------------------------------------------------------------------- 3

5.3

ACTIONS AND GEOMETRICAL DATA -------------------------------------------------------------------- 3

5.3.1 5.3.2 5.3.3

Actions -------------------------------------------------------------------------------------------------------------- 3 Geometrical data ------------------------------------------------------------------------------------------------- 4 Design Situations ------------------------------------------------------------------------------------------------- 4

5.4

DESIGN AND CONSTRUCTION CONSIDERATIONS ------------------------------------------------- 5

5.5

DETERMINATION OF EARTH PRESSURES ------------------------------------------------------------ 6

5.5.1 5.5.2 5.5.3 5.5.4 5.5.5

General ------------------------------------------------------------------------------------------------------------- 6 At rest values of earth pressure------------------------------------------------------------------------------- 7 Limiting values of earth pressure ----------------------------------------------------------------------------- 7 Intermediate values of earth pressure ----------------------------------------------------------------------- 7 Compaction effects ---------------------------------------------------------------------------------------------- 7

5.6

WATER PRESSURES ------------------------------------------------------------------------------------------ 8

5.7

ULTIMATE LIMIT STATE DESIGN -------------------------------------------------------------------------- 8

5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 5.7.6 5.7.7

General ------------------------------------------------------------------------------------------------------------- 8 Overall stability ---------------------------------------------------------------------------------------------------- 8 Foundation failure of gravity walls ---------------------------------------------------------------------------- 8 Rotational failure of embedded walls ------------------------------------------------------------------------ 8 Vertical failure of embedded walls --------------------------------------------------------------------------- 9 Structural design of retaining structures -------------------------------------------------------------------- 9 Failure by pull-out of anchorages ----------------------------------------------------------------------------- 9

5.8

SERVICEABILITY LIMIT STATE DESIGN ----------------------------------------------------------------- 9

5.8.1 5.8.2

General ------------------------------------------------------------------------------------------------------------- 9 Displacements ---------------------------------------------------------------------------------------------------- 9

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5

RETAINING STRUCTURES

5.1

GENERAL

1

The provisions of this Part 5 apply to retaining structures in general. These are structures used to retain ground comprising soil, rock or backfill and water and this at an angle steeper than the angle they would normally adopt without the presence of those structures. Common retaining structures used within the state of Qatar taking into account the prevailing geologic conditions are: Sheet Piles

(b)

Bored and Cast in Place Concrete Piles

Secant Piles

(c)

Diaphragm Walls

(d)

Composite Shoring Systems

(e)

Concrete Retaining Walls

(ii)

Counter Fort Retaining Wall

(iii)

Gravity Retaining Wall

(iv)

Buttressed Retaining Wall

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Cantilever Retaining Wall

Reinforced Soil Retaining Structures Geogrid and Geotextile Reinforced Earth Systems

(ii)

Galvanized Strips Reinforced Earth System

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Soil and Rock Nailing Systems

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Contiguous Piles

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(a)

This revision of Section 4 – Part 5 is considered preliminary and shall be reviewed and amended as needed in the next revision to elaborate on various subjects not covered herein.

3

This revision of Section 4 – Part 5 is based generally on “EN1997-1:2004+A1:2013” Eurocode 7.

4

Section 4 – Part 5 will cover at this stage the general design aspects knowing that the construction procedures shall be added in future revisions of this Section. Hence, at this stage, the construction related subjects of the retaining structures will follow relevant Parts of the QCS.

5.2

LIMIT STATES

1

During the design of retaining structures the following typical limit states should be considered:

5.2.2

Ultimate Limit State

1

Loss of overall stability: it should be demonstrated that an overall stability failure is unlikely.

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Foundation failure of retaining structures with footings: it should be demonstrated that the foundation pressures (lateral and vertical) do not exceed neither the ground allowable bearing capacity nor the sliding resistance. Uplift pressures under the foundation due to water seepage should also be included in the analysis.

3

Foundation failure of gravity walls, which is the loss of equilibrium of the wall considered as a rigid body.

4

Failure of embedded walls by rotation or horizontal translation or by lack of vertical equilibrium.

5

Failure of a structural element such as a wall, anchorage, wale or strut, including failure of the connection between those elements.

6

Failure of a retaining structure by hydraulic heave, internal erosion or piping, unacceptable leakage of water, or transport of soil particles through or under the wall caused by excessive hydraulic gradients.

5.2.3

Serviceability Limit State

1

Unacceptable movement of the retaining structure, which may affect the appearance or functionality of the structure itself, or other neighbouring structures or utilities influenced by the movement.

2

Unacceptable change in the groundwater regime.

5.3

ACTIONS AND GEOMETRICAL DATA

5.3.1

Actions

1

Generally, the forces exerted on retaining structure with values assumed known at the beginning of the calculation are considered as 'actions', while forces with initially unknown values, to be determined by the interaction of the retaining structure with support elements (ground springs, anchorages, struts, etc.), are considered as 'reactions'. The following actions are to be taken into account: Weight of backfill material

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(b)

Surcharges

(c)

Weight of water

(d)

Wave forces for marine projects

(e)

Seepage forces

(f)

Collision forces

(g)

Temperature effects

(h)

Forces from propping elements (i.e. post-tensioned anchors)

(i)

Siesmic related effects

The above actions should result in the determination of various earth pressures acting on the retaining structure.

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5.3.2

Geometrical data

1

This paragraph covers the uncertainties in the geometrical data namely excavation and water levels. In general, small variations in geometrical data are considered to be covered by the safety factors included in the calculations. However, since the design of retaining structures is sensitive to ground and water levels, special requirements are included in this paragraph, mainly for unforeseen over-dig in front of the wall and groundwater levels change on both sides of the wall.

2

Unforeseen over-dig in front of the wall

Equal to 10% of the wall height above excavation level (up to a maximum of 0.5 m), for cantilever walls;

(b)

Equal to 10% of the distance between the lowest support and the excavation level (up to a maximum of 0.5 m), for supported walls.

Groundwater levels in front of and behind the wall

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The selection of the levels of the phreatic surfaces in front of and behind the wall must consider long-term variations of the groundwater regime and/or the ground permeability, the presence of perched or artesian aquifers and the possibility that drainage behind the wall may cease to function with time. Design Situations

1

The following conditions shall be considered during the design of retaining structures: Anticipated variations in soil properties

(b)

Variations in actions and the ways they are combined

(c)

Excavation, scour or erosion in front of the retaining structure The effect of compaction of the backfill behind the retaining structure

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5.3.3

(e)

The effect of anticipated future structures and surcharge loads/unloads

(f)

Anticipated ground movements

(g)

Inclination of the wall to the vertical

(h)

Variations in groundwater table and the seepage forces in the ground

(i)

Horizontal as well as vertical equilibrium for the entire retaining structure

(j)

The shear strength and weight density of the ground

(k)

The rigidity of the wall and the supporting system

(l)

The wall roughness

(m)

Seismic effect on the various forces

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5.4

DESIGN AND CONSTRUCTION CONSIDERATIONS

1

The design of retaining structures requires consideration of all relevant Ultimate Service States and Service Limit States.

2

For retaining structures without strict serviceability requirements, the geometry is usually determined by Ultimate Limit State design calculations and checked by Service Limit State calculations (if relevant). For the retaining structures with strict serviceability requirements, the Service Limit State requirements often govern the design.

3

The design and construction considerations should cover the following: Demonstrate that vertical equilibrium can be achieved for the assumed pressure distributions and actions on the wall.

(b)

Verification of vertical equilibrium may be achieved by reducing the wall friction parameters.

(c)

Retaining walls should be designed in such a way that there are visible signs of the approach of an ultimate limit state. The design should prevent brittle failure of the structure, e.g. sudden collapse without conspicuous preliminary deformations.

(d)

A critical limit state should be considered to occur if the wall has displaced enough to cause damage to nearby structures or services. Although collapse of the wall may not be imminent, the degree of damage may considerably exceed a serviceability limit state in the supported structure.

(e)

The design methods and partial factor values recommended by “EN19971:2004+A1:2013” are usually sufficient to prevent the occurrence of ultimate limit states in nearby structures, provided that the soils involved are of at least medium density or firm consistency and adequate construction methods and sequences are adopted. Special care should be taken, however, with some highly over-consolidated clay deposits in which large at rest horizontal stresses may induce substantial movements in a wide area around excavations.

(f)

The complexity of the interaction between the ground and the retaining structure sometimes makes it difficult to design a retaining structure in detail before the actual execution starts. In this case, use of the observational method for the design should be considered. The observational method consists of setting criteria enabling monitoring during construction, allowing necessary corrective actions to be taken to rectify the design. Hence, the following requirements shall be set before construction:

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(g)

(i)

Acceptable limits of behaviour

(ii)

The range of potential behaviour shall be analysed showing acceptable probability that the actual behaviour will be within the acceptable limits

(iii)

A plan of monitoring shall be established (including necessary instruments and procedures) enabling the comparison of the actual behaviour to the acceptable limits. The monitoring shall allow early detection of nonconformities, allowing enough time for corrective actions to be taken successfully.

(iv)

A list of contingency actions shall be established which could be used if the actual observed behaviour is outside of the acceptable limits.

The effects of constructing the wall, including: (i)

The provision of temporary support to the sides of excavations;

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(ii)

The changes of in situ stresses and resulting ground movements caused both by the wall excavation and its construction;

(iii)

Disturbance of the ground due to driving or boring operations;

(iv)

Provision of access for construction;

The required degree of water tightness of the finished wall;

(i)

The practicability of constructing the wall to reach a stratum of low permeability, so forming a water cut-off. The resulting equilibrium ground-water flow problem shall be assessed;

(j)

The practicability of forming ground anchorages in adjacent ground;

(k)

The practicability of excavating between any propping of retaining walls;

(l)

The ability of the wall to carry vertical load;

(m)

The ductility of structural components;

(n)

Access for maintenance of the wall and any associated drainage measures;

(o)

The appearance and durability of the wall and any anchorages;

(p)

For sheet piling, the need for a section stiff enough to be driven to the design penetration without loss of interlock;

(q)

The stability of borings or slurry trench panels while they are open;

(r)

For fill, the nature of materials available and the means used to compact them adjacent to the wall.

(s)

Drainage systems

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(ii)

It shall be demonstrated both by comparable experience and by assessment of any water discharge that the drainage system will operate adequately without maintenance.

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(i)

The quantities, pressures and eventual chemical content of any water discharge should be taken into account.

5.5

DETERMINATION OF EARTH PRESSURES

5.5.1

General

1

The Determination of the earth pressures shall take into account the acceptable mode and amount of any movement and strain, which may occur at the limit state under consideration.

2

In the following context the words "earth pressure" should also be used for the total earth pressure from soft and weathered rocks and should include the pressure of ground-water.

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3

Calculations of the magnitudes of earth pressures and directions of forces resulting from them shall take account of the issues highlighted under paragraph “5.3.3”.

4

The amount of mobilized wall friction and adhesion should be considered as a function of: The strength parameters of the ground

(b)

The friction properties of the wall-ground interface

(c)

The direction and amount of movement of the wall relative to the ground

(d)

The ability of the wall to support any vertical forces resulting from wall friction and adhesion

A concrete wall or steel sheet pile wall supporting sand or gravel may be assumed to have a design wall ground interface parameter  d  k. cv ;d . k should not exceed 2/3 for precast

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concrete or steel sheet piling. For concrete cast against soil, a value of k = 1.0 may be assumed. For a steel sheet pile in clay under undrained conditions immediately after driving, no adhesive or frictional resistance should be assumed. Increases in these values may take place over a period of time. In the case of structures retaining rock masses, calculations of the ground pressures shall take into account the effects of discontinuities, with particular attention to their orientation, spacing, aperture, roughness and the mechanical characteristics of any joint filling material.

7

Account shall be taken of any swelling potential of the ground when calculating the pressures on the retaining structure.

5.5.2

At rest values of earth pressure

1

When no movement of the wall relative to the ground takes place, the earth pressure shall be calculated from the at rest state of stress. The determination of the at-rest state shall take into account the stress history of the ground.

5.5.3

Limiting values of earth pressure

1

Limiting values of earth pressures shall be determined taking into account the relative movement of the soil and the wall at failure and the corresponding shape of the failure surface.

5.5.4

Intermediate values of earth pressure

1

Intermediate values of earth pressure occur if the wall movements are insufficient to mobilize the limiting values. The determination of the intermediate values of earth pressure shall take into account the amount of wall movement and its direction relative to the ground.

2

The intermediate values of earth pressures may be calculated using, for example, various empirical rules, spring constant methods or finite element methods.

5.5.5

Compaction effects

1

The determination of earth pressures acting behind the wall shall take into account the additional pressures generated by any placing of backfill and the procedures adopted for its compaction.

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WATER PRESSURES

1

Determination of characteristic and design water pressures shall take account of water levels both above and in the ground.

2

When checking the ultimate and serviceability limit water pressures shall be accounted for in the combinations of actions considering the possible risks of flooding or change in groundwater levels from either sides of the retaining structure.

3

For structures retaining earth of medium or low permeability (silts and clays), water pressures should normally be assumed to act behind the wall. Unless a reliable drainage system is installed, or infiltration is prevented, the values of water pressures should normally correspond to a water table at the surface of the retained material.

4

Where sudden changes in a free water level may occur, both the non-steady condition occurring immediately after the change and the steady condition shall be examined.

5

Where no special drainage or flow prevention measures are taken, the possible effects of water-filled tension or shrinkage cracks shall be considered.

5.7

ULTIMATE LIMIT STATE DESIGN

5.7.1

General

1

The design of retaining structures shall be checked at the ultimate limit state for the design situations appropriate to that state, as specified in 5.3.3, using the design actions or action effects and design resistances.

2

All relevant limit modes shall be considered. These will include, as a minimum, limit modes of the types illustrated in Figures 5.1 to 5.6 for the most commonly used retaining structures.

3

Calculations for ultimate limit states shall establish that equilibrium can be achieved using the design actions or effects of actions and the design strengths or resistances. Compatibility of deformations shall be considered in assessing design strengths or resistances.

5.7.2

Overall stability

1

Principles and calculations should be used as appropriate to demonstrate that an overall stability failure will not occur and that the corresponding deformations are sufficiently small taking into account progressive failure and liquefaction into account as relevant.

5.7.3

Foundation failure of gravity walls

1

The principles of foundation design shall be used as appropriate to demonstrate that a foundation failure is sufficiently remote and that deformations will be acceptable. Both bearing resistance and sliding shall be considered. Failure modes shown in Figure 5.2 should be verified as a minimum.

5.7.4

Rotational failure of embedded walls

1

It shall be demonstrated by equilibrium calculations that embedded walls have sufficient penetration into the ground to prevent rotational failure. As a minimum, limit modes of the types illustrated in Figure 5.3 should be considered.

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5.6

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The design magnitude and direction of shear stress between the soil and the wall shall be consistent with the relative vertical displacement, which would occur in the design situation.

5.7.5

Vertical failure of embedded walls

1

It shall be demonstrated that vertical equilibrium can be achieved using the design soil strengths or resistances and design vertical forces on the wall. As a minimum, the limit mode of the type illustrated in Figure 5.4 should be considered.

2

Where downward movement of the wall is considered, upper design values shall be used in the calculation of pre-stressing forces, such as those from ground anchorages, which have a vertical downward component. The design magnitude and direction of shear stress between the soil and the wall shall be consistent with the check for vertical and rotational equilibrium. If the wall acts as the foundation for a structure, vertical equilibrium shall be checked using the principles of Pile Foundations Design.

5.7.6

Structural design of retaining structures

1

Retaining structures, including their supporting structural elements such as anchorages and props, shall be verified against structural failure in accordance with EN1997-1:2004+A1:2013 “2.4 Geotechnical Design by Calculation” and EN1992, EN1993, EN1995 and EN1996. As a minimum, limit modes of the types illustrated in Figure 5.5 should be considered.

5.7.7

Failure by pull-out of anchorages

1

It shall be demonstrated that equilibrium can be achieved without pull-out failure of ground anchorages. Anchors shall be designed in accordance with Anchorage Design procedures with minimum the limit modes of the types illustrated in Figure 5.6 (a, b) should be considered. For dead-man anchors, the failure mode illustrated in Figure 5.6 (c) should also be considered.

5.8

SERVICEABILITY LIMIT STATE DESIGN

5.8.1

General

1

The design of retaining structures shall be checked at the serviceability limit state using the appropriate design situations as specified in 5.3.3. The assessment of design values of earth pressures should take account of the initial stress, stiffness and strength of the ground and the stiffness of the structural elements.

2

The design values of earth pressures should be derived taking account of the allowable deformation of the structure at its serviceability limit state. These pressures need not necessarily be limiting values.

5.8.2

Displacements

1

Limiting values for the allowable displacements of walls and the ground adjacent to them shall be established for a particular deformation is the value at which a serviceability limit state, such as unacceptable cracking or displacement of adjacent structures or utilities, is deemed to occur. This limiting value shall be agreed during the design, taking into account the tolerance to displacements of supported structures and services.

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2

If the initial cautious estimate of displacement exceeds the limiting values, the design shall be justified by a more detailed investigation including displacement calculations.

3

It shall be considered to what extent variable actions, such as vibrations caused by traffic loads behind the retaining wall, contribute to the wall displacement.

4

Displacement calculations should also be considered in the following cases: (a)

where the wall retains more than 6m of cohesive soil of low plasticity,

(b)

where the wall retains more than 3m of soils of high plasticity;

(c)

where the wall is supported by soft clay within its height or beneath its base.

Displacement calculations shall take into account the stiffness of the ground and structural elements and the sequence of construction.

6

The effect of vibrations on displacements shall be considered with regard to the following:

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Foundations for structures subjected to vibrations or to vibrating loads shall be designed to ensure that vibrations will not cause excessive settlements.

(b)

Precautions should be taken to ensure that resonance will not occur between the frequency of the dynamic load and a critical frequency in the foundation-ground system, and to ensure that liquefaction will not occur in the ground.

(c)

Vibrations caused by earthquakes shall be considered using the guidelines of the designated section of the QCS.

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(a)

Figure 5.1 – Examples of Limit Modes for Overall Stability of Retaining Structures (EN 1997-1:2004+A1:2013)

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Figure 5.2 – Examples of Limit Modes for Foundation Failures of Gravity Walls (EN 1997-1:2004+A1:2013)

Figure 5.3 – Examples of Limit Modes for Rotational Failures of Embedded Walls (EN 1997-1:2004+A1:2013)

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Figure 5.4 – Example of a Limit Mode for Vertical Failure of Embedded Walls (EN 1997-1:2004+A1:2013)

Figure 5.5 – Examples of Limit Modes for Structural Failure of Retaining Structures (EN 1997-1:2004+A1:2013)

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Figure 5.6 – Examples of Limit Modes for Failure by Pull-out of Anchoes (EN 1997-1:2004+A1:2013)

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END OF PART

QCS 2014

Section 05: Concrete Part 01: General

Page 1

GENERAL------------------------------------------------------------------------------------------------------------ 2

1.1 1.1.1 1.1.2 1.1.3 1.1.4

INTRODUCTION --------------------------------------------------------------------------------------------------- 2 Scope ----------------------------------------------------------------------------------------------------------------- 2 References----------------------------------------------------------------------------------------------------------- 2 Definitions ------------------------------------------------------------------------------------------------------------ 3 Approved Products ------------------------------------------------------------------------------------------------ 4

1.2 1.2.1 1.2.2 1.2.3 1.2.4

IMPLEMENTATION ----------------------------------------------------------------------------------------------- 4 Approved Installers ------------------------------------------------------------------------------------------------ 4 Field Quality Control ----------------------------------------------------------------------------------------------- 4 Rejected materials ------------------------------------------------------------------------------------------------- 5 Records --------------------------------------------------------------------------------------------------------------- 5

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Section 05: Concrete Part 01: General

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GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section includes the requirements for concrete work for pipelines, roadworks, runways, structures, water retaining structures, foundations and bases for structures and equipment.

2

This Part includes relevant standards, definitions, abbreviations, and requirements for testing facilities, rejected materials, and record keeping.

3

Related Sections are as follows:

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Aggregates Cementitious Materials Water Admixtures Property Requirements Concrete Plants Transportation and Placing of Concrete Formwork Curing Reinforcement Construction Joints Inspection and Testing of Hardened Concrete Protective Coatings to Concrete Hot Weather Concrete Miscellaneous Precast Concrete Prestressed Concrete Water Retaining Structures

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This Section: Part 2, Part 3, Part 4, Part 5, Part 6, Part 7, Part 8, Part 9, Part 10, Part 11, Part 12, Part 13, Part 14, Part 15, Part 16, Part 17, Part 18, Part 19,

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Section 1, Section 2, Section 4, Section 6, Section 8, Section 9,

General Quality Assurance and Quality Control Foundations and Retaining Structures Roadworks Drainage Works Mechanical and Electrical Equipment

1.1.2

References

1

The following standards are referred to in this Part: ASTM C31 ..................Standard Practice for Making and Curing Concrete Test Specimens in the Field ASTM C39 ..................Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens ASTM C143 ................Standard Test Method for Slump of Hydraulic-Cement C Concrete ASTM C1064 ..............Standard Test Method for Temperature of Freshly Mixed HydraulicCement Concrete

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Section 05: Concrete Part 01: General

Page 3

BS 6100, ....................Glossary of Building and civil engineering terms BS EN 932-1 ..............Tests for general properties of aggregates. Methods for sampling BS EN 932-2 ..............Tests for general properties of aggregates. Methods for reducing laboratory samples BS EN 12350-1 ..........Method of sampling fresh concrete in site BS EN 12350-2 ..........Testing fresh concrete. Slump-test BS EN 12390-1 ..........Shape, dimensions and other requirements for specimens and moulds BS EN 12390-2 .......... Making and curing specimens for strength tests GSO ISO 1920-1 ........Testing of concrete —Part 1: Sampling of fresh concrete GSO ISO 1920-2 ........Testing of concrete – Part 2: Properties of fresh concrete GSO ISO 1920-3 ........Testing of concrete – Part 3: Making and curing test specimens Definitions

1

Definitions used in this Section.

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1.1.3

The following are terms and abbreviations used:

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degree Celsius calorie centimetre day Characteristic compressive strength of concrete determined by testing cylinders Compressive strength of concrete determined by testing cylinders Characteristic compressive strength of concrete determined by testing cubes Compressive strength of concrete determined by testing cubes Mean compressive strength of concrete Mean compressive strength of concrete at the age of (j) days ground granulated blast furnace slag guaranteed ultimate tensile strength hour kilogram kilojoule kilonewton litre metre square metre cubic metre milligram minute millimetre square millimetre months mega Pascal kilo Pascal moderate sulphate resisting Portland cement ordinary Portland cement pulverised fuel ash polyvinylchloride second silica fume sulphate resisting Portland cement

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C cal cm d fck,cyl fc,cyl fck,cube fc,cube fcm fcm,j GGBS GUTS h kg kJ kN l m 2 m 3 m mg min mm 2 mm months MPa kPa MSRPC OPC PFA PVC s SF SRPC

QCS 2014

ton ppm

1000 kg part per million

micron

10

µm

10 meter

Page 4

-6 -6

Reference to a technical society, institution, association or governmental authority is made in accordance with the following abbreviations.

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American Association of State Highway and Transportation Officials American Concrete Institute American Society for Testing and Materials American Welding Society British Standard British Standard Code of Practice British Standards Institution Cement and Concrete Association Construction Industry Research and Information Association Concrete Reinforcing Steel Institute Concrete Society Deutsches Institut fur Normung e.V. Euro Norm Federal Highway Authority GCC Standardization Organization Institution of Civil Engineers International Organization for Standardization Prestressed Concrete Institute Qatar Construction Specifications Qatar Standards United Kingdom Department for Transport

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AASHTO ACI ASTM AWS BS BSCP BSI C & CA CIRIA CRSI CS DIN EN FHWA GSO ICE ISO PCI QCS QS UK DfT Products

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Section 05: Concrete Part 01: General

Approved Products

1

The contract specific documentation may identify approved products and approved or prequalified manufacturers and suppliers of products used in concrete work.

1.2

IMPLEMENTATION

1.2.1

Approved Installers

1

The contract specific documentation may identify approved or prequalified providers of concrete construction services.

1.2.2

Field Quality Control

1

The Contractor shall carry out the test procedures required by this Section and any other tests and test procedures as directed by the Engineer from time to time. The test procedures shall be carried out using the facilities of an approved independent testing laboratory.

2

Supply, storage, sampling and testing of all materials shall be the responsibility of the Contractor, unless the Contract specifies otherwise.

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1.1.4

QCS 2014

Section 05: Concrete Part 01: General

Page 5

The Engineer may also require the Contractor to take samples of materials and deliver them to the Central Materials Laboratory for additional tests to be carried out by the Employer. Sampling procedures shall be in accordance with BS EN 932 or relevant ASTM Standards, and sample sizes shall conform to the requirements shown in Table 1.1.

4

The minimum equipment required for testing on Site is given in Table 1.2. This equipment shall be maintained on Site at all times during concreting operations together with the necessary scoops, buckets, sample containers, and other items required for sampling. The cube curing tank shall be located in an air-conditioned area as stated in part 06.

1.2.3

Rejected materials

1

Any material rejected by the Engineer, in particular cement which has deteriorated or aggregates which have segregated or become contaminated, shall be immediately removed from the Site.

1.2.4

Records

1

The Contractor shall maintain on the Site full records of all work carried out accurately related to the location of the work on site, which shall include:

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formwork props were fully removed all cubes and other tests

(c)

daily maximum and minimum temperatures.

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(b)

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One copy of all test results shall be sent to the Engineer immediately upon completion of the tests

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Table 1.1 Sampling Procedure and Minimum Sample Sizes for Central Materials Laboratory

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Cement

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Material

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the time and date when all concrete was poured, formwork removed and when

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(a)

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Aggregate

Reinforcement Water

Test

Min. Sample

Full range of tests

Composite sample of 7 kg taken from at least 12 bags

Full range of tests

200 kg

Sieve analysis Chemical analysis Soundness test Water absorption Particle density Flakiness index Fines content LA Abrasion value

50 kg

Tensile test

500 mm

Bend test

300 mm

Full range of tests

5 litres

QCS 2014

Section 05: Concrete Part 01: General

Page 6

Table 1.2 Minimum Testing Equipment for Each Site* Test

Equipment to be Provided

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ASTM C1064

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Cube curing BS EN 12390-2 or GSO ISO 1920-3 or ASTM C39

Hessian or sacking, impervious sheet Maximum/minimum thermometer Waterproof marking crayon/paint or equivalent Curing tank (in air conditioned room) Supply of packing materials for sending cubes to commercial laboratory Concrete thermometer

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Cube making BS EN 12390-1 and BS EN 12350-1:2000 or GSO ISO 1920-1 and GSO ISO 1920-3 or ASTM C31 and C39

Slump cone with base plate Compacting rod, circular cross-section and round ends Remixing container, 300 mm ruler, moist cloth Scoop and shovel Timer 100 or 150 mm cubical or cylindrical 1 moulds Compacting rod or bar Set of tools for assembling and stripping moulds Remixing container Trowel, Scoop, Shovel and Mallet Mould release agent in closed container with brush

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Slump test BS EN 12350-2 or GSO ISO 1920-2 or ASTM C143

Minimum Number Required 1 1 1 1 1

6 1 1 1 lot 1 1 1 Lot 1

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1 - The use of 100 mm cube and cylinder moulds are permitted when the nominal maximum aggregate size is not greater than 20mm

END OF PART

QCS 2014

Section 05: Concrete Part 10: Curing

Page 1

CURING .................................................................................................................. 2

10.1 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 2 Storage 2

10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8 10.2.9 10.2.10 10.2.11 10.2.12

CURING .................................................................................................................. 2 General 2 Water for Curing 3 General Requirements 3 Curing of Formed Surfaces 4 Curing of Unformed Surfaces 4 Moisture Curing 4 Moisture Retaining Cover Curing 4 Liquid Membrane Curing 5 Steam Curing 5 Pavements and other slab on ground 5 Buildings, bridges, and other structures 5 Mass concrete 6

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QCS 2014

Section 05: Concrete Part 10: Curing

Page 2

10

CURING

10.1

GENERAL

10.1.1

Scope

1

This part covers the requirements for the curing of concrete.

2

Related Sections and Parts are as follows:

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References AASHTO M 148.74, ...Liquid Membrane Curing

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ACI 308 ..................... Guide to Concrete Curing

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10.1.2

.

This Section Part 1, ............ General Part 4, ............ Water Part 6, ............ Property Requirements Part 15, ........... Hot Weather Concreting Part 16, ........... Miscellaneous.

ASTM C 309, .............. Specification for Liquid Membrane-forming Compounds for Curing Concrete

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BS 7542,..................... Method of test for curing compounds for concrete. Quality management systems -- Requirements

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ISO 9001: 2008 Submittals

1

The Contractor shall submit to the Engineer the proposed method of curing for approval.

10.1.4

Quality Assurance

1

The Contractor shall submit to the Engineer for approval the details of proposed curing media, if any. Details shall include chemical tests for the product in accordance with BS 7542 and details of quality assurance procedures, including ISO 9001 certificates if held.

10.1.5

Storage

1

Chemical curing compounds shall be stored in accordance with manufacturer's recommendations.

10.2

CURING

10.2.1

General

1

The Contractor shall ensure that curing is provided for 24 hours per day including holidays and that all related necessary plant and labour resources are also available.

2

Special attention shall be given to the curing of vertical and overhanging surfaces to ensure satisfactory curing.

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10.1.3

QCS 2014

Section 05: Concrete Part 10: Curing

Page 3

The Contractor shall adopt curing measures that preclude the possibility of thermal shock to the concrete during curing. This may be achieved by ensuring that the temperature of the water used for curing does not differ from that of the concrete by more than 15 C.

4

Curing shall continue for at least 7 days and until it attains an in-place compressive strength of the concrete of at least 70% of the specified compressive or flexural strength, whichever period is longer. Curing shall not stop unless otherwise approved by the Engineer.

5

When low W/cm is used, the concrete shall be preferably cured by water.

10.2.2

Water for Curing

1

Water used for any curing purposes shall conform to the requirements of Part 4 of this Section.

10.2.3

General Requirements

1

Freshly placed concrete shall be protected from sun, wind, rain, exposure and excessive drying out.

2

All concrete shall be cured for a period of time required to obtain the full specified strength, but not less than seven consecutive days. The method of curing shall be by water for the first seven days and by water or membrane until the concrete has reached the full specified strength.

3

For mixtures with a low to zero bleeding rate, or in the case of aggressively evaporative environments, or both, the curing shall start at early anytime between placement and final finishing of the concrete. The curing shall be by reducing the moisture loss from surface using fogging systems and the use of evaporation reducers such as monomolecular water curing compound.

4

Exposed surfaces shall be protected from air blown contamination until 28 d after the concrete is placed.

5

The method of curing shall ensure that sufficient moisture is present to complete the hydration of the cement, and shall be to the approval of the Engineer. The method of curing shall not:

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(a)

disfigure permanently exposed surfaces

(b)

affect bonding of subsequent coatings

(c)

increase the temperature of the concrete.

6

During the curing period, exposed concrete surface shall be protected from the direct rays of the sun.

7

When liquid membrane is used to cure the concrete, it shall not be applied if bleeding water is present on the surface of the concrete.

8

The applied film of the liquid membrane shall be continuous and protected from rain and any damages for at least 14 days.

QCS 2014

Section 05: Concrete Part 10: Curing

Page 4

Curing of Formed Surfaces

1

Formed surfaces, including the underside of beams, girders, supported slabs and the like, by moist curing with the forms in place for the full curing period, or until the forms are removed.

2

When the forms are stripped, curing shall continue by any approved method.

3

When liquid membrane curing is used, it shall be applied immediately after de-shuttering. In such cases the concrete surface shall be prepared prior to the application of the membrane as recommended by the manufacturer.

4

Water curing is not required when liquid membrane is used.

10.2.5

Curing of Unformed Surfaces

1

Unformed surfaces shall be protected as soon as possible after the concrete has been placed by polythene sheeting. When sufficiently hard, hessian or other absorbent material shall be placed on the concrete surface and shall be kept wet for the required period. The hessian shall be overlaid with a sheet of 1000 gauge polythene to assist in the retention of water. Alternatively a curing method approved by the Engineer may be used.

2

Once the concrete is sufficiently hard, the top exposed surface of walls, columns and beams shall be water cured and covered with wet hessian for the required curing period.

10.2.6

Moisture Curing

1

Moisture curing shall be performed by :

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10.2.4

covering the surface of the concrete with water and keeping it continuously wet

(b)

continuous use of fine fog water sprays

(c)

covering the surface with a saturated absorptive cover and keeping it continuously wet.

(d)

Burlap, cotton mats, and other absorbent materials can be used to hold water on horizontal or vertical surfaces.

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Wet straw or hay can be used for wet-curing small areas, but there is the danger that wind might displace it unless it is held down with screen wire, burlap, or other means

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(e)

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(a)

2

Where method (a) is employed, the bunds used shall not be made from fill from excavations or any other areas where there is the possibility of chloride contamination.

10.2.7

Moisture Retaining Cover Curing

1

The concrete surface shall be covered with a suitable absorptive covering, such as wet hessian.

2

The absorptive covering shall be overlaid with a 1000 gauge polythene sheet.

3

The cover shall be in the widest practical widths and shall have 100 mm side and end laps.

4

Any penetrations or tear in the covering shall be shall be repaired with the same material and waterproof tape.

QCS 2014

Section 05: Concrete Part 10: Curing

Page 5

Liquid Membrane Curing

1

Liquid membrane curing shall be in accordance with the requirements of BS 7542, ASTM C 309 or C1315 when tested at the rate of coverage use on the job.

2

ASTM C 156 shall be used as a test method to evaluate water-retention capability of liquid membrane forming compounds. ASTM C 1151 provides an alternative laboratory test for determining the efficiency of liquid membrane-forming compounds.

3

Membrane forming curing compounds shall be applied in accordance with the manufacturer's recommendations immediately after any water sheen which may develop after finishing has disappeared from the surface and within 2 h of stripping formwork on formed surfaces.

4

Membrane forming curing compounds shall not be used on surfaces against which additional concrete or other material is to be bonded unless:

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10.2.8

it is proven that the curing compound will not prevent bond, or

(b)

positive measures are taken to remove it completely from those areas which are to receive bonded applications

(c)

on fair faced concrete surfaces.

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(a)

Steam Curing

1

An enclosure shall be formed around the concrete using tarpaulin or other suitable means.

2

Application of steam shall not be commenced until at least 2 h after final placement of concrete.

3

Steam shall be applied at a temperature between 65 C and 80 C.

4

Excessive rates of heating and cooling shall be prevented during steam curing and temperatures in the enclosure shall not be allowed to increase or decrease by more than 22 C per hour.

5

The maximum steam temperature shall be maintained in the enclosure until concrete has reached its specified strength.

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10.2.9

10.2.10 Pavements and other slab on ground 1

Curing shall ensure that no plastic shrinkage crack will occur, this can be done by protective measures such as sun shields, wind breaks, evaporation reducers, or fog spraying should be initiated immediately to reduce evaporation.

2

Mats used for curing can either be left in place and kept saturated for completion of the curing, or can be subsequently replaced by a liquid membrane-forming curing compound, plastic sheeting, reinforced paper, straw, or water

10.2.11 Buildings, bridges, and other structures 1

Additional curing shall be provided after the removal of forms

QCS 2014

Section 05: Concrete Part 10: Curing

Page 6

2

After the concrete has hardened and while the forms are still in place on vertical and other formed surfaces, form ties may be loosened when damage to the concrete will not occur and water applied to run down on the inside of the form to keep the concrete wet.

3

Care shall be taken to prevent thermal shock and cracks when using water that is significantly cooler than the concrete surface. Curing water should not be more than about o 11 C cooler than the concrete.

4

Immediately following form removal, the surfaces shall be kept continuously wet by a water spray or water-saturated fabric or until the membrane-forming curing compound is applied. Curing

10.2.12 Mass concrete Mass concrete is often cured with water for the additional cooling benefit in warm weather; however, this can be counterproductive when the temperature gradient between the warmer interior and the cooler surface generates stress in the concrete.

2

Horizontal or sloping unformed surfaces of mass concrete can be maintained continuously wet by water spraying, wet sand, or water saturated fabrics.

3

For vertical and other formed surfaces, after the concrete has hardened and the forms are still in place, the form ties may be loosened and water supplied to run down the inside of the form to keep the concrete wet

4

Care shall be taken to prevent thermal shock and cracks when using water that is significantly cooler than the concrete surface. Curing water should not be more than about o 11 C cooler than the concrete.

5

Curing shall start as soon as the concrete has hardened sufficiently to prevent surface damage.

6

For unreinforced massive sections not containing ground granulated blast-furnace slag or pozzolan, curing shall be continued for not less than 2 weeks. Where ground granulated blast-furnace slag or pozzolan is included in the concrete, the minimum time for curing shall be not less than 3 weeks.

7

For reinforced mass concrete, curing shall be continuous for a minimum of 7 days or until 70% of the specified compressive strength is obtained, if strength is the key concrete performance criterion. For construction joints, curing shall be continued until resumption of concrete placement or until the required curing period is completed.

8

Curing shall not stop until favourable differential temperature is attained and at the approval of the Engineer.

9

For mass concrete, thermocouples shall be used to monitor the temperature differential of the concrete.

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END OF PART

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 1

REINFORCEMENT ................................................................................................. 2

11.1 11.1.1 11.1.2 11.1.3 11.1.4 11.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 3 Quality Assurance 3 Delivery Storage and Handling 3

11.2 11.2.1 11.2.2 11.2.3

REINFORCING MATERIALS .................................................................................. 4 Reinforcing Bars 4 Welded Steel Wire Fabric 4 Tie Wire 5

11.3 11.3.2 11.3.3

INSPECTION, SAMPLING AND TESTING.............................................................. 5 Sampling 5 Testing 6

11.4

CUTTING AND BENDING OF REINFORCEMENT ................................................. 6

11.5 11.5.1 11.5.2 11.5.3 11.5.4 11.5.5 11.5.6 11.5.7 11.5.8 11.5.9 11.5.10 11.5.11

FIXING OF REINFORCEMENT ............................................................................... 6 General 6 Welding 7 Mechanical Splices 8 Bundling and Splicing of Bundled Bars 8 Examination 8 Electrolytic Action 8 Cover 8 Reinforcement 8 Forms and Linings 9 Tanking 9 Adjustment and Cleaning 9

11.6 11.6.2 11.6.3 11.6.4

PROTECTIVE COATINGS TO REINFORCEMENT ................................................ 9 Epoxy Coated Reinforcing Bars 9 Handling of Epoxy Coated Reinforcement 11 Testing of Epoxy Coated Reinforcement 11

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QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 2

11

REINFORCEMENT

11.1

GENERAL

11.1.1

Scope

1

This Part includes tension, compression, and temperature reinforcing steel, including welded wire fabric, and epoxy coated reinforcing. The work includes furnishing, fabrication, and placement of reinforcement for cast-in-place concrete, including bars, welded wire fabric, ties, and supports.

2

Related Sections and Parts are as follows: This Section

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References

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ASTM A416/A416M....Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete

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ASTM 615/615M ........Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

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ASTM A706, ...............Specification for Low-allow Steel Deformed Bars for Concrete Reinforcement

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ASTM A881/A881M ...Standard Specification for Steel Wire, Deformed, Stress-Relieved or Low-Relaxation for Prestressed Concrete Railroad Ties Filled

Epoxy-Coated

Seven-Wire

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ASTM A882/A882M- ..Standard Specification for Prestressing Steel Strand

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ASTM A955/A955M-14 Standard Specification for Deformed and Plain Stainless-Steel Bars for Concrete Reinforcement

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ASTM A1035/ A1035M Deformed and Plain, Low-carbon, -Chromium, -Steel Bars for Concrete Reinforcement:

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Part 16 ............. Miscellaneous Part 17 ............. Structural Precast Concrete

BS 4449 : 2005...........Specification for Carbon steel bars for the reinforcement of concrete BS 4482: 2005,...........Specification for Cold reduced steel wire for the reinforcement of concrete BS 4483: 2005............Steel fabric for the reinforcement of concrete BS 5896,.....................Specification for high tensile steel wire and strand for the prestressing of concrete. BS 8666,.....................Specification for scheduling, dimensioning, bending and cutting of steel reinforcement for concrete EN 1011, ....................Welding. Recommendation for welding of metallic materials EN 1992-1-1 Eurocode 2: Design of concrete structures. General rules and rules for buildings ISO 14654, .................Epoxy- coated steel for the reinforcement of concrete ISO 14656, .................Epoxy powder and sealing material for the coating of steel for the reinforcement of concrete

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 3

ISO 3766 ...................Construction drawings -- Simplified representation of concrete reinforcement ISO 9000, ..................Quality management systems. Fundamentals and vocabulary QS ISO 6935-1:2007, .Steel for the reinforcement of concrete -Part 1: Plain bars QS ISO 6935-2:2007 ..Steel for the reinforcement of concrete Part 2: Ribbed bars QS ISO 6935-3:2007 ..Steel for the reinforcement of concrete Part 3: Welded fabric Submittals

1

Product data including the manufacturer’s specification and installation instructions for proprietary materials and reinforcement accessories shall be provided.

2

The Contractor shall submit the manufacturer’s records of chemical and physical properties of each batch of billet steel bars and a certificate that the respective material furnished meets the requirements for the steel reinforcement specified. The manufacturer’s records shall include certificates of mill as well as analysis, tensile and bend tests of the reinforcement.

3

Three copies of the steel test report shall be furnished with each consignment of steel reinforcement. The steel shall be tagged and cross-referenced with mill certificates.

11.1.4

Quality Assurance

1

The Contractor shall submit to the Engineer for source approval details of the proposed source of supply of the reinforcement. Details shall include chemical and physical tests for the past six months production and any independent test results for this period. Details of quality assurance procedures, including ISO 9000 certificate if held, shall also be given.

2

The Contractor shall furnish the Engineer with a certificate of compliance for each shipment of epoxy coated bars. The certificate of compliance shall state that representative samples of the epoxy coated bars have been tested and that the test results comply with the requirements herein specified. Test results shall be retained by the Contractor for seven years. A complete set of test results shall also be handed to the client at the completion of reinforcement works, and shall be made available to the Engineer upon request.

11.1.5

Delivery Storage and Handling

1

On delivery, bars in each lot shall be legibly tagged by the manufacturer. The tag shall show the manufacturer’s test number and lot number and other applicable data that will identify the material with the certificate issued for that lot of steel. The fabricator shall furnish three copies of a certification which shows the batch number or numbers from which each size of bar in the shipment was fabricated.

2

Storage of reinforcement shall be on suitable structures a minimum of 450 mm above the ground surface to prevent damage and accumulation of dirt, rust and other deleterious matter. Storage facilities shall be such as to permit easy access for inspection and identification. Reinforcement bundles shall be clearly tagged with bar schedule and bar mark reference.

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11.1.3

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 4

3

The reinforcement shall not be roughly handled, dropped from a height, or subjected to shock loading or mechanical damage. Steel reinforcing bars shall be kept clean and shall be free from pitting, loose rust, mill scale, oil, grease, earth, paint, or any other material which may impair the bond between the concrete and the reinforcement. The reinforcement shall be covered to ensure protection from wind blown dust, condensation and other deleterious materials.

11.2

REINFORCING MATERIALS

11.2.1

Reinforcing Bars

1

Reinforcement shall be from an acceptable source. All steel reinforcement bars shall comply with the requirements of: QS ISO 6935 with minimum grade of B500 MPa or

(ii)

BS 4449 with minimum grades of B500 MPa ; or..

(iii)

ASTM A615 / A615M with minimum grade of 75 [520MPa]; or

(iv)

Deformed and Plain, Low-carbon-Chromium-Steel Reinforcement: ASTM A1035/ A1035M

(v)

ASTM A1022/A1022M-14a Standard Specification for Deformed and Plain Stainless Steel Wire and Welded Wire for Concrete Reinforcement

(vi)

ASTM A955/A955M-14 Standard Specification for Deformed and Plain Stainless-Steel Bars for Concrete Reinforcement

(vii)

Other types of reinforcement, as approved by Qatar Standards

Bars

for

Concrete

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(i)

As per project design, other steel grades of less than B500MPa may be used only for stirrups and secondary reinforcement of diameter of 10mm or less.

3

If the steel has excessive surface rust, dust or other deleterious material then the steel shall be sand blasted. Sand for blasting shall not contain materials deleterious to the durability of the reinforcement or concrete. Dune sand shall not be used for the sandblasting of reinforcement.

4

For extreme exposure class X5; protection measures such as epoxy coated bars; Lowcarbon-chromium-steel bars; or Stainless Steel may be considered.

11.2.2

Welded Steel Wire Fabric

1

Steel fabric reinforcement shall comply with the requirements of QS ISO 6935-3 or BS 4483 and shall be delivered to Site in flat mats.

2

Welded intersections shall not be spaced more than:

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(a)

300 mm for plain round bars

(b)

400 mm apart for deformed high yield bars in direction of calculated stress except when used as stirrups.

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 5

Tie Wire

1

Tie wire shall conform to the requirements of BS 4482.

2

1.6 mm black annealed mild steel shall be used for tie wire.

3

No wires smaller than size D-4 shall be used.

11.3

INSPECTION, SAMPLING AND TESTING

1

Inspection of reinforcing steel and the installation thereof will be conducted by the Engineer.

2

The Contractor shall give 24 hour notice to the Engineer before closing forms or placing concrete.

3

The Engineer may instruct the Contractor to break out and remove completely all sections of the work already constructed under any of the following circumstances:

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11.2.3

reinforcing steel sample under test fails to meet the specification requirements at any time

(b)

the Engineer considers that samples which were presented to him for test were not truly representative

(c)

a previously rejected reinforcing steel has been used in the Works.

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(a)

Sampling

1

Representative samples of all reinforcing steel proposed for use in the Works must be submitted by the Contractor, before work is commenced, to the Engineer for his written approval.

2

Manufacturer's certificates stating clearly for each sample: (a)

place of manufacture expected date and size of deliveries to site

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11.3.2

(c)

all relevant details of composition, manufacture, strengths and other quality of the steel.

3

The Engineer reserves the right to sample and inspect reinforcement steel upon its arrival at the work site.

4

Frequency of sampling and the method of quality control shall be in accordance with steel bars manufactured standard QS ISO 6935 or BS 4449 .

5

Where epoxy coated steel is used, a sample of the coating material shall be supplied with each batch in an airtight container and identified by the batch number.

6

Allow 14 days for Engineer’s review of samples.

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 6

Testing

1

Tests shall be carried out when directed by the Engineer.

2

Tests shall be carried out in accordance with QS ISO 6935 or BS 4449.

3

The following information shall be provided with each delivery of reinforcement: elastic limit

(b)

ultimate strength

(c)

stress/strain curve

(d)

cross-sectional area

(e)

deformation/bond characteristics of deformed bars.

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11.3.3

The Contractor shall allow for dimensions and weight measurements, tensile, bend and/ or rebend tests at own cost, for each size of bar to be used in the concrete construction.

5

Test results for each bar size shall be submitted to the Engineer three weeks before concrete work commences on Site.

6

Full testing shall be required if the source of supply of reinforcement changes, in which case the cost of such extra testing will be borne by the Contractor.

7

When any test results do not conform to the relevant standard the reinforcement steel shall be removed from the Site and all costs resulting therefrom shall be borne by the Contractor.

11.4

CUTTING AND BENDING OF REINFORCEMENT

1

Cutting and bending of reinforcement shall be in accordance with ISO 3766 or BS 8666 and shall be done without the application of heat. Bends shall have a substantially constant curvature. For epoxy coated steel the provisions of Clause 11.6.1 of this Part shall apply

2

Steel bars manufactured according to the approved ASTM standards shall be bent according to the same standard.

3

Reinforcement shall not be straightened or rebent without the approval of the Engineer. If permission is given to bend projecting reinforcement care shall be taken not to damage the concrete and to ensure that the radius is not less than the minimum specified in ISO 3766 or BS 8666.

11.5

FIXING OF REINFORCEMENT

11.5.1

General

1

All reinforcement shall be securely and accurately fixed in positions shown on the Drawings to ensure that the reinforcement steel framework as a whole shall retain its shape. The framework shall be supported to retain its correct position in the forms during the process of placing and consolidating the concrete.

2

The ends of all tying wires shall be turned into the main body of the concrete and not allowed to project towards the surface.

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Section 05: Concrete Part 11: Reinforcement

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3

No part of the reinforcement shall be used to support access ways, working platform or for the conducting of an electric current.

4

The Contractor’s specific attention is drawn to the following general requirements: (a)

lapped joints shall be as indicated on the Drawings and/or in accordance with the requirements of EN 1992-1-1 or BS 8666

(b)

hooks shall be semicircular with a straight length of at least: (i)

four bar diameters for mild steel

(ii)

six bar diameters for high yield steel.

Welding

1

Welding shall not be used unless authorised by the Engineer and recommended by the reinforcement manufacturer.

2

Where welding is approved it shall be executed under controlled conditions in a factory or workshop.

3

Welding shall not take place on site without the approval of the Engineer and unless suitable safeguards and techniques are employed and the types of steel employed have the required welding properties.

4

Welding if approved, may be used for:

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11.5.2

fixing crossing or lapping reinforcement in position

(b)

fixing bars to other steel members

(c)

structural welds involving transfer of loads between reinforcement or between bars and other steel members.

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The length of run deposited in a single pass shall not exceed five times the bar diameter. If a longer welded length is required, the weld shall be divided into sections with the space between runs made not less than five times the bar diameter.

6

Butt welds shall be formed by flash butt welding or metal-arc welding. Other methods may be approved, subject to their satisfactory performance in trial joints.

7

Metal-arc welding or electrical resistance welding may be used for fixing suitable steels or for lapped joints.

8

Flash butt welding shall be executed with the correct combination of flashing, heating, upsetting and annealing, using only machines which automatically control this cycle of operations.

9

Metal-arc welding shall comply with EN 1011 and the recommendations of the reinforcement manufacturer.

10

Welded joints shall not be made at bends in the reinforcement. Joints in parallel bars of principle reinforcement shall be staggered, unless otherwise approved. The distance between staggered joints shall be not less than the end anchorage length joints.

11

Weldable reinforcement where shown on the Drawings shall conform to ASTM A706.

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Section 05: Concrete Part 11: Reinforcement

Page 8

Mechanical Splices

1

Mechanical splices shall comply with EN 1992-1-1 or BS 8666, and shall be used as and where indicated on the Drawings.

2

Details of mechanical splices shall be submitted to the Engineer for approval.

11.5.4

Bundling and Splicing of Bundled Bars

1

Bundling and splicing of bundled bars shall be in accordance with EN 1992-1-1 or BS 8666.

2

Splicing, except where indicated on the Drawings or approved shop drawings, will not be permitted without the approval of the Engineer.

11.5.5

Examination

1

The Contractor shall notify the Engineer at least 24 hours before commencing the fixing of reinforcement in order to facilitate the inspection of formwork.

2

The Contractor shall ensure that areas to receive reinforcement are cleaned before fixing.

11.5.6

Electrolytic Action

1

Reinforcement shall not be fixed or placed in contact with non-ferrous metals.

11.5.7

Cover

1

Correct concrete cover to reinforcement shall be maintained with the aid of approved spacer pieces.

2

The cover shall not be less than given in Section 5 Part 6.

3

Spacers, chairs and other supports shall be provided as necessary to maintain the reinforcement in its correct position.

4

In a member where the nominal cover is dimensioned to the links, spacers between the links and formwork shall be the same dimension as the nominal cover.

5

Spacer bars shall be of the same diameter as longitudinal bars, but not less than 25 mm in diameter, and shall be fixed between two layers at 1.5 m centres except where bundled bars are detailed.

6

Spacers, chairs and other supports shall be made of concrete, plastic or other material to the approval of the Engineer. Where supports are made of concrete they shall have at least the same cube strength as the concrete in the host member.

11.5.8

Reinforcement

1

Placing of all reinforcement steel bars will be checked by the Engineer and in no case is concrete to be placed around any reinforcement steel that has not been approved by the Engineer. Insertion of bars into or the removal of bars from concrete already placed will not be permitted.

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11.5.3

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 9

2

Reinforcement steel temporarily left projecting from the concrete at the joints shall not be bent without the prior approval of the Engineer.

11.5.9

Forms and Linings

1

Damage to forms and linings shall be avoided.

11.5.10 Tanking 1

Reinforcement shall not be fixed until completion of placing tanking (membrane) protection.

11.5.11 Adjustment and Cleaning

.

Check position of reinforcement before and during placing concrete: pay particular attention to the position of top reinforcement in cantilever sections

(b)

ensure that reinforcement is clean and free from corrosive pitting, loose rust, loose mill scale, oil and other substances which may adversely affect reinforcement, concrete, or the bond between the two.

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1

Protect projecting reinforcement from the weather where rust staining of exposed concrete surfaces may occur.

3

At the time of concreting, all reinforcement steel shall have been thoroughly cleaned and freed from all mud, oil or any other coatings that might destroy or reduce the bond:

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clean all set or partially set concrete which may have been deposited thereon during the placing of a previous lift of concrete

(b)

all uncoated rust bars shall be again sand blasted and pressure washed.

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Immediately before concrete placing the reinforcing steel shall be washed thoroughly with high pressure potable water jets to remove any deposited salts.

11.6

PROTECTIVE COATINGS TO REINFORCEMENT

1

All the forgoing clauses of this part apply equally to epoxy coated reinforcing bars.

11.6.2

Epoxy Coated Reinforcing Bars

1

Reinforcing steel which are to be coated shall be free of slivers, scabs, excessive pitting, rust, grease, oil and other surface defects detrimental to proper coating.

2

The surface shall be prepared in accordance with ISO 14654.

3

Coating shall be applied to the cleaned surface as soon as possible after cleaning and before any visible oxidation to the surface occurs.

4

Reinforcing steel shall not have surface defects that would be detrimental to coating.

5

Coating material shall be epoxy resin powders as specified in ISO 14654 and ISO 14656 for coating of reinforcing bars and as follows:

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(a)

epoxy resin powders which do not meet the above requirements must be tested by an approved independent testing laboratory and accepted by the Engineer before use

QCS 2014

6

Section 05: Concrete Part 11: Reinforcement

Page 10

(b)

only fusion bonded epoxy-coated reinforcing steel will be accepted

(c)

no other means of epoxy coating will be approved.

Patching material shall be: (a)

furnished by the epoxy coating manufacturer

(b)

compatible with the coating

(c)

inert in concrete

(d)

suitable for repairs to the coated reinforcing bars to be made by the coating applicator and the Contractor at the project site.

Fabrication shall be performed before coating except as hereinafter specified for bent bars and straight bars less than 7.6 m long.

8

Bent reinforcing steel bars shall be coated after bending, unless the fabricator can show that satisfactory results can be obtained by coating before bending.

9

Any visible cracks in the coating on the outside of the bend or damage to coating resulting in debonding of the coating after bending shall be rejected.

10

Bars less than 7.6 m long may be sheared or sawn to length after coating, provided:

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end damage to coating does not extend more than 12 mm back

(b)

cut end is patched before any visible oxidation appears.

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(a)

Flame cutting will not be permitted.

12

Epoxy coating shall be checked visually after cure for continuity of coating and shall be free from holes, contamination, cracks and damaged areas.

13

There shall not be more than two holidays (pinholes not visually discernible) in any 300 mm of the epoxy coated bar.

14

A holiday detector shall be used in accordance with the manufacturer's instruction to check the epoxy coating for holidays. A 67.5 V detector such as the Tinker and Rasor Model M-1 or its approved equivalent shall be used.

15

Patching of holidays is not required if there are less than three holidays per 300 mm length. Bars having three or more holidays per 300 mm shall be cleaned and recoated or replaced as directed by the Engineer.

16

Epoxy coating film shall be cured and/or post cured to a fully cured condition. A representative proportion of each production lot shall be checked by the epoxy coating applicator, using the method most effective for measuring cure to ensure that the entire production lot of epoxy coating is supplied in the fully cured condition.

17

Contractor shall repair all coating damaged by fixtures used to handle or support the bars in the coating process as follows:

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11

(a)

patching shall be done as soon as possible and before visible oxidation occurs

(b)

excessive patching from other causes will not be permitted

QCS 2014

(c)

Section 05: Concrete Part 11: Reinforcement

Page 11

satisfactory correction shall consist of proper adjustment of process, and rerunning the bars through the plant.

The Engineer reserves the right for access to the epoxy coating applicator’s plant to witness epoxy coating processes for project work and to obtain specimens from test bars for any testing desired.

19

All chairs, tie wires and other devices used in connecting, supporting, securing or fastening epoxy coated reinforcement steel shall be made of or coated with a dielectric material.

20

Before the reinforcement is lowered into place and before placement of the concrete, the coated bars shall be inspected by the Engineer for damage to the epoxy coating.

21

Sheared ends of bars and other areas requiring limited repair due to scars and minor defects shall be repaired, using the specified patching or repair materials.

11.6.3

Handling of Epoxy Coated Reinforcement

1

Reinforcement steel bars shall be handled and stored in a manner to prevent damage to bars or, where used, the epoxy coating.

2

Bars, or where used epoxy coating, damaged in handling or other operations shall be satisfactorily repaired at no additional cost to the Employer.

3

Where epoxy coated bars are used all handling systems shall have plastic mandrel and padded contact areas wherever possible.

4

Where epoxy coated bars are used all bundling bands shall be padded.

5

All bundles shall be lifted with a strongback, multiple supports or a platform bridge so as to prevent bar to bar abrasion from sags in the bar bundle.

6

Bars or bundles shall not be dropped or dragged.

7

During vibration care shall be taken to ensure that the epoxy-coated reinforcement is not damaged by the pokers.

11.6.4

Testing of Epoxy Coated Reinforcement

1

Adhesion and flexibility of the epoxy coating shall be evaluated on test bars coated with each production lot.

2

At least 1 % of the length or 6 m, whichever is less, of each size of bar to be coated shall be furnished as test bars.

3

Test bars may be in one length or multiple lengths as required to have one test bar of each size with each production lot.

4

The production epoxy coated test bars shall be evaluated by bending 120  (after rebound) around a mandrel of a diameter corresponding to size of bar indicated in Table 11.1.

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Section 05: Concrete Part 11: Reinforcement

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Table 11.1 Mandrel Diameter for Bar Diameter for Evaluation Test of Epoxy Coated Test Bars Diameter of Mandrel (mm)

10 12 13 14 16 18 20 22 24 25 26 28 30 32 34 36

79 95 103 111 127 143 159 175 191 198 206 222 238 254 270 286

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Bar Diameter (mm)

Bend shall be made at a uniform rate and may take up to one minute to complete.

6

Bend test shall be conducted at a room temperature of between 20 °C and 30 °C after the specimen has been exposed to room temperature for a sufficient time to ensure that it has reached thermal equilibrium.

7

No cracking of the epoxy coating shall be visible to the naked eye on the outside radius of the bent bar.

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END OF PART

QCS 2014

Section 05: Concrete Part 12: Joints

Page 1

JOINTS.................................................................................................................... 2

12.1 12.1.1 12.1.2 12.1.3 12.1.4 12.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Definitions 3

12.2 12.2.1 12.2.2

CONSTRUCTION JOINTS ...................................................................................... 4 General 4 Construction Joints in Water Retaining Structures 4

12.3 12.3.1 12.3.2 12.3.3

MOVEMENT JOINTS .............................................................................................. 5 General 5 Joint Filler 6 Joint Sealants 6

12.4 12.4.1

SLIP BEARINGS ..................................................................................................... 7 General 7

12.5 12.5.1 12.5.2 12.5.3 12.5.4

WATERSTOPS ....................................................................................................... 7 General 7 Waterstops 7 Butyl Rubber Waterstops 8 Water Swelling Gaskets 8

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Section 05: Concrete Part 12: Joints

Page 2

12

JOINTS

12.1

GENERAL

12.1.1

Scope

1

This part deals with movement and construction joints, slip bearings, waterstops and associated sealants and filler materials.

2

Related Sections and Parts are as follows:

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12.1.2

.

This Section Part 1 ............... General Part 10, ............ Curing Part 15, ............ Hot Weather Concreting Part 16, ............ Miscellaneous References

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ASTM D1751 ..............Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Non-extruding and Resilient Bituminous Types) ASTM D2240 ..............Standard Test Method for Rubber Property—Durometer Hardness

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ASTM D3575 ..............Standard Test Methods for Flexible Cellular Materials Made From Olefin Polymers

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BS 903........................Physical testing of rubber BS 2571......................General purpose flexible PVC compounds for moulding and extrusion

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BS 2782,.....................Methods of testing plastics BS 6093,.....................Design of joints and joining in building construction

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BS 7164,.....................Chemical tests for raw and vulcanized rubber

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BS EN 1992-3 ............Eurocode 2. Design of concrete structures. Liquid retaining and containing structures

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BS EN ISO 7214 ........Cellular plastics. Polyethylene. Methods of test CRD-C572 ..................Corps of Engineers Specifications for Polyvinylchloride Waterstop ISO 9001 ....................Quality management systems. Requirements

12.1.3

Submittals

1

The Contractor shall submit for approval by the Engineer as soon as practicable after acceptance of his Tender and not less than three weeks before commencement of concreting, drawings showing his proposals for the position of construction joints having due regard to any that may be shown on the Contract Drawings.

QCS 2014

Section 05: Concrete Part 12: Joints

Page 3

For slide bearings the Contractor shall provide at least three samples of the proposed material, together with the manufacturer's technical specifications and recommendations in respect of application and performance.

3

For slip joints the Contractor shall provide at least three samples of materials proposed, together with manufacturer's technical specifications and recommendations in respect of application and performance.

4

For waterstops the Contractor shall provide at least three samples of proposed types, including prefabricated joints and junctions, if applicable. If joints are to be made up on site, provide worked samples, including samples for each make of waterstop, where samples from different manufacturers are provided.

5

The Contractor must supply a certificate of compliance for the joint sealant, stating that it meets the requirements of the specification. The Contractor shall also supply the Manufacturer’s technical and installation data for the proposed material. The Contractor shall provide details of previous installations of the product, with the client name, structure name, type of joint and value of contract.

6

The Contractor shall prepare shop drawings that show the layout of the waterstops, specials and joints.

12.1.4

Quality Assurance

1

The joint sealant, including primers and debonding materials shall be compatible with each other and shall be supplied from a manufacturer operating the ISO 9001 or 9002 Quality Assurance Scheme.

12.1.5

Definitions

1

Construction Joint: The surface where two successive placements of concrete meet, across which it is desirable to develop and maintain bond between the two concrete placements, and through which any reinforcement which may be present is not interrupted.

2

Contraction Joint: Formed, sawed, or tooled groove in a concrete structure to create a weakened plane and regulate the location of cracking resulting from the dimensional change of different parts of the structure. (See also Isolation Joint.)

3

Expansion Joint: A separation between adjoining parts of a concrete structure which is provided to allow small relative movements such as those caused by thermal changes to occur independently.

4

Isolation Joint: A separation between adjoining parts of a concrete structure provided to isolate and element and thus allow independent movement.

5

Joints Fillers: Materials that are used to fill space within movement joints during construction. They may provide support to a sealant applied subsequently.

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QCS 2014

Section 05: Concrete Part 12: Joints

Page 4

CONSTRUCTION JOINTS

12.2.1

General

1

Where construction joints are required in slabs or beams (designed by Direct Design Method DDM) they shall be located within the middle third of their spans, and at one-third to onequarter of span in slabs and beams subject to a maximum spacing of approximately 9 metres. Where slabs are supported by beams then the beams and slabs shall be constructed in one operation.

2

In all cases vertical stop boards of a form to be approved by the Engineer shall be provided by at the end of each section of work which is to be concreted in one operation and the concrete shall be thoroughly compacted against these stop boards.

3

Where slabs, beams and walls incorporate construction joints, panels shall generally be constructed consecutively. Where this is not possible a gap not exceeding one metre shall be formed between adjacent panels. This gap shall not be concreted until a minimum interval of 7 d has expired since the casting of the most recent panel.

4

The size of bays for reinforced floors, walls and roofs shall be as shown on the drawings but in no event shall they exceed 7.5 m in either direction and 6 m when unreinforced or with nominal reinforcement.

5

Horizontal construction joints in walls will only be permitted when the wall is continuous with the floor slab. Walls shall be keyed on cast kickers 150 mm high or on the tops of walls meeting the soffits of suspended members.

6

Construction joints in monolithic structures shall be aligned with each other whenever practicable.

7

Before placing new concrete against concrete which has already set the latter shall be treated to expose the aggregate over the full section and leave a sound irregular surface. This shall be done while the concrete is still fresh by means of water spray and light brushing or other means approved by the Engineer.

8

Immediately before the new concrete is placed all foreign matter shall be cleaned away and the surface moistened.

9

If during the course of the Contract it should become apparent that the Contractor’s methods of forming construction joints are not proving effective the Engineer may order the Contractor to execute at the Contractor’s expense such preventative measures as the Engineer may consider necessary to ensure the watertightness of the construction joints in further work.

12.2.2

Construction Joints in Water Retaining Structures

1

The floor may be designed as fully restrained against shrinkage and thermal contraction and should be cast directly onto the blinding concrete.

2

In large structures, the floor shall be designed as a series of continuous strips with transverse induced contraction joints provided to ensure that cracking occurs in predetermined positions. Longitudinal joints between the strips should form contraction joints.

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12.2

QCS 2014

Section 05: Concrete Part 12: Joints

Page 5

Waterstops shall be incorporated into construction joints, crack induced joints, contraction joints and expansion joints in water retaining structures. The Contractor shall ensure that all such joints are watertight and any joints which may leak or weep shall be rectified by the Contractor to the Engineer’s satisfaction.

4

The spacing of construction joints, crack induced joints, contraction joints and expansion joints in water retaining structures shall be shown on the design drawings.

5

Where the positions or type of joints are not indicated on the drawings, the spacing of construction joints or crack induced joints in water retaining structures shall not exceed 5 m.

6

Where the positions or type of joints are not indicated on the drawings in the ground floor slab, construction joints, crack induced joints, contraction joints and expansion joints shall be incorporated into the works as appropriate. for slabs on grade, construction joints or crack induced joints should be provided at areas where differences in subgrade and slab support may cause cracks. The slab shall be cast in strips not more than 15 metres wide across the width of the building. Within each strip for both directions, crack induced joints shall be provided at areas where cracks are expected and not more than 5.0 metre spacing, and construction or contraction joints shall be provided at not more than 15.0m spacing.

7

Construction or contraction joints shall be provided between adjacent strips.

8

Waterstops of a type acceptable to the Engineer shall be embedded in the concrete. The waterstop should be made of a high quality material, which must retain its resilience through the service life of the structure for the double function of movement and sealing. The surface of waterstops should be carefully rounded to ensure tightness of the joint even under heavy water pressure. To ensure a good tightness with or without movement of the joints, the waterstop should be provided with anchor parts. The cross-section of the waterstops should be determined in accordance with the presumed maximum water pressure and joint movements. The complete works of fixed and welded connections must be carried out strictly in accordance with the manufacturer’s instructions.

9

Engineer’s acceptance shall be obtained by the Contractor, prior to start of work, on the casting sequence and the layout of joints.

12.3

MOVEMENT JOINTS

12.3.1

General

1

Movement joints for expansion and contraction shall be constructed in accordance with the details and to the dimension shown on the Drawings or where otherwise ordered by the Engineer and shall be formed of the elements specified.

2

Movement Joints in Water Retaining Structures shall be in accordance with the details and to the dimension shown on the Drawings and EN 1992-3.

3

The Contractor shall pay particular attention to the effects of climatic extremes on any material which he may desire to use on any movement joint and shall submit for approval by the Engineer his proposals for the proper storage, handling and use of the said materials having due regard for any recommendations made by the manufacturer in this connection.

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Section 05: Concrete Part 12: Joints

Page 6

Joint Filler

1

Joint fillers shall conform to the requirements of BS 6093 or ASTM D1751 or equivalent if they are bituminous type or to the requirements of ASTM D3575 or BS EN ISO 7214 or equivalent if they are polymer foam type.

2

The joint filler shall be fixed to the required dimensions of the joint cross-section and shall provide a firm base for the joint sealer.

3

When required between two concrete surfaces as a resilient movement joint, the filler shall be an approved granulated cork bound with insoluble synthetic resin.

4

When required between blockwork and concrete as a low density movement joint filler or for building details it shall be an approved bitumen impregnated fibreboard or preformed closed cell polyethylene.

12.3.3

Joint Sealants

1

All joints to be sealed shall be formed and the groove grit blasted to remove all traces of deleterious materials such as form oil or curing compounds and also to remove any surface laitance from the sides of the joint. The joint shall be dry prior the application of priming. Where the use of grit blasting is not possible the Contractor may propose alternative methods subject to the approval of the Engineer.

2

The back of the joint shall receive a debonding tape or polyethylene foam backer cord in order to provide the correct depth to width ratio and prevent three sided adhesion.

3

The areas adjacent to the joint shall be protected using masking tape.

4

The sides of the joint shall be primed with the relevant primer as recommended by the sealant manufacturer and the sealant material applied in accordance with the manufacturers instructions.

5

The sealant material shall be a non-biodegradable multicomponent pitch polyurethane elastomeric joint sealant, carefully selected as appropriate for the specific climatic and environmental exposure conditions expected. Alternative types of sealant will be considered, including epoxy-polyurethane, rubber bitumen and acrylic, subject to the requirements of the specification and the approval of the Engineer.

6

Where the joint sealant is to be in contact with a protective coating the Contractor shall satisfy the Engineer that the sealant and protective coating are compatible

7

Sealants shall exhibit the following properties:

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12.3.2

(a)

Movement accommodation factor

25 %

(b)

Shore ‘A’ hardness

(c)

Solids content

(d)

Service temperature range

(e)

Chemical resistance to Sewage, Sabkha, Mineral acids and Alkalis

(f)

Width to depth ratio

20 - 25

100 %

2:1

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0 C to 90 C

QCS 2014

Section 05: Concrete Part 12: Joints

Page 7

Where shown on the Drawings sealants shall also be suitable for use with potable water.

9

All surface preparation, priming, mixing and application shall be carried out in strict accordance with the manufacturer’s instructions.

10

The sealant shall have a proven track record of no less than ten years under similar local conditions.

12.4

SLIP BEARINGS

12.4.1

General

1

Slip bearings shall be preformed low friction bearing strips to form a thin sliding joint.

2

They shall be extruded from specially formulated polyethylene to form a durable lamina resistant to sewage, mineral acids and alkalis, solvents and weathering.

3

Slip bearings shall be applied in two layers with the bottom layer bonded to the substrate with a high quality solvent borne adhesive based on polychloroprene rubber. The substrate shall be clean and free from deleterious materials such as form oil or curing compounds and surface laitance. The surface shall be level and even along the full length of the joint

4

The applied loads for slip bearings shall not exceed 0.7 MPa.

5

Operating temperatures shall be up to 80 C

6

The coefficient of friction shall not exceed 0.15

12.5

WATERSTOPS

12.5.1

General

1

Waterstops and associated materials shall be by a manufacturer with a minimum of ten years experience in the field of engineering waterproof products.

2

PVC waterstops shall be suitable for storage, handling, installation and service within a range of 15 C to 65 C.

12.5.2

Waterstops

1

The waterstop shall be a high performance system forming a continuous network as shown on the Drawings.

2

Site jointing is to be limited to butt joints and shall be performed strictly in accordance with the manufacturer’s instructions.

3

Centrally placed waterstops shall employ centre bulbs/shutter stop with ribs on the web sections.

4

Externally placed waterstops shall have ribs on either side of the centre of the waterstop. The water bar used at the location of expansion joints shall have a bulb in the centre to accommodate the movements.

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Section 05: Concrete Part 12: Joints

Page 8

5

Waterstops shall have a minimum thickness of 3 mm.

6

The minimum test performance data for PVC waterstops shall be as follows: Tensile strength Elongation at break Hardness

>12 MPa 300 % Shore ‘A’ 80 to 90

The materials shall be tested in accordance with BS 2571 or BS 2782 or CRD–C572 or ASTM D2240.

12.5.3

Butyl Rubber Waterstops

1

Butyl rubber waterstops shall have the properties stated in Table 12.1 when tested in accordance with BS 903.

Property

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BS 903

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Table 12.1 Properties Requirements of Butyl Rubber Waterstops

.

7

Requirements 3

Density

Part A26

Handness

Part A2

Tensile Strength

Part A2

Elongation at break point

Not less than 450 %

Part A/6

Water Absosption (48 hours immersion)

Not exceeding 5 %

1100 kg/m (± 5 %) 60-70 IRHD Not less than 17.5 N/mm

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Part A1

Butyl rubber waterstops shall be suitable for storage, handling, installation and service within a temperature of 0 °C to 40 °C

12.5.4

Water Swelling Gaskets

1

Where active sealing is required for critical areas, waterstops shall be hydrophilic polymer modified chloroprene rubber strips. The rubber strips shall conform to the following properties as applicable: Water pressure resistance

:

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(b)

Expansion in contact with water :

(c)

:

Reversible

:

- 30 to + 70 °C

(d)

2

5 Bar (50 m)

Application Temperatures

2 x original SRE

The selected rubber strips shall be available for three exposures: (a)

Fresh Water

(b)

Seawater

(c)

Chemicals (if the condition demands or upon the Engineer’s request)

The supplier shall furnish references upon request of the Engineer. END OF PART

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 1

INSPECTION AND TESTING OF HARDENED CONCRETE .................................. 2

13.1 13.1.1 13.1.2 13.1.3 13.1.4 13.1.5 13.1.6

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Non-Compliance of Work 3 General Fieldwork Requirements 4

13.2 13.2.1 13.2.2 13.2.3 13.2.4

CONCRETE CORES ............................................................................................... 4 General 4 Drilling Cores 5 Testing for Strength 6 Assessment of Strength 7

13.3

REINFORCEMENT COVER MEASUREMENTS ..................................................... 7

13.4 13.4.1 13.4.2 13.4.3 13.4.4

ULTRASONIC PULSE MEASUREMENTS .............................................................. 8 General 8 Selection of Test Locations 8 Execution of Tests 8 Estimated In-Situ Cube Strength 9

13.5

RADIOGRAPHY OF CONCRETE ........................................................................... 9

13.6 13.6.1 13.6.2 13.6.3 13.6.4

SURFACE HARDNESS ........................................................................................... 9 General 9 Method of Test 9 Equipment 10 Reporting 10

13.7 13.7.1 13.7.2

CHEMICAL CONTENT .......................................................................................... 10 Sampling 10 Laboratory Testing 11

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QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 2

13

INSPECTION AND TESTING OF HARDENED CONCRETE

13.1

GENERAL

13.1.1

Scope

1

This Part of the specification covers the inspection, sampling and testing of hardened concrete.

2

Related Section and Parts are as follows:

.

This Section Part 6 ............... Property Requirements References

1

The following standards are referred to in this part of the specification:

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ACI 214.4R .................Guide for Obtaining Cores and Interpreting Compressive Strength Results

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ACI 318 ERTA ............Building Code Requirements for Structural Concrete (ACI 318-08) and Commentary

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ASTM C42 ..................Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete

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ASTM C823 ................Standard Practice for Examination and Sampling of Hardened Concrete in Constructions

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BS 1881-124 ..............Testing concrete. Methods for analysis of hardened concrete

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BS 1881-204, .............Testing concrete. Recommendations on the use of electromagnetic covermeters BS EN 12350..............Testing fresh concrete

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BS EN 12504-1 ..........Testing concrete in structures cored specimens taking, examining and testing in compression BS EN 12504-2 ..........Non-destructive testing. Determination of rebound number

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BS EN 12504-3:2005 Testing concrete in structures. Determination of pull-out force BS EN 12504-4 ..........Determination of ultrasonic pulse velocity BS EN 13791..............Assessment of in-situ compressive strength in structures and precast concrete components GSO ISO 1920-6 ........ Testing of concrete – part 6: sampling, preparing and testing of concrete core . 13.1.3

Submittals

1

The Contractor shall submit to the Engineer his quality assurance procedures for the particular parts of the testing work that will be carried out.

2

The Contractor shall submit for the Engineer’s approval the curriculum vitae (CV) of the supervisor proposed for the work.

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 3

The Contractor shall through testing agency prepare a factual report that identifies the test methods used and the test results. The report shall also identify any unusual results or pertinent information relating to the testing. The report shall be presented in hard and electronic copies.

4

For each of the test results the Contractor shall identify the precision or repeatability of the particular sampling and testing method. This shall be as given from experience of the particular test by the laboratory or as expected from information in the particular test standard.

5

In-place tests will be valid only if the tests have been conducted using properly calibrated equipment in accordance with recognized standard procedures and acceptable correlation between test results and concrete compressive strength has been established and is submitted.

6

Non-destructive tests shall not be used as the sole basis for accepting or rejecting concrete, but they may be used to “evaluate” concrete when the standard-cured strengths fail to meet the specified strength criteria

13.1.4

Quality Assurance

1

All field and laboratory testing of concrete shall be carried out by an independent laboratory approved by the Engineer.

2

The evaluation of concrete in structure is needed when an existing structure is to be modified or redesigned; to assess structural adequacy when doubt arises about the compressive strength in the structure due to defective workmanship, deterioration of concrete due to fire or other causes;when an assessment of the in-situ concrete strength is needed during construction; to assess structural adequacy in the case of non-conformity of the compressive strength obtained from standard test specimens; assessment of conformity of the in-situ concrete compressive strength when specified in a specification or product standard.

13.1.5

Non-Compliance of Work

1

If the 28 d works test cubes as defined in clause 6.6 of this Section fail to meet the minimum criteria, the Engineer shall direct the Contractor to carry out in-place methods to estimate the concrete strength by non-destructive testing, in-situ drilling of concrete cores or load testing.

2

The parts or elements of the structure made from the defective batch or batches of concrete as represented by the works test cubes shall be identified by the Engineer and based on this information the Engineer shall instruct the Contractor on the required number and position of concrete cores.

3

The Engineer shall review the concrete core test results in conjunction with BS EN 13791 or ACI 318 whichever is applicable to the structural design.

4

Based on this assessment the Engineer shall decide the acceptability of the concrete in the structural element and may either:

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(a)

accept the concrete

(b)

instruct that certain remedial works are carried out

(c)

instruct that the element is replaced.

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 4

General Fieldwork Requirements

1

The Contractor shall make all arrangements to provide safe stable access to testing locations.

2

When gaining access to testing locations and whilst testing the Contractor shall take care not to damage the structure or leave it in an untidy or unclean state.

3

The Contractor shall take precautions to ensure that cooling water from concrete coring/other operations is discharged such as not to cause a mess or damage the interior or exterior parts of the structure.

4

The Contractor shall be responsible for arranging the water supply required for testing.

5

The Contractor shall arrange for a suitable power supplies. Where testing is being carried out on an occupied structure a power supply from the building services may not available and the Contractor shall make arrangements for power supply and extension leads of adequate length.

6

The Contractor shall appoint a qualified field supervisor to co-ordinate and manage the field work. The supervisor shall have not less than five years experience of such work.

7

Before starting the work, the Engineer with the Contractor’s supervisor will mark the positions where field testing is to be carried out. A unique referencing system to identify each sample or testing location will be adopted, and this will either be referenced on sketch plans or drawings or by a detailed description used throughout the report to identify test locations.

8

If testing is being carried out on an occupied structure the Contractor shall co-ordinate with the owner or operator of the structure to arrange the detailed programme for the works and gain access to the various parts of the structure.

9

As soon as laboratory test results are available these shall be submitted by hand or faxed to the Engineer in draft form. The testing laboratory, or technical bureau assigned by the testing agency, assigned by the contractor shall provide a technical report providing visual information and analysing the tests conducted.

10

All core holes, dust sample holes and exploratory investigation areas shall be reinstated with a proprietary non shrink cementitious repair mortar. The preparation of the hole or area before reinstatement shall be carried out as per the recommendation of the repair mortar supplier.

11

Before filling any core holes, dust sample holes or exploratory investigation areas, the Contractor shall allow the Engineer time to inspect these areas and obtain written confirmation from the Engineer before filling.

13.2

CONCRETE CORES

13.2.1

General

1

The drilling and testing of cores shall be carried out in accordance with BS EN 13791 & BS EN 12504-1, or GSO ISO 1920-6 or ASTM C42 and ACI 214.4 whichever is applicable to the structural design.

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13.1.6

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 5

All of the supplementary information listed by the relevant standards shall be included in the test report with photographs of the cores.

3

An assessment of in-situ compressive strength for a particular test region shall be based on at least 3 cores. Consideration shall be given to any structural implications resulting from taking cores. The diameter of concrete core shall be at least 100 mm for strength evaluation unless clear spacing of reinforcement is less than 100 mm and approved by Engineer.

4

The preferred minimum core diameter is three times the nominal maximum size of the coarse aggregate, but it shall be at least two times the nominal maximum size of the coarse aggregate

5

The Engineer will advise the required number and locations of cores. If the results of the initial coring are inconclusive, the Engineer may instruct that further cores be taken at certain locations.

6

Unless otherwise directed by the Engineer, the Contractor shall ensure that coring does not cut through any reinforcing steel. The required diameter and depth of concrete cores shall be as stated in table 13.1

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Table 13.1

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Minimum Depth of Sampling of Concrete for Testing Purposes (ASTM C823) Thickness of Section, m

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Types of Construction

0.3 or less 0.3 or greater

entire depth 0.3

0.15 or less

entire depth

0.15 – 0.6

one half the thickness or 0.15 whichever is greater

0.6 or greater

0.6

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Slabs, pavements, walls, linings, foundations, structural elements accessible from one side only 2 Suspended slabs , walls, conduits, foundations, structural elements exposed to the atmosphere at two or more sides; concrete products Massive sections

Minimum Depth to Be Sampled, m

1 The requirements of table 13.2.1 may not provide the quantities or dimensions of samples that are required for all tests, in that case, the necessary additional quantity of concrete in pieces of appropriate minimum size should be taken at each sampling location. 2 When suspended slabs are cored, it is desirable to leave the lower 25 mm uncored, so as not to lose the core by its falling from the barrel and to make it easier to patch the core hole. 13.2.2

Drilling Cores

1

Before beginning coring operations the Contractor shall use a proprietary cover meter to identify the position of steel reinforcing bars at the testing location.

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 6

The Engineer may instruct that the core is taken through the concrete without hitting any reinforcement or the Engineer may instruct that the core is taken in a position where it is expected reinforcement will be cut in order to provide a sample of the reinforcement to check its condition. The locations of all drilling points shall be chosen so that the core contains no steel parallel to its length.

3

Before capping, the core shall have a length of at least 95 % of its diameter. Once prepared for test the core shall have a length at least equal to the diameter and not more than 1.2 times its diameter.

4

Cores of both 100 mm and 150 mm nominal diameters may be tested provided that the aggregate size does not exceed 20 mm and 40 mm respectively. Where possible 150 mm cores should be taken to reduce the variability due to drilling and increase the reliability of the testing, unless reinforcement is congested and the use of 100 mm cores will reduce the possibility that the core will contain steel or it is necessary to restrict the sampling to a length of less than 150 mm.

5

Where the size of the section precludes the use of 100 mm or 150 mm cores, smaller cores may be used with the permission of the Engineer.

6

During drilling operations, a log of observations that may affect the interpretation of core samples shall be prepared.

7

If instructed by the Engineer, immediately after the core has been cut and removed and the structure a carbonation test will be carried out by using a 1 or 2 % solution of phenolphthalein poured over the cut surface. A photograph shall be taken of the cut core with the phenolphthalein solution applied to provide a record of the test.

8

If during the drilling of the core, the core collapses due to weak honeycombed or defective concrete, the Contractor shall stop the drilling operation and carry out testing at an adjacent location as advised by the Engineer. If when testing at the second location, the core again breaks due to honeycombed or defective concrete the freshly cut core shall be retained for reference and a note made of the condition.

13.2.3

Testing for Strength

1

The compressive strength of field concrete cores shall be assessed in accordance with BS EN 13791.

2

The details of the concrete core in accordance with BS EN 13791 shall be recorded and two photographs on either side of the core taken.

3

Where there is reinforcement in the core, the size and the type of bar shall be noted along with its cover to the concrete surface, the condition of reinforcing bars shall be noted with a detailed description of any corrosion of the reinforcement.

4

Before carrying out the compressive strength testing of the cores, the Contractor shall inform the Engineer to allow him to witness the testing if required.

5

Crushed core samples shall be retained by the laboratory and only disposed of after written approval by the Engineer.

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Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 7

Assessment of Strength

1

The estimated in-situ strength of the concrete shall be calculated from the core result using BS EN 13791, ACI 214.4 or ACI 318 whichever is applicable by the structural design.

13.3

REINFORCEMENT COVER MEASUREMENTS

1

The measurement of cover to reinforcing steel and other metallic items in concrete shall be carried out in accordance with BS 1881 Part 204 using an electromagnetic device that estimates the position depth and size of the reinforcement.

2

The locations for checking cover and the spacing between measurements shall be advised by the Engineer based on the objective of the investigation. The Contractor shall carry out calibrations of the electric magnetic device for a particular bar size to allow the bar diameter to be measured.

3

While testing, the orientation of steel bars shall be checked.

4

The electromagnetic device shall incorporate scale or digital display range and shall be calibrated in accordance with BS 1881 Part 204. When calibrated in this manner the indicated cover to steel reinforcement shall be accurate to within 5 % or 2 mm which ever is the greater over the working range given by the manufacturer.

5

The cover meter shall be used in accordance with the manufacturers instructions and checks on the zero carried out as specified.

6

The search head shall be traversed systematically across the concrete, and, where reinforcement is located, rotated until the maximum disturbance with electromagnetic field is indicated by the meter.

7

The cover to the reinforcement shall be noted along with the axis of the reinforcement. The cover shall also be recorded on the concrete surface with chalk or a suitable non-permanent marking pen.

8

Care should be taken to avoid interference from other metallic sources or magnetic material.

9

The cover meter checks shall be carried out by an operator with five years experience.

10

The test report on cover shall include the following information:

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13.2.4

(a)

date

(b)

time and place of test

(c)

description of the structure or component under investigation

(d)

location of test areas

(e)

make and type of cover meter used

(f)

date of last laboratory calibration of cover meter

(g)

details of site calibration of cover meter, indicated values of cover

(h)

estimated accuracy of quantitative measurements

(i)

configuration of steel reinforcement

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 8

ULTRASONIC PULSE MEASUREMENTS

13.4.1

General

1

The ultrasonic velocity test equipment shall be capable of measuring the transit time of a pulse vibration through concrete. The length of the pulse part between the transducer equipment shall be measured, and the pulse velocity calculated.

2

Ultrasonic pulse velocity testing shall be carried out in accordance with the provisions of BS EN 12504-4.

3

Velocities shall be measured at a number of locations around a structure and a velocity contour of the structure established. A minimum of 40 velocities shall be measured for each structural element.

13.4.2

Selection of Test Locations

1

Wherever possible direct transmission arrangements shall be used. The transducers shall be mounted on a specially formed moulded surface.

2

The minimum path length shall be 100 mm for concrete in which the nominal maximum size of aggregate is 20 mm or less and 150 mm for concrete in which the nominal maximum size of aggregate is between 20 mm and 40 mm. but the path length shall not be longer than required to detect small regions of bad concrete.

3

Where concrete contains steel the pulse velocity shall be adjusted in accordance with the requirement of BS EN 12504-4.

4

Locations that contain reinforcement directly along or close to the pulse paths shall be avoided.

5

Where repositioning is not possible the semi-direct transmission measurement, where transducers are placed on adjacent faces of the concrete, may be used.

13.4.3

Execution of Tests

1

Positions chosen for the test locations shall be clearly and accurately marked on the surface of the concrete.

2

The surface of the concrete shall be shall be cleaned and free from grit and dust. Path lengths shall be determined to an accuracy of 1 % and a suitable couplant (such as grease) applied to each of the test points.

3

Pulse transit times shall be measured by a skilled operator, with a minimum of five years experience in the use of the equipment.

4

Pulse velocity measurement equipment shall be in accordance with the requirements of BS EN 12504-4.

5

Test results shall be examined and any unusual readings repeated carefully for verification or amendment.

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13.4

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 9

Estimated In-Situ Cube Strength

1

A correlation shall be established between the cube crushing strength of the particular mix used in the structure and the pulse velocity.

2

Where it is not possible to obtain cubes with the same mix design as the original structure a combination of coring and ultrasonic pulse velocity testing may be carried out at the direction of the Engineer, where the cores are used to provide the correlation information required for the interpretation of the ultrasonic pulse velocity tests.

13.5

RADIOGRAPHY OF CONCRETE

1

Gamma rays and high energy X-rays, which illustrate by radiographs the concrete defects: The testing shall be carried out in accordance with the requirements of BS 1881-205 or equivalent.

13.6

SURFACE HARDNESS

13.6.1

General

1

Testing of concrete surfaces for hardness using rebound hammers shall be carried out in accordance with BS EN 12504-2.

2

The rebound hammer shall only be used for estimation of concrete strength where a specific correlation is carried out of the concrete from the structure being tested; this shall be from works test cubes or cores taken from the structure.

3

The correlation between concrete strength and the rebound number shall be carried out in accordance with BS EN 12504-2. The precision of the correlation curve between the mean rebound number and strength shall be stated and this shall be used when reporting any strength interpretations from surface hardness readings. The use of general manufacturers’ correlation or calibration curve for strength shall not be used.

4

It should be noted that the rebound hammer number only provides information on a surface layer of approximately 30 mm in depth of the concrete and that this should be quoted in the test report.

5

The rebound hammer maybe used to establish the uniformity of the finish products or similar elements in a structure at a constant age, temperature, maturity and moisture condition.

13.6.2

Method of Test

1

A minimum of 12 readings shall be taken to establish a single surface hardness at a particular location.

2

The reading shall be on a regular grid between 20 mm to 50 mm spacing over an area not exceeding 300 mm by 300 mm.

3

The mean of each set of readings shall be calculated including abnormally high and abnormally low results unless there is good reason to doubt the validity of a particular reading.

4

The coefficient of variation and the standard deviation of the readings shall be reported.

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13.4.4

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Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 10

Equipment

1

The rebound hammer shall be a proprietary type that has been used successfully and serviced for a minimum of five years.

2

The hammer shall comprise of a mass propelled by a spring that strikes a plunger in contact with the surface.

3

The manufacturers’ literature shall identify the impact energy and contact area of the plunger for the hammer.

13.6.4

Reporting

1

The test report shall affirm that the hardness was determined in accordance with BS EN 12504-2 and shall provide the following information:

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13.6.3

date time and place of test

(b)

description of structure and location of test

(c)

details of concrete

(d)

type of cement

(e)

cement content

(f)

type of aggregate

(g)

type of curing

(h)

age of concrete

(i)

type of compaction of concrete

(j)

forming of surface

(k)

moisture condition of the surface

(l)

carbonation state of surface

(m)

any suspected movement of the concrete under test

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direction of test

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(a)

(o)

any other factors that are considered significant in influencing the hardness readings.

2

The details of the rebound hammer correlation with strength including the mean, range, standard deviation and coefficient and variation of each reading shall also be included.

13.7

CHEMICAL CONTENT

13.7.1

Sampling

1

The Engineer shall instruct the depth increments over which the dust samples are to be taken, the types of chemical testing to be carried out and the quantity of sample required.

2

The depth of sample shall not be less than the concrete cover to the reinforcement and at least 50 mm from the surface of concrete. In presence of reinforcement, the chemical content shall be tested at least at two levels before and after the depth of reinforcement from the surface of concrete.

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 11

To provide uniform samples of cement matrix and aggregate, three separate holes shall be drilled at one location. The diameter of the holes shall be between 12 and 20 mm.

4

Care shall be taken to discard the material from any render or finish unless this is specifically required under the investigation.

5

Care shall be taken to ensure that dust increments are accurately measured by marking the drill bit.

6

The dust samples increments shall be carefully transferred to plastic bags and sealed to avoid contamination. Each sealed bag shall be uniquely identified by the sample identification and depth increment.

13.7.2

Laboratory Testing

1

Residual split samples of dust from the field investigation shall be retained until the Engineer has reviewed the chloride test results. The Engineer may instruct that repeat tests are carried out on certain samples.

2

Chloride testing of concrete dust samples shall be by an acid soluble method in accordance with BS 1881 Part 124. The results shall be reported to two decimal places.

3

Sulphate testing of concrete dust samples shall be in accordance with BS 1881 Part 124, using an acid soluble method.

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END OF PART

QCS 2014

Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 1

PROTECTIVE TREATMENTS FOR CONCRETE ................................................... 2

14.1 14.1.1 14.1.2 14.1.3 14.1.4 14.1.5 14.1.6 14.1.7 14.1.8 14.1.9

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Preinstallation and Co-ordination 4 Delivery, Storage and Handling 4 Protection 4 General Requirements for all Treatments 5 Final Inspection 5

14.2 14.2.1 14.2.2 14.2.3 14.2.4

EPOXY COATING ................................................................................................... 5 General 5 Surface Preparation 5 Materials 6 Application 6

14.3 14.3.1 14.3.2 14.3.3 14.3.4

WATERPROOF MEMBRANE ................................................................................. 6 General 6 Materials 7 Waterproof Membrane 7 Application 7

14.4 14.4.1 14.4.2 14.4.3 14.4.4

PENETRATIVE PRIMER ......................................................................................... 8 General 8 Material 8 Surface Preparation 8 Application 8

14.5 14.5.1 14.5.2 14.5.3 14.5.4

PROTECTIVE COATING ........................................................................................ 9 General 9 Surface Preparation 9 Material 10 Application 10

14.6 14.6.1 14.6.2 14.6.3 14.6.4 14.6.5 14.6.6 14.6.7 14.6.8 14.6.9 14.6.10 14.6.11

PLASTIC SHEET LINER FOR CONCRETE STRUCTURES ................................. 11 General 11 Shop Drawings and Submittals 11 Liner Material Requirements 11 Plastic Sheet Liner Strip Properties 12 Basic Sheet Dimensions 12 Liner Details 12 Installation 13 Testing Requirements 13 Special Requirements 14 Joints in Lining for In-Situ Concrete Structures 15 Testing and repairing damaged surfaces 15

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 2

14

PROTECTIVE TREATMENTS FOR CONCRETE

14.1

GENERAL

14.1.1

Scope

1

This Part covers the materials and application requirements for coatings for concrete surfaces including epoxy coatings, waterproof membranes, penetrative primers, protective coatings, and coatings and treatments for specialist applications where there is a harsh environment.

2

Related Section and Parts are as follows:

References

1

The following standards are referred to in this Part:

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This Section Part 1, ............. General

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ASTM D412 ................Test Methods for Vulcanized Rubbers and Thermoplastic Elastomers Tension ASTM D543 ................Test Method for Resistance of Plastics to Chemical Reagents

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ASTM D570 ................Test Method for Water Absorption of Plastics ASTM D638 ................Test Method for Tensile Properties of Plastics (Metric)

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ASTM D746 ................Test Method for Brittleness Temperature of Plastics and Elastomers by Impact

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ASTM D882 ................Test Methods for Tensile Properties of Thin Plastic Sheeting

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ASTM D1000 ..............Test Method for Pressure Sensitive Adhesive Coated Tapes Used for Electrical and Electronic Applications

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ASTM D1004 ..............Test Method for Initial Tear Resistance of Plastic Film and Sheeting

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ASTM D4541 ..............Test Method for Pull Off Strength of Coatings Using Portable Adhesion Testers ASTM E 96 .................Test Methods for Water Vapor Transmission of Materials

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ASTM E154 ................Test Methods for Water Vapor Retarders Used in Contact with Earth Under Concrete Slabs, on Walls, or as Ground Cover BS 1881......................Testing Concrete BS EN 12350..............Testing fresh concrete CIRIA Technical Note 130, Protection of Reinforced Concrete by Surface Treatments. ISO 9000 ....................Quality management and quality assurance standards ISO 9001 ....................Quality systems - Model for quality assurance in design, development, production, installation and servicing 14.1.3

Submittals

1

The Contractor shall submit manufacturers' specifications, installation instructions and other data to show compliance with the requirements of this part of the specification and the Contract Documents.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 3

The Contractor shall submit samples of all materials to be used in the works before delivery of material to Site. Samples of membrane waterproofing shall be 300 mm square. Samples of liquid components shall be a minimum of one litre.

3

The Contractor shall submit comprehensive test results for the protective coating system as per the tests in the specification which shall clearly indicate whether the values are mean values measured in current production or minimum values which the property does not fall below.

4

The Contractor shall clearly state the chemical composition of the material and the process by which protection is given to the concrete.

5

In addition to the test methods identified in this clause of this specification, the Engineer may require the Contractor to carry out further tests to different standards.

6

If the Contractor wishes to propose a material which has been tested to alternative standards, the Contractor shall submit correlation tests showing the comparable values of the two test methods. These test results shall be comprehensive giving full details of the sample conditioning, preparation, method of test, criteria for assessment etc.

7

The Contractor shall submit comprehensive information of previous applications of the material in similar conditions and environments. This information shall include: project name, type/grade of material used, quantity of material used, name of client, name of consultant, name of Contractor. If requested by the Engineer, the Contractor shall supply the contact details of the client, consultant or Contractor where the material was previously installed.

8

The Contractor shall submit a guaranty for the protective coating system and the workmanship. The guaranty shall be worded to reflect the required performance of the material and shall be approved by the Engineer. The guaranty shall be worded to include the phrase ‘the Contractor shall, at the convenience of the Employer, effect all repairs and replacements necessary to remedy defects all to the complete satisfaction of the Engineer’. Unless stated otherwise in the contract specific documentation, the performance guaranty shall be for a period of ten years except for the penetrative primer which shall be for a period of five years.

9

The use of alternatives may be considered by the Engineer. If the Contractor wishes to propose such systems, a technical submission shall be made which shall include a comprehensive justification giving an explanation of why the proposed system is equivalent or superior to the one designated.

14.1.4

Quality Assurance

1

The protective coating system shall be supplied by a manufacturer who is certified to the ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of the ISO 9000 series certificate that clearly states the scope of the certification.

2

The protective coating system shall be supplied by a manufacturer who provides technical assistance on the suitability for the application and installation for the material. For the initial use of the material on Site, the Contractor shall arrange for the technical representative of the manufacturer to be present to demonstrate the correct use of the material.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

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The protective coating system shall be applied by a contractor or subcontractor who is certified to the ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of the ISO 9000 certificate that clearly states the scope of the certification. the Engineer may permit the use of an applicator who is not certified to ISO 9000 if the applicator works to a quality system that is approved by the Engineer.

4

The works shall be executed by an approved specialist subcontractor having a minimum of 5 years successful experience in the installation of the specified material. Only tradesmen experienced with the installation of the materials specified shall be used.

14.1.5

Preinstallation and Co-ordination

1

After approval of all materials and before installation, a prework conference with the Engineer shall be held at the Site. The meeting shall be attended by representatives of the Engineer, Contractor, subcontractor, and manufacturer.

2

The parties shall:

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review drawings, specifications and approved materials

(b)

correct conflicts, if any, between approvals and specification requirements

(c)

examine Site conditions, including inspection of substrate, material labels and methods of storing materials

(d)

review installation procedures and scheduling

(e)

review protection methods for finished work from other trades.

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(a)

Before applying the coating system to the permanent works the Contractor shall carry out a small trial of the coating system for the review and approval of the Engineer.

14.1.6

Delivery, Storage and Handling

1

Materials shall be delivered in their original, tightly sealed containers or unopened packages, all clearly labelled with the manufacturer's name, brand name, and number and batch number of the material where appropriate. Materials and equipment shall be stored as directed in a neat and safe manner.

2

Storage areas shall comply with the manufacturers requirements with regard to shade, ventilation and temperature limits and shall be located away from all sources of excess heat, sparks or open flame. Containers of liquid material shall not be left open at any time in the storage area.

3

Materials not conforming to these requirements will be rejected by the Engineer and shall be removed from the Site and replaced with approved materials.

4

The Contractor shall deliver materials to Site in ample time to avoid delay in job progress and at such times as to permit proper co-ordination of the various parts.

14.1.7

Protection

1

The Contractor shall protect the protection system installation from damage during the construction period so that it will be without any indication of abuse, defects or damage at the time of completion.

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The Contractor shall protect the building/structure from damage resulting from spillage, dripping and dropping of materials.

3

The Contractor shall prevent any materials from running into and clogging drains.

4

Materials and plant shall not be stored on any newly constructed floor without the permission of the Engineer.

5

Impervious membranes shall be laid as protection to all concrete surfaces in contact with the soil and shall consist of tanking or similar accepted material, based on soil investigation report.

6

All foundations shall be provided with protection such as epoxy coatings or similar other accepted equivalents so that concrete is not exposed to harmful effects of soil, chlorides etc.

14.1.8

General Requirements for all Treatments

1

Protective treatments shall be applied where designated in the contract specific documentation.

2

All protective coating systems to be used shall be applied strictly in accordance with the manufacturers recommendations.

3

The Contractor shall take all necessary precautions against fire and other hazards during delivery, storage and installation of flammable materials specified herein and comply any regulations imposed by the Civil Defence Department of the Ministry of the Interior in respect of the storage and use of hazardous materials required under this section.

4

The Engineer shall specify the required final colour of the coating and the Contractor shall submit samples showing the colour before ordering the materials.

14.1.9

Final Inspection

1

Upon completion of the installation, an inspection shall be made by a representative of the material manufacturer in order to ascertain that the system has been properly installed.

14.2

EPOXY COATING

14.2.1

General

1

The coating shall be a decorative flexible high solids, epoxy polyurethane coating applied in two coats to a dry film thickness of 200 m minimum.

14.2.2

Surface Preparation

1

The surface of the concrete shall be free from oil, grease, loose particles, decayed matter, moss or algae growth and general curing compounds. All surface contamination and surface laitance shall be removed by high pressure water jetting or sweep blasting.

2

Blow holes and areas of substantial pitting shall then be filled with a solvent free thixotropic epoxy resin fairing coat. The mixing and application of this coat shall be in accordance with the product manufacturer’s recommendations.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 6

Where surface cracking is apparent these cracks shall be chased, by an approved mechanical means, to the depth of the crack. A thixotropic epoxy resin shall be applied using a trowel, scraper or filling knife ensuring that full compaction is achieved into the chased section and providing a flush finish with the concrete surface. A minimum period of 24 h shall be allowed before applying any subsequent protective coating systems.

14.2.3

Materials

1

External above ground coating materials shall provide protection against chlorides and carbonation, and be UV and abrasion resistant.

2

The above ground coating shall be applied over the below ground coating and shall continue for a minimum of 150 mm above the ground level.

3

The epoxy coating shall be UV stable.

4

The finished coating shall be pinhole free and have a total minimum dry film thickness of 200 m.

5

The materials used in the coating system shall comply with the following requirements:

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> 85 % -20 C to 70 C 4 MPa 6 MPa greater than 3.5 MPa 90 MPa (neat resin) 6-8 % (neat resin) Nil 50 mg 97 MPa @ 7 days -6 46.8 x 10 mm/mm/degree C

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Solids content Service temperature Tensile strength (DIN 53504) Resistance against crack (DIN 53515) Adhesion to concrete (ASTM D-4541) Compressive strength (ASTM D-695) Tensile elongation (ASTM D-638) Water absorption (MIL D-24613) Abrasion resistance (ASTM C-501) Compressive strength (ASTM C-579) Thermal coefficient of expansion (ASTM C-531) Application

1

Where required by the Engineer, trial areas not exposed in the finished work shall first be treated using the selected materials.

2

The exposed concrete surfaces as defined in the documents or as agreed with the Engineer shall be treated with the material.

3

The coating shall be applied by spray, roller or brush to achieve a finish acceptable to the Engineer.

4

In all operations of storage, mixing and application, the Contractor is to comply with the health and safety recommendations of the manufacturer and governing authorities.

14.3

WATERPROOF MEMBRANE

14.3.1

General

1

This Subpart covers the use of waterproof membrane for general protection to buried concrete.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 7

Where indicated on the Drawings or directed by the Engineer, concrete in contact with the ground shall be protected by a preformed flexible self-adhesive bituminous type membrane.

3

The laying, lapping and sealing of the membrane shall be in accordance with the manufacturer’s instructions.

14.3.2

Materials

1

The material shall be an externally applied waterproof membrane shall be an impervious, cold applied flexible laminated sheet, consisting of multilayer high density cross-laminated polyethylene film with a backing of self-adhesive rubber bitumen compound, protected with silicone coated release paper.

2

Primer for Sheet Membrane: As recommended by the manufacture of the sheet membrane.

3

Protection Board: Provide a minimum 6 mm thick asphalt protection board manufactured from selected aggregates, bound in modified bitumen encased between two layers of strengthened asphalt paper. The bituminous material shall be a minimum of 1.0 mm thick and the membrane shall be capable of bridging crack widths in the substrate up to 0.6 mm wide.

14.3.3

Waterproof Membrane

1

The material shall be suitable for use in the Gulf region the compound shall be specially formulated for hot climates and shall have proven experience in the Middle East.

2

The waterproofing material shall conform to the standards detailed in Table 14.1

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Table 14.1 Waterproof Membrane Property Requirements

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Property

Standard ASTM D638

Tear resistance

ASTM D1004

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Elongation Film

Value Longituduial 210 % Transverse 160 % Longitudinal 340 MPa Transverse 310 MPa

Adhesion to primed concrete

ASTM D1000

1.8 MPa

Elongation compound

ASTM D1000

1.8 MPa

Puncture resistance

ASTM E154

220 N over 65 mm

Water resistance

ASTM D570

After 24 h. 0.14 % After 35 d 0.95 %

Environmental resistance Moisture vapour transmission rate

ASTM D543 ASTM E96

Minimum thickness

2

0.3g/M 24 h 1.0 mm.

14.3.4

Application

1

Waterproofing membranes placed on vertical concrete faces shall be protected by preformed asphalt board.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 8

Boards shall be bonded onto position with high quality solvent borne contact adhesive based on polychloroprene rubber.

3

The Contractor shall co-ordinate the installation of waterproofing membrane with floor drains, equipment bases and other adjacent work and mask adjacent work to prevent soil marks.

4

Areas where waterproofing is applied shall be protected from all traffic and where necessary backfilling. All damage to finished portions of the waterproofing membrane shall be either repaired or replaced, or both, in a manner acceptable to the Engineer.

14.4

PENETRATIVE PRIMER

14.4.1

General

1

The system shall be a penetrating hydrophobic treatment that protects concrete from both water and chloride intrusion, while permitting water vapour transmission.

2

The treatment shall significantly reduce the absorption of water and water borne salts but allow the transmission of water vapour from the substrate.

3

The treatment shall not produce any discoloration of the substrate and shall have excellent resistance to weathering.

14.4.2

Material

1

The material shall be a low viscosity silane-siloxane system which penetrates deeply into a porous substrate and reacts to produce a bonded hydrophobic lining to the pores.

2

The material shall be resistant to petrol, oil, and atmospheric contaminants such as car exhaust fumes and industrial exhausts.

14.4.3

Surface Preparation

1

The surface shall be dry, free from oil and grease, loose particles, decayed matter, algae growth and curing compounds.

2

If the concrete surface is newly cast and has a very smooth finish, the surface shall be roughened by sand or grit blasting, water blasting or some mechanical means. The Engineer shall decide if this means of preparation is required.

3

Moss or algae growth on the surface shall be removed using a proprietary fungicidal wash in accordance with the manufacturer’s recommendations.

4

Concrete finishing required shall be completed before the application of the treatment.

5

Cracks of width greater than 0.2 mm shall be filled in accordance with the manufacturer’s recommendations.

14.4.4

Application

1

Unless directed otherwise by the Engineer the treatment shall be applied a minimum period of 24 h after the wet curing period, and shall be surface dry.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 9

The Contractor shall carry out tests to verify the depth of penetration of the material. These tests shall be carried out on specimens of the actual mix design and shall use coloured dyes to trace the penetration of the material.

3

Where fine cracking has occurred in the concrete (at a width not greater than 0.3 mm for reinforced concrete and 0.2 mm for water retaining structures) an additional four 'stripe coats' of the treatment shall be applied before the main treatment.

4

The application of the material on surfaces shall be by a low pressure spray direct from the can. Under no circumstances should thinning of the material be carried out.

5

The rate of application shall ensure that the surface is completely saturated. The impregnated coating shall be applied to two or more flood coats each flood coat shall be a 2 minimum of 0.4 l/m .

6

The material shall be applied strictly in accordance with the manufacturers instructions and as follows:

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the material shall be applied by a fine nozzle spray

(b)

application will not be permitted when the ambient air temperature is above 35 C or in windy conditions

(c)

the surface shall be cleaned by a stiff brush or compressed air to remove all loose deposits

(d)

concrete to be treated shall be surface dry for a minimum period of 24 h before impregnation

(e)

membranes, joint sealers and cast in concrete ancillaries shall be masked off before treatment

(f)

application shall be made by saturation flooding

(g)

the interval between application shall be at least 6 h

(h)

treated areas shall be protected from sea water and rain for 6 h after treatment.

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(a)

PROTECTIVE COATING

14.5.1

General

1

The coating system shall be used for the protection of new or existing reinforced concrete structures against carbonation or chloride induced corrosion.

2

The system shall comprise of a penetrating, reactive primer and an acrylic polymer top coat system to minimise ingress of acidic gases, chlorides and water.

14.5.2

Surface Preparation

1

Before application, all surfaces must be dry and free from oil, grease, loose particles, decayed matter, moss or algae growth and general curing compounds.

2

All such contamination and laitence must be removed by the use of grit blasting, high pressure water jetting or equivalent mechanical means.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 10

Before proceeding to apply the protective coatings, all surfaces which are not to be coated but which may be affected by the application of the coating shall be fully masked and, in particular, flora and fauna shall be protected.

4

Blow holes and areas of pitting shall be made good with a one part modified cementitious material and allowed to cure in accordance with the manufacturer's recommendations. In particular, the application shall be in accordance with the manufacturer's recommendations, with respect to the maximum application thickness.

14.5.3

Material

1

The materials are required to provide in-depth protection against carbonation and chloride penetration whilst permitting water vapour transmission from the concrete.

2

The primer shall be a low viscosity silane-siloxane system which penetrates deeply into a porous substrate and reacts to produce a bonded hydrophobic lining to the pores.

3

The material employed for the coating shall comply with the following requirements:

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400 µm 200 µm R Value at 325 microns > 161 metres.

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Wet film thickness Dry film thickness Carbon Dioxide diffusion resistance (Taywood Engineering Laboratories) Water vapour transmission (Taywood Engineering Laboratories) Reduction in chloride ion penetration (BS 1881 : Part 124) Tear Resistance (ASTM D624) Crack bridging (BRE Method) Chloride Ion Diffusion (Taywood Engineering Labororatories)

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Shall be more than 13 g/m .d 94 % minimum at 28 d 7.3 kN/mm 5.1 mm

2

-10

3.63 x 10

2

cm /sec.

Where test methods are not specified, the procedure for establishing compliance with the above criteria shall be agreed with the Engineer.

5

The Contractor is required to adhere strictly to the manufacturer's recommendations regarding the use, storage, application and safety rules in respect of the approved materials.

14.5.4

Application

1

Where required by the Engineer, trial areas not exposed in the finished work shall first be treated using the selected materials. These trial areas shall be noted on the Drawings and shall be carried out using the type of materials, mixing procedures and applications that will be used on the contract and shall be approved by the Engineer before the Contractor commences with the general work.

2

The exposed concrete surfaces as defined in the documents or as agreed with the Engineer shall be conditioned by the application of a penetrating hydrophobic treatment. The primer shall be allowed to dry in accordance with the manufacturer's requirements.

3

The Contractor shall then apply two coats of pigmented topcoat in accordance with the manufacturer's instructions. The finished coating shall be pinhole free and have a total minimum dry film thickness of 150 m. The colour and finish is to be as agreed with the Engineer.

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The coating shall be applied by spray, roller or brush to achieve a finish acceptable to the Engineer.

5

In all operations of storage, mixing and application the Contractor shall comply with the health and safety recommendations of the manufacturer and governing authorities.

14.6

PLASTIC SHEET LINER FOR CONCRETE STRUCTURES

14.6.1

General

1

This Subpart covers the supply and installation of sheet liners in reinforced concrete structures.

2

The liner must be continuous and free of pinholes both across the joints and in the liner itself.

3

All work for and in connection with the installation of the lining in concrete pipe and structure, and the field sealing and welding of joints, will be done in strict conformity with all applicable specifications, instructions, and recommendations of the lining manufacturer.

14.6.2

Shop Drawings and Submittals

1

The Contractor shall submit to the Engineer for approval the following:

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liner schedule

(b)

material certifications

(c)

test results

(d)

material samples

(e)

the manufacturer of the lining will submit an affidavit attesting to the successful use of its material as a lining for sewer pipes and structures for a minimum period of five years in service conditions recognised as corrosive or otherwise detrimental to concrete.

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(a)

Liner Material Requirements

1

The sheet liner shall be manufactured from, high molecular weight PVC or PE resin and other components necessary to make a material of permanent flexibility suitable for a liner in concrete pipes and structures in sewerage service. The weld strips and the joint strips shall be made from like material. For PVC and PE sheet liners, the actual resin used in manufacture must constitute not less than 99 % of the resin used in the formulation.

2

Copolymer resins will not be permitted.

3

All plastic sheets including locking extensions, all joints and welding strips shall be free of cracks, asperities and other defects that may affect the protective properties of the material.

4

The properties of PVC and PE sheet are shown in Table 14.2

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Page 12

Table 14.2 Properties of PVC and PE Sheet Liners Property

Test Method

PVC Elongation at break Tensile Strength Low Temp. Brittleness PE Elongation at break Tensile Strength Low Temp. Brittleness

Requirement

ASTM D638/882 ASTM D638/412 ASTM D746

300 % 15 MPa 0°C

ASTM D638/882 ASTM D638/412 ASTM D746

Exceeds 600 % 10-20 MPa -75 °C

Plastic Sheet Liner Strip Properties

1

Except at shop welds, all plastic sheet liners and strips shall have the properties shown in Table 14.3 when tested at 25 °C.

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Table 14.3 Properties of Plastic Sheet Liner Strips

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Property

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Shore Durometer

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Weight change

15 MPa 200 % 1 s 50 - 60 5 (with respect to 10 s 35 - 50 5) 1.5 %

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Tensile strength Elongation at break

Requirement

Basic Sheet Dimensions

1

The minimum thickness of the material shall be as shown in Table 14.4

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14.6.5

Table 14.4 Plastic Sheet Liner Minimum Dimensions

Material Thickness

Sheet with locking extensions Sheet, plain Joint strip Weld strip

Structures 4.0 mm 2.3 mm 1.9 mm 2.4 mm

14.6.6

Liner Details

1

Locking extensions (T-shaped) shall be of the same materials as that of the liner and shall be integrally extruded with the sheet.

2

Locking extensions shall be approximately 65 mm apart and shall be at least 10 mm high.

3

Sheets not used for shop fabrication into larger sheets shall be shop tested for pinholes using an electrical spark tester set at 9000 V per 1.0 mm thickness of lining minimum. Holes shall be repaired and retested.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 13

14.6.7

Installation

1

Installation of the lining, including preheating of sheets in cold weather and the welding of all joints, shall be performed in accordance with the recommendations of the manufacturer.

2

The lining to be held snugly in place against inner forms by means of steel banding straps or other means recommended by the manufacturer.

3

Concrete that is to be poured against the lining shall be vibrated, spaded, or compacted in a careful manner to protect the lining and produce a dense, homogenous concrete, securely anchoring the locking extensions into the concrete.

4

In removing forms care shall be taken to protect the lining from damage. In particular:

(b)

when forms are removed, any nails that remain in the lining to be pulled, without tearing the lining, and the resulting holes clearly marked.

(c)

form tie holes to be marked before ties are broken off and all areas of serious abrasion or damage shall be marked.

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All nail and tie holes and all cut, torn, and seriously abraded areas in the lining shall be patched as follows: patches made entirely with welding strip to be fused to the liner over the entire patch area

(b)

larger patches may consist of smooth liner sheet applied over the damaged area with adhesive

(c)

all edges must be covered with welding strip fused to the patch and the sound lining adjoining the damaged area.

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(a)

Hot joint compounds, such as coal tar, shall not be poured or applied to the lining.

7

The Contractor shall take all necessary measures to prevent damage to the installed lining from equipment and materials used in or taken through the work.

14.6.8

Testing Requirements

1

Samples taken from sheets, joints or weld strips shall be tested to determine material properties. Determination of tensile strength and elongation shall be in accordance with ASTM D 412 using Die B. Determination of indentation hardness shall be in accordance with ASTM D 2240 using a Type D Durometer, except that a single thickness of material and indentation hardness shall be made on 25 mm by 75 mm specimens. Thickness of specimens shall be the thickness of the sheet or strip.

2

The measurement of initial physical properties for tensile strength, weight, elongation and indentation hardness shall be determined before chemical resistance tests.

3

Chemical resistance tests shall be carried out to determine the physical properties of the specimens after exposure to chemical solutions. Test specimens shall be conditioned to constant weight at 43 °C before and after submersion in the solutions detailed in Table 14.5 for a period of 112 d at 25  3 °C.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 14

Volumetric percentages of concentrated reagents of CP grade: At 28 day intervals, specimens shall be removed from each chemical solution and tested. If any specimen fails to meet the 112 day exposure, the material will be subject to rejection.

5

Pull test for locking extensions: Liner locking extensions embedded in concrete shall withstand a test pull of at least 18 kN/m, applied perpendicularly to the concrete surface for a period of 1 min, without rupture of the locking extensions or withdrawal from embedment. This test shall be made at a temperature between 21 °C to 27 °C inclusive.

6

Shop-welded joints: Shop-welded joints, used to fuse individual sections of liner together, shall be a least equal to the minimum requirements of the liner for thickness, corrosion resistance and impermeability. Welds shall show no cracks or separations and shall be tested for tensile strength. Tensile strength measured across the welded joint in accordance with ASTM D 412 using Die B shall be at least 15 MPa. Test temperature shall be 25  3 C and the measured minimum width and thickness of the reduced section shall be used.

7

Spark test: All liner shall be shop tested for holes with a spark tester set to provide from 15 000 to 20 000 V. Sheets having holes shall be satisfactorily repaired in the shop before shipment from the manufacturer’s plant.

8

The Contractor shall provide the Engineer with certified copies of test reports before the shipment of the product to the Site.

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Table 14.5 Chemical Resistance Tests

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Chemical Solutions Sodium Hydroxide Nitric Acid

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5% 1% 1%

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Ferric Chloride

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Ammonium Hydroxide

20 %

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Sulphuric Acid

Concentration

0.1 %

Detergent (Linear alkyl benzyl sulphonate or LAS)

0.1 % BOD not less than 700 mg/l

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Phosphoric Acid 14.6.9

Special Requirements

1

Liner sheets to be closely fitted and properly secured to the inner forms.

2

50 %

(a)

sheets that are to be cut to fit curved and warped surfaces shall use a minimum number of separate pieces

(b)

a 50 mm wide water resistant tape or welding strip shall be welded on the back of butt joints to prevent wet concrete from flowing around the edges.

Unless otherwise shown on the Drawings, the lining will be returned at least 75 mm at the surfaces of contact between the concrete structure and items not of concrete and (a)

the same procedure will be followed at joints where the type of protective lining is changed or the new work is built to join existing unlined concrete

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 15

(b)

at each return, the returned liner will be sealed to the item in contact with the plastic lined concrete with an adhesive system

(c)

if the liner cannot be sealed with this adhesive because of the joint at the return being too wide or rough or because of safety regulations, the joint space shall be densely caulked with lead wool or other approved caulking material to a depth of 50 mm and finish with a minimum of 25 mm of an approved corrosion resistant material.

14.6.10 Joints in Lining for In-Situ Concrete Structures Field joints and Lining at joints shall be free of all mortar and other foreign material and shall be clean and dry before joints are made.

2

All welding is to be in strict conformance with the specifications of the lining manufacturer.

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all welds shall be physically tested by a non-destructive probing method

(b)

all patches over holes, or repairs to the liner wherever damage has occurred.

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Each transverse welding strip which extends to a lower edge of the liner will be tested by an approved testing agency at the cost of the Contractor. the welding strips will extend 50 mm below the liner to provide a tab.

(b)

a 5 kg pull will be applied to each tab. The force will be applied normal to the face of the structure by means of a spring balance

(c)

liner adjoining the welding strip will be held against the concrete during application of the force

(d)

the 5 kg pull will be maintained if a weld failure develops until no further separation occurs.

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All surfaces covered with lining, including welds, will be tested with an approved electrical holiday detector with the instrument set at 9000 V per 1.0 mm of lining minimum:

defective welds will be retested after repairs have been made tabs shall be trimmed away neatly by the installer of the liner after the welding strip has passed inspection.

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14.6.11 Testing and repairing damaged surfaces

(g)

inspection will be made within two days after joints has been completed in order to prevent tearing the projecting weld strip and consequent damage to the liner from equipment and materials used in or taken through the work.

END OF PART

QCS 2014

Section 05: Concrete Part 15: Hot Weather Concreting

Page 1

HOT WEATHER CONCRETING ............................................................................. 2

15.1 15.1.1 15.1.2 15.1.3 15.1.4 15.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definition of Hot Weather 2 System Description 3 Submittals 3

15.2

PLACING TEMPERATURE ..................................................................................... 3

15.3

PLANNING CONCRETING ..................................................................................... 4

15.4

MIX DESIGN ........................................................................................................... 4

15.5 15.5.1 15.5.2 15.5.3 15.5.4 15.5.5 15.5.6

TEMPERATURE CONTROL ................................................................................... 4 General 4 Aggregates 4 Water 5 Cement 5 Addition of Ice 5 Liquid Nitrogen 6

15.6

BATCHING AND MIXING ........................................................................................ 6

15.7

TRANSPORTATION ............................................................................................... 6

15.8

PLACING AND FINISHING ..................................................................................... 6

15.9

CURING AND PROTECTION.................................................................................. 7

15.10

INSPECTION AND TESTING .................................................................................. 7

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Section 05: Concrete Part 15: Hot Weather Concreting

Page 2

HOT WEATHER CONCRETING

15.1

GENERAL

15.1.1

Scope

1

This Part covers the precautions to be taken for hot weather concreting for all structural concrete except blinding concrete, where a minimum compressive strength is specified.

2

Related Sections and Parts are as follows:

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This Section Part 6, .............. Property Requirements Part 7, .............. Concrete Plants Part 8 .............. Transportation and Placing of Concrete Part 10 ............. Curing

.

15

References

ta

ACI 305R-91...............American Concrete Institute , Hot Weather Concreting

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ASTM C1064 ..............Measuring the Temperature of Concrete

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BS EN 1992-1-1 .........Eurocode 2, Design of concrete structures. General rules and rules for buildings

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BS EN 480..................Admixtures for concrete, mortar and grout. Test methods

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BS EN 934..................Admixtures for concrete, mortar and grout Definition of Hot Weather

1

The requirements of the following clauses of the specification are applicable during the hot weather period in Qatar.

2

The hot weather period shall be defined as starting when the maximum ambient air shade temperature on the Site exceeds 35 C for three consecutive days. The end of the hot weather period shall be defined as the period when the maximum air shade temperature is below 35 C on three consecutive days.

3

The Contractor shall establish a thermometer on Site that records the ambient air shade temperature. The thermometer shall be established at a position to provide representative air temperature for the Site conditions. If requested by the Engineer the Contractor shall arrange for the calibration of the Site thermometer.

4

Hot Weather” shall mean any combination of the following conditions that tends to impair the quality of freshly mixed or hardened concrete by accelerating the rate of moisture loss and rate of cement hydration, or otherwise causing detrimental results such as:

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15.1.3

(a)

High ambient temperature (when the shade temperature is above 40 deg C on a rising thermometer, 43 deg C on a falling thermometer),

(b)

High concrete temperature,

(c)

Low relative humidity,

(d)

High wind speed

QCS 2014

Section 05: Concrete Part 15: Hot Weather Concreting

(e)

the rate of evaporation exceeds 0.75 kg/m /h

Page 3

2

15.1.4

System Description

1

The Contractor shall undertake hot weather concreting procedures that are effective in controlling the following potential problems associated with concreting in hot weather: increased water demand of the mix

(b)

increased rate of slump loss

(c)

increased rate of setting

(d)

increased tendency for plastic shrinkage cracking

(e)

decreased long-term strength

(f)

increase tendency for drying shrinkage and cracking

(g)

increased tendency for differential thermal effects with consequent cracking

(h)

decreased durability from cracking where there is increased permeability.

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Submittals

1

The Contractor shall prepare weekly in advance his proposed concreting programme showing the quantities to be placed and the anticipated placing hours.

2

At least one month before the start of the hot weather period the Contractor shall submit his specific proposals for the control of the concrete temperature for the constituent materials; cement, water aggregates.

3

Where required the Contractor shall submit to the Engineer his proposals for the use of liquid nitrogen for cooling which shall include details of previous project application and the intended methods to be used and quantities of liquid nitrogen.

15.2

PLACING TEMPERATURE

1

This Subpart of the specification applies at all times of the year and at all times of the day.

2

Maximum fresh concrete temperature (at placement) shall not exceed 32°C unless construction testing to verify a proposed concrete mixture will function satisfactorily at a concrete temperature greater than 32°C. No concrete shall be placed if the concrete temperature is above 35°C

3

Concrete shall not be placed if the shade temperature exceeds 40ºC.

4

The temperature of each truck of concrete shall be measured using either a glass, dial type or electronic thermometer, just before the placing of the concrete and the temperature recorded on the delivery ticket. The maximum temperature at placing shall apply to the entire load of concrete in the truck or conveyer.

5

The Contractor shall allow for the increase in concrete temperature in the period from dispatch from the plant while in transportation or whilst awaiting placement on Site and take adequate measures to ensure the maximum temperature is not exceeded.

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Section 05: Concrete Part 15: Hot Weather Concreting

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PLANNING CONCRETING

1

During the hot weather period as defined in Clause 15.1.3 of this Part, the Contractor shall plan concreting operations such that no concreting takes place between the hours of 10:00 hours and 17:00 hours.

2

The Contractor shall arrange concrete pours such that the programme of works can be achieved without concreting during the period from 10:00 hours to 17:00 hours.

3

The Contractor shall nominate one member of his staff to be the co-ordinator for the supply of concrete. The co-ordinator’s responsibilities shall include ensuring the batched rate matches that of delivery and placement and the preparations needed before commencing a concrete pour.

15.4

MIX DESIGN

1

In the hot weather period, the Contractor shall review all concrete mix designs to ensure that the design slump or workability specified is achieved without increase in the mix water content. The Contractor shall make modifications to the mix design to allow for increased slump loss during transportation in hot weather.

2

This shall be achieved by adjusting the proportion of admixture, plasticiser or super plasticiser. The permitted range of admixture shall be clearly stated on the concrete mix design with nominal values for cold weather and hot weather use.

3

Under no circumstances will the addition of extra water that increases the water cement ratio be permitted during hotter weather.

4

All concrete materials and proportions used in periods of hot weather shall be those that have a satisfactory record of use in such conditions.

15.5

TEMPERATURE CONTROL

15.5.1

General

1

The Contractor’s specific proposals for the control of the concrete temperature shall include extent and type of shading of aggregates, method of chilling mix water and procedures for batching and mixing, transportation, placing and finishing, curing and protection.

2

These shall include calculations in accordance with ACI 305R, clause 3.1 “estimating concrete temperature”. The Contractor shall calculate the temperature of freshly produced concrete based on the input temperatures of the constituent materials and the weights from particular mix designs. The calculations shall make allowance for the rise in temperature between mixing and placing due to the transportation and waiting period. The calculations shall successfully demonstrate that the temperature can be maintained below 32 C at the point of placing.

15.5.2

Aggregates

1

All practical means shall be employed to keep the aggregates as cool as possible.

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15.3

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Section 05: Concrete Part 15: Hot Weather Concreting

Page 5

Stockpiles of aggregates shall be shaded from direct sunlight. Shades shall extend beyond the edge of aggregate storage areas and stockpile layouts shall be such that direct sunlight is not incident on the aggregates. Shades shall be constructed to allow access for mechanical shovels or means of conveyance. Shades and stockpiles shall be constructed so as to permit the free flow of air over the aggregates. Embedded cooling pipes may also be used to cool the aggregate.

3

Sprinkling of coarse aggregates to reduce temperature by evaporation or direct cooling shall not be permitted.

15.5.3

Water

1

Mix Water shall be cooled by storing in underground tanks or insulated tanks above ground.

2

The water shall be chilled by the use of proprietary chillers or the addition of ice to the water tank. Measures shall be taken to ensure that ice pieces are not inadvertently deposited directly into the mixer.

3

Water shall not be chilled below a temperature of 5 C.

4

Tanks, pipes or trucks used for the storage or transportation of water shall be insulated and painted white.

5

The mechanical refrigeration equipment and insulated water storage shall be adequate for the anticipated hourly and daily production rates of concrete during the hot weather period.

6

Mixing water may also be chilled by injection of liquid nitrogen into an insulated holding tank, such procedures shall be to the approval of the Engineer.

7

Ice shall be completely melted in mixing water prior to adding water to the mixer.

15.5.4

Cement

1

The use of freshly ground cement at very high temperatures is not permitted.

2

The cement shall be kept below the temperature which there is a tendency of false set.

3

Under no conditions shall the temperature of the cement exceed 75 C when it enters the mixture.

4

The Contractor shall make arrangements for storage on Site to allow cooling of freshly ground and delivered cement.

15.5.5

Addition of Ice

1

Crushed shaved or chipped ice can be used as part of the mixing water for reducing the concrete temperature.

2

The maximum nominal size of ice particles shall be 10 mm and all the ice must be melted before the completion of mixing of the concrete in the pan.

3

To ensure proper concrete mixing the maximum proportion by substitution shall be 75 % of the batch water requirement.

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Page 6

Crushed ice shall be stored at a temperature that will prevent lumps from forming by refreezing of particles.

5

The batching plant shall incorporate a mechanical system for correctly proportioning and weighing the ice to be added to the mixture.

6

The quantity of ice shall be deducted from the total batch water.

7

The Contractor shall ensure there are adequate quantities of ice in suitable refrigerated storage on the Site at the plant to meet the anticipated daily and hourly production rates of concrete during the hot weather period.

15.5.6

Liquid Nitrogen

1

Freshly mixed concrete maybe cooled by the injection of liquid nitrogen.

2

Care shall be taken to ensure that the concrete directly adjacent the injection nozzle is not frozen.

3

The use of liquid nitrogen for cooling concrete shall include a nitrogen supply vessel and injection facility for the batching plant or one or more injection stations for truck mixers.

4

The system may be set up at the Site for injection just before placing.

5

Proper safety precautions as advised by the supplier of the liquid nitrogen shall be used.

15.6

BATCHING AND MIXING

1

The drums of concrete mixer trucks shall be painted white to minimise solar heat gain.

2

Where a truck mixer has been left standing in the sun, the empty drum shall be sprayed with water and the drum flushed out with cold water before batching. Care shall be taken to ensure all water is removed from the drum before batching.

3

The temperature of the concrete shall be checked after discharge from the mixer and written on the delivery ticket. Temperature check shall be carried out at the plant on the concrete 3 floor for every 50 m produced or every hour which ever is the minimum.

4

A water-reducing, set-retarding chemical admixture conforming to the requirements of BS EN 480 Parts 1, 2 and 4 may be used in varying proportions under different air temperature conditions.

15.7

TRANSPORTATION

1

The transportation, placing, compaction and finishing of concrete shall be at the fastest possible rate. Delivery of concrete to the Site shall be properly scheduled to match the rate of placement and compaction.

15.8

PLACING AND FINISHING

1

If the temperature of the first truck of concrete of a particular pour is above the specification maximum temperature limit then placing shall not commence.

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Section 05: Concrete Part 15: Hot Weather Concreting

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If a pour is in progress and the temperature of a particular truck exceeds the maximum permitted temperature the placing may be allowed to continue at the discretion of the Engineer in order to avoid the possible development of a cold joint.

3

However, no further concreting pours shall take place until the Contractor has submitted revised calculations, in accordance with ACI 305R clause 3.1 to demonstrate that the maximum temperature will not be exceeded in the future. Before beginning new pours the temperature of the concrete constituent materials shall be monitored to verify that they meet the assumptions of the calculations.

15.9

CURING AND PROTECTION

1

Curing and protection shall conform to the requirements of Part 10 of this Section.

2

Evaporation shall be minimised, particularly during the first few hours subsequent to placing concrete, by suitable means such as applying moisture by fog spraying or any other means acceptable to the Engineer.

15.10

INSPECTION AND TESTING

1

All thermometers used for the measurement of concrete temperature shall be calibrated weekly against a glass mercury thermometer. Calibration shall be carried out over the temperature range of 10 C to 100 C using a water bath with ice or heating.

2

The method used to determine acceptance of temperature controlled concrete should be in accordance with ASTM C1064.

3

All concrete test specimens for strength or other purposes shall be carefully protected and cured.

4

Specimens shall be protected from accidental damage by plant personnel or equipment on Site.

5

Specimens shall be kept moist by the addition of water or covering by suitable curing materials.

6

The exact time of preparation of the specimen on Site shall be noted and the time when it is transferred to the laboratory. These times shall be written on the test report.

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END OF PART

QCS 2014

Section 05: Concrete Part 16: Miscellaneous

Page 1

MISCELLANEOUS .................................................................................................. 2

16.1 16.1.1 16.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

16.2 16.2.1 16.2.2 16.2.3 16.2.4 16.2.5 16.2.6 16.2.7 16.2.8

PAVEMENT QUALITY CONCRETE ........................................................................ 3 Scope 3 Mix Designs 3 Cement 4 Water 4 Aggregates 5 Admixtures 5 Air content 5 Density 5

16.3 16.3.1 16.3.2 16.3.3

CEMENTITIOUS GROUT ........................................................................................ 6 General 6 Material 6 Workmanship 6

16.4 16.4.1 16.4.2

SCREEDS ............................................................................................................... 7 Scope 7 General 7

16.5

CELLULAR CONCRETE ......................................................................................... 9

16.6 16.6.1 16.6.2 16.6.3

REPAIR OF CONCRETE ........................................................................................ 9 General 9 Honeycombing or Spalling 9 Crack injection 11

16.7

POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE ......................................................... 13 General 13 Resin 13 Minimum strength 14

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16.7.1 16.7.2 16.7.3

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Section 05: Concrete Part 16: Miscellaneous

Page 2

16

MISCELLANEOUS

16.1

GENERAL

16.1.1

Scope

1

This Part deals with miscellaneous items related to concrete works including pavement quality concrete, no fines concrete, lightweight concrete, cementitious grout, screeds, repair of concrete and guniting.

2

Related Sections and Parts are as follows:

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Part 2, .............. Aggregate Part 3, .............. Cementitious Material Part 4, .............. Water Part 5, .............. Admixture Part 6, .............. Property Requirements Part 7, .............. Concrete Plants Part 8, .............. Transportation and Placing of Concrete Part 9, .............. Formwork Part 10, ............ Curing Part 15, ............ Hot Weather Concreting.

.

This Section

References

1

The following standards are referred to in this Part:

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16.1.2

ACI 506, .....................Guide to Shotcrete

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ASTM C989 –10, ........Standard Specification for Slag Cement for Use in Concrete and Mortars

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BS 146,.......................Portland-blast furnace cement

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BS 812,.......................Testing aggregates BS 1881,.....................Testing concrete

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BS 2782,.....................Methods of testing plastics BS 3892,.....................Pulverised fuel ash BS 4551,.....................Methods of testing mortars, screeds and plasters BS 5075,.....................Concrete admixtures BS 6319,.....................Testing of resin and polymer / cement compositions for use in construction BS 6610,.....................Specification for pozzolanic pulverised-fuel ash cement. BS 8203,.....................Code of practice for installation of resilient floor coverings. BS 8500,.....................Concrete BS EN 197-1, .............Cement. Composition, specifications and conformity criteria for common cements BS EN 480,.................Admixtures for concrete, mortar and grout. Test methods (parts: 1, 2, 4, 5, 6, 8, 10, 11, and 12) BS EN 934,.................Admixtures for concrete, mortar and grout (parts: 2, 6) BS EN 998,.................Specification for mortar for masonry

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Section 05: Concrete Part 16: Miscellaneous

Page 3

BS EN 1744-1, ...........Tests for chemical properties of aggregates. Chemical analysis BS EN 12350,.............Testing fresh concrete BS EN 12390-5, .........Flexural strength of test specimens BS EN 12620,............. Aggregates for concrete EN 197-4:2004 ...........Cement. Composition, specifications and conformity criteria for low early strength blastfurnace cements EN 197-4, ...................Cement. Composition, specifications and conformity criteria for low early strength blastfurnace cements EN 12350, ..................Testing fresh concrete EN 1744-1, .................Tests for chemical properties of aggregates. Chemical analysis

.

GSO EN 206-1, ..........Concrete Specification, performance, production and conformity

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SHW 1000 ..................Specification for Highway Works – UK ROAD PAVEMENTS – CONCRETE MATERIALS

PAVEMENT QUALITY CONCRETE

16.2.1

Scope

1

This Subpart covers the mix design for concrete used for aircraft aprons and roadworks as surface slabs, continuously reinforced concrete roadbase, and wet lean mix except cement bound granular material used as a roadbase or sub-base or as a backfill material for excavations.

16.2.2

Mix Designs

1

Concrete in rigid or composite pavements shall be one of the grades given in Table 16.1 below, in accordance, with the pavement design shown on the Drawings or as directed by the Engineer.

2

All concrete for use in pavements shall be designed mixes or equivalent standard mixes in accordance with the relevant clauses of BS 8500 and GSO EN 206-1, except where otherwise specified.

3

Prescribed mixes may be used for rapid construction with the approval of the Engineer.

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16.2

Table 16.1 Pavement Grades Pavement Layer

BS 8500 and GSO EN 2061Designed Mix

Surface Slabs Unreinforced Concrete

C40

Jointed Reinforced Concrete ( JRC )

C40

Continuously Reinforced Concrete Pavement ( CRCP )

C40

Continuously Reinforced Concrete Roadbase ( CRCR )

C40

Ground Anchorage Beam

C40

BS 8500 and GSO EN 206-1 Standard Mix

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Section 05: Concrete Part 16: Miscellaneous

Page 4

BS 8500 and GSO EN 2061Designed Mix

BS 8500 and GSO EN 206-1 Standard Mix

Wet Lean Mix Concrete 4

C20

ST4

Wet Lean Mix Concrete 3

C15

ST3

Wet Lean Mix Concrete 2

C10

ST2

Wet Lean Mix Concrete 1

C7.5

ST1

Pavement Layer

Cement

1

The general term 'cement' in this Part means the materials shown below.

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16.2.3

Complying with

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EN 197-1

Specification for pozzolanic pulverised-fuel ash cement (grades C20 or below)

BS 6610

BS 146 or EN 197-4

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Cement. Composition, specifications and conformity criteria for common cements Portland blast furnace cement

The use of a combination of Portland cement and ground granulated blast furnace slag is permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate the minimum combined cementitious material content required for the mix.

3

The use of a combination of Portland cement and pulverised fuel ash (PFA) is permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate the minimum combined cementitious material content required for the mix. PFA shall be in accordance with BS 3892.

4

The use of microsilica in the mix designs will be permitted if approved by the Engineer.

5

The Engineer will stipulate the minimum combined cementitious material content required for the mix where PFA or GGBFS are used.

6

The maximum proportion of ground granulated blastfurnace slag with Portland cement shall be as per Table 6.6 of Part 5.6.

7

In combination with Portland cement, the proportion of PFA by mass to the total cement shall be as per Table 6.6 of Part 5.6.

8

The limit of chloride content of the concrete shall be as stated in Table 6.5 of Part 5.6.

9

The minimum cement content for concrete pavements shall be preapproved by Qatar Standards.

16.2.4

Water

1

Water for use in the making and curing of concrete shall conform to the requirements of Part 4 of this Section.

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Section 05: Concrete Part 16: Miscellaneous

Page 5

The water content shall be the minimum required to provide the agreed workability for full compaction of the concrete to the required density, as determined by trial mixes or other means approved by the Engineer..

16.2.5

Aggregates

1

The requirements of Part 2 of this specification will govern, except as modified below.

2

Aggregates for all pavement concrete shall be complying with BS EN 12620

3

Alternatively coarse aggregate of recycled and secondary aggregate materials may be used to replace up to 50% by mass of coarse aggregate

4

The nominal size of coarse aggregate shall not exceed 40 mm. When the spacing between longitudinal reinforcement is less than 90 mm, the nominal size of coarse aggregate shall not exceed 20 mm.

5

If requested by the Engineer, the Contractor shall carry out tests on the proposed aggregate combination to check for the possibility of alkali silica reaction. Such tests shall be carried out in accordance with the procedure laid down in Part 2 of this Section.

16.2.6

Admixtures

1

Plasticisers or water reducing admixtures shall comply with BS 5075, BS EN 480 and BS EN 934. Admixtures containing calcium chloride shall not be used.

2

Other chloride-free admixtures may be used with the approval of the Engineer.

16.2.7

Air content

1

The total quantity of air in air-entrained concrete as a percentage of the volume of the mix shall be 5  1.5 % for mixes of nominal aggregate size 20 and be 4  1.5 % for mixes of nominal aggregate size 40.

2

The air content shall be determined at the point of delivery by a pressure type air meter in accordance with BS EN 12350-7, at the rate of one determination per 300 m2 of slab or at least six times per day whichever is the greater, in conjunction with tests for workability and strength. For areas less than 300 m2, the rate shall be at least one determination to each 20 m length of slab or less constructed at one time or at least three times per day. If the air content is outside the specified limits, a further determination shall be made immediately on the next available load of concrete before discharging. If the air content is still outside the limit, the Contractor shall immediately adjust the air content of the concrete to improve its uniformity, before further concrete is used in the Works.

3

The air-entraining agent shall be added at the mixer, by an apparatus capable of dispensing the correct dose within the tolerance for admixtures given in EN 206-1, and so as to ensure uniform distribution of the agent throughout the batch during mixing.

16.2.8

Density

1

The density of concrete Grades greater than C30 shall be such that without air-entrainment the total air voids are not more than 3 %. With air entrainment, the total air voids shall be not more than 8 %, for 20 mm aggregate or 7 % for 40 mm aggregate.

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Section 05: Concrete Part 16: Miscellaneous

Page 6

The density of concrete Grades B15 and B20, mix ST4 or below shall be at least 95 %, of the theoretical maximum dry density.

16.3

CEMENTITIOUS GROUT

16.3.1

General

1

This Subpart covers a general purpose non-shrink cementitious grout. The grout shall be used to where it is necessary to eliminate shrinkage when filling the void between a base plate and a substrate such as in the grouting of stanchion bases, anchorage fixings, including masts, anchor bolts and fence posts.

2

The grout shall be supplied by a reputable construction chemical company as a single pack prepackaged cement based product which is chloride free.

3

For a particular application, the Contractor shall submit a method statement detailing how the formwork will be placed and the points where the grout will be poured.

4

Before beginning work on large repetitive works, the Contractor shall arrange for a site trial of the materials and methods with the suppliers representative being present to train the Contractor’s personnel in the correct use of the material.

16.3.2

Material

1

The grout shall be suitable for filling gaps of thickness up to 100 mm and shall be free flowing and non shrink.

2

Positive volumetric expansion shall take place while the grout is plastic by means of gaseous expansion to avoid shrinkage and cracking.

3

The compressive strength of the grout when tested in accordance with BS EN 12390-3 shall be a minimum of 25 MPa at 24 h, 40 MPa at 7 d and 50 MPa at 28 d.

4

The grout shall exhibit a high early strength gain yet not be subject to cracking or other detrimental effects.

5

At ambient temperatures above 35 C, cool water shall be used for mixing the grout before placing.

16.3.3

Workmanship

1

The storage handling and pouring of the grout shall be in strict accordance with the manufacturer’s instructions.

2

The substrate surface shall be free from oil grease or loose or partially bonded material.

3

If the concrete surface is defective or has laitance it shall be cut back to a sound base.

4

Bolt holes and fixing pockets shall be blown clean of dirt or debris.

5

The substrate shall be soaked with fresh potable water before grouting, although immediately before grouting, free water shall be removed and blown out of bolt holes or pockets.

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Grout shall not be placed in a gap of less than 25 mm for base plates larger than 1 m wide. For larger base plates or flow areas the manufacturers instructions shall be followed.

7

Base plates and metallic items shall be clean and free from oil, grease, or scale.

8

Vent holes shall be provided to allow the release of air from isolated spots.

9

Formwork shall be made leak proof by the use of form rubber strip or mastic sealant between the constructive formwork and joints. Formwork shall extend above the required pour height and if necessary shall be extended to allow a hydrostatic head to aid placement.

10

The grout shall be mixed mechanically with a slow speed drill fitted with a high-shear mixer.

11

The quantity of water to be added to the preweighed bags shall be enough to give the desirable consistency as trowelable or flowable.

12

Mixing shall take place for a minimum of 5 min.

13

The grout shall be placed within the time limit specified by the manufacturer depending on the actual application temperature.

14

Grout shall be poured from one side and it shall be verified that the grout has flowed under all of the base plate with no voids. Pouring from several sides shall not be permitted.

15

Exposed areas of grout shall be thoroughly cured in accordance with Part 10 of this Section.

16.4

SCREEDS

16.4.1

Scope

1

This Subpart covers screeds that provide by means of a layer of mortar a level surface in flooring applications and to provide falls on flat concrete roofs.

16.4.2

General

1

Screeds shall be suitable for application onto a concrete substrate.

2

The screeds shall be suitable for receiving surface finishes which may arrange from thin flexible sheeting to ceramic tiling. The screed is not intended to be the final wearing surface.

3

Screed mortars shall generally comprise sand and cement modified by additives or substituted by other materials such as polymers in order to provide specific performance requirements.

4

For screeds of thickness greater than 40 mm it is permissible to incorporate a proportion of 10 mm aggregate.

5

Aggregates used for screeds shall not contain deleterious materials such as coal or iron particles which may affect the finish the surface of the screed.

6

Admixtures for mortar screeds shall assist workability or alter rates of setting and hardening and shall comply with the appropriate part of BS EN 480 and BS EN 934.

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Section 05: Concrete Part 16: Miscellaneous

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7

Polymer based additives may be used to improve adhesion and strength of thin or featured screeds, these shall be based on polyvinyl acetate (PVA) styrene bituene rubber (SPR) or acrylic polymers.

8

Ready to use sand cement screeds shall comply with the material requirements BS EN 998.

9

Screeds with a rapid drying time to enable earlier floor finishes to be applied shall be used strictly in accordance with the manufacturers’ instructions.

10

The interface of the screed in the concrete substrate shall be specified as one of the following options by the Engineer: Monolithic with the concrete base: The screed shall be applied within 3 hours of placing the concrete base.

(b)

Bonded to the concrete base: Screed shall be laid onto a concrete base which is hardened and is subsequently been prepared to receive the screed, the minimum thickness of the screed shall be 25 mm and the maximum thickness 40 mm.

(c)

As an unbonded screed: The screed shall be laid on a separating layer.

(d)

As a floating screed: The screed shall be laid on an insulating material.

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The cement and sand screed mix shall have the minimum amount of water added to give sufficient workability and allow the material to be thoroughly compacted.

12

Pan type mixes shall be used to ensure efficient mixing of materials, the cement to aggregate ratio shall be between 1 to 3 and 1 to 4.5 by weight. The mixing of the sand cement, water and admixtures shall ensure a thorough homogeneous mixture with no balling up of the cement.

13

Screeds shall be laid either between carefully levelled and trued batons or between strips of screed laid and compacted to a finished level.

14

For bonded screed where a high degree of bond is required the surface laitance of the concrete base shall be mechanically removed to expose the coarse aggregate. A thin layer of neat cement grout shall be applied to the prewetted or dampened concrete and the screed applied and compacted while the grout is wet.

15

Screeds shall be fully compacted by heavy hand or mechanical tamping. The screed at joints around the perimeter shall be particularly well compacted to avoid breaking out and curling.

16

Screeds thicker than 50 mm shall be laid in two approximately equal layers; screed shall be kept protected by waterproof sheeting for at least 7 days after laying.

17

Sheet and non ceramic tiling finishes shall only be applied after the screed has cured and necessary strength achieved.

18

If requested by the Engineer the Contractor shall carry out a soundness and impact test in accordance with BS 8203.

19

Screeds shall be laid in bays of a size to minimise thermal moisture contraction. Contraction or movement joints shall be provided as appropriate, where shown on the drawings or as directed by the Engineer. Bays shall be laid alternatively.

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Section 05: Concrete Part 16: Miscellaneous

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Bay sizes shall be approximately 15 m2 for 100 mm thick screed and 12 m2 for 75 mm thick screed.

16.5

CELLULAR CONCRETE

1

Cellular Concrete (CC) is conventional concrete, where natural aggregate (gravel) is exchanged for an insulation medium, namely air, embedded in an organic and biodegradable foam. It behaves, like conventional concrete, in particular concerning curing, hardening and most important "ageing ". CC infinitely increases its strength by hydration as long as exposed to humidity in the atmosphere.

2

CC offer more thermal insulation and a substantially higher fire-rating than conventional concrete.

3

Minimum compressive strengths shall be 4.0 MPa.

4

The required density and strength of the CC shall be specified on the drawings and approved by the Engineer.

5

The method of production of Cellular Concrete shall be shown on the drawings or directed by the Engineer. The Contractor shall submit full technical details of the materials and method of production for the CC along with a list of previous projects where the particular system has been used.

6

After source approval of the material and system the Contractor shall submit a mix design for the CLC for the approval of the Engineer. After the review and approval of the mix theoretical mix design the Contractor shall carry out a trial mix to check the workability of the fresh concrete and to allow samples to be made for compressive strength and density.

7

The Engineer may also instruct that tests are carried out for abrasion resistance and thermal insulation properties.

8

Cellular Concrete shall not be used for structural reinforced members.

16.6

REPAIR OF CONCRETE

16.6.1

General

1

The extent and nature of the defects in concrete shall be established in accordance with Part 15 of this Section. Based on these results the Engineer shall confirm the acceptability of the work and whether remedial works are required.

2

If remedial works are required the Contractor shall submit a detailed method statement identifying the specific materials to be used and the sequence of activities for the repair.

3

Only proprietary proven materials that form part of a standard repair system shall be used.

16.6.2

Honeycombing or Spalling

1

Where there is honeycombed concrete or concrete damaged by physical forces such as impact that has caused spalling, the concrete shall be replaced using a high strength free flowing cementitious micro-concrete.

2

The areas of repair shall be marked out and agreed with the Engineer.

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All honeycombed, loose, cracked or friable concrete in these areas shall be removed until sound concrete is reached. Due account shall be taken of propping or other instructions given by the Engineer regarding sequences of removal and repair.

4

The equipment and methods used to break out the concrete shall be such that no reinforcing steel or other embedded items such as conduits, lifting sockets, or other inserts are loosened or damaged unless so directed by the Engineer.

5

Where the removal of concrete by mechanical means is difficult due to reinforcement congestion, then the use of high pressure water jetting shall be considered and necessary provisions for protecting the rest of the structure shall be made.

6

The prepared void shall be profiled so that entrapment of air is avoided during the repair process using fluid micro-concrete.

7

The minimum depth of repair shall be 40 mm throughout. The perimeter of the area to be repaired shall first be cut to a depth of 10 mm using a suitable tool. Feather edges will not be accepted.

8

The prepared concrete surface shall be sound and clean and free of loose particles, dust and debris.

9

Where exposed reinforcement is sound, it shall be mechanically cleaned of rust and loose millscale.

10

Reinforcement damaged during the removal of concrete or the preparation process shall, if required by the Engineer, be repaired or replaced.

11

Adequate formwork shall be provided in accordance with of Part 9 of this Section. This shall be securely fixed to withstand the hydraulic pressures of the fluid micro-concrete repair material without distortion or movement during placement.

12

The formwork shall be watertight at all joints between panels and between the formwork and the existing concrete surface so as to prevent grout leakage.

13

The formwork shall be constructed from appropriate materials as agreed with the Engineer to achieve the required finish.

14

Formwork surfaces that are to be in contact with the repair micro-concrete shall be treated with a suitable mould release agent. This shall be used in accordance with the manufacturer's recommendations.

15

The entry point of the feed pipe into the form shall be at the lowest point of the void. Sufficient hydrostatic head or pumping pressure shall be maintained to ensure that the void is filled completely and no air remains entrapped.

16

Where necessary, provision shall be made for controllable bleed points to prevent air entrapment and enable the extent of flow of the repair material to be assessed.

17

The formwork shall be inspected by the Engineer and, if approved, filled with clean water which demonstrates that the formwork is grout-tight and saturates the prepared concrete surfaces. The formwork shall be then be completely drained and resealed

18

In situations where the completed repair will be subjected to constant immersion an epoxy bonding agent shall be applied in accordance with the manufacturers’ instructions.

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19

Both the Compressive strength and Flexural strength shall be at a water:powder ratio of 0.18 and tested at 20 oC

20

The thermal conductivity and the elastic modulus of the repair material shall be compatible with the host concrete.

21

If requested by the Engineer, recent test results of the material for the following properties shall be submitted: (a)

thermal conductivity

(b)

elastic modulus, BS 1881

(c)

expansion characteristics, ASTM C 827, CRD 621-82A

(d)

flow characteristic, UK DOT BD 27/86 paragraph 4.6 B.

The micro-concrete shall be mixed and placed in accordance with the manufacturer's recommendations, particularly with regard to water content, mixing equipment and placing time.

23

As far as possible the placing of the micro-concrete shall be continuous. The mixing operation shall be timed so that there is minimal interruption in the material flow. If, however, placing is interrupted, the operation shall recommence as soon as possible while the repair material retains its flow characteristics.

24

The formwork shall not be removed until the repair micro-concrete has achieved a compressive strength of at least 10 MPa or as directed by the Engineer.

25

Immediately after removal of the formwork the repair area shall be cured in accordance with Part 10 of this Section.

26

The repair material shall:

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be shrinkage compensated in both liquid and cured states

(b)

contain no metallic expansion system

(c)

be prepacked and factory quality controlled

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be a free-flowing cementitious material that has a coefficient of thermal expansion fully compatible with the host concrete and which complies with the requirements of Table 16.3.

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Table 16.3 Property requirements of micro concrete Property

Test Method

Minimum Value

Compressive strength

BS EN 12390-3 @ 28 d

50 MPa

Flexural strength

BS 4551 @ 28 d

10 MPa

Anchorage bond

BS 8110

Passes

16.6.3

Crack injection

1

This clause of the specification covers non-active cracks within concrete elements caused by shrinkage or other structural movement. Non-active cracks shall be injected with a lowviscosity epoxy resin to fill and seal the crack and restore the structural integrity.

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Section 05: Concrete Part 16: Miscellaneous

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Before to starting the injection operation it shall be established by testing and investigation work that cracks manifest within concrete elements due to either or both shrinkage or structural movement are non-active.

3

The extent of the cracks to be filled will be as directed by the Engineer. The cracks to be filled shall be marked out in detail on the concrete elements by the Contractor and agreed with the Engineer before proceeding.

4

The extent of the work may be adjusted by the Engineer as the project proceeds, according to the conditions found.

5

Grease, oil or other contaminants shall be removed. Algae and other biological growth shall also be removed by scrubbing with bactericide or detergent and clean water. If necessary, wire brushes shall be used.

6

Loose or spalling areas of concrete, laitance, traces of paint or other coating materials within the marked out scope of the work shall be removed.

7

All cracks shall be thoroughly cleaned out using clean, oil-free compressed air. Both the concrete surface and the cracks shall be allowed to dry thoroughly before continuing.

8

The injection nipples shall be fixed at intervals along the length of each crack. The distance between each nipple will depend on the width and depth of the crack.

9

Spacing shall be close enough to ensure that the resin will penetrate along the crack to the next point of injection. This will normally be between 200 mm and 100 mm.

10

Each nipple shall be firmly bonded to the concrete surface by using a sealant. The sealant shall be supplied in two pans (liquid base and hardener system). The two components shall be thoroughly mixed together for 3 to 4 min until a putty-like consistency is achieved.

11

The mixed sealant shall be applied to the metal base of each surface-fixed nipple. They shall be pressed firmly into place and held for several seconds until secure. The mixed sealant shall be applied around each embedded nipple, ensuring a complete seal is made. In this way, all the nipples shall be fixed along the length of the crack.

12

In the case of a wall or slab which is cracked all the way through, nipples shall be located on both sides with those at the back placed at midway points between those it the front.

13

The surface of the cracks between the nipples shall be sealed with a band of sealant 30 to 40 mm wide and 2 to 3 mm thick. Both sides if cracks which go all the way through a wall or slab shall be sealed in this way.

14

The prepared cracks shall be allowed to cure for 12 to 24 h. At low ambient temperatures (5 °C to 12 °C) the curing time will be extended and the Contractor shall ensure that the surface sealant has adequately cured before continuing.

15

One end of the injection hose shall be attached to the lowest nipple on vertical cracks or to either end of horizontal cracks.

16

Each crack shall be treated in a single, continuous operation. Sufficient material shall therefore be made ready before the commencement of the work.

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The Contractor shall to ensure that sufficient cracks are prepared to provide effective use of the mixed material.

18

The preparation, mixing and application of the materials shall be undertaken in strict accordance with the manufacturer's recommendations. The Contractor is to ensure that all necessary tools and equipment are on Site.

19

Both the compressive strength and flexural strength shall be tested at 7 d.

20

The material shall exhibit excellent bond to concrete and when tested for tensile adhesion the failure shall be in the concrete and not at the interface.

21

The injection resin shall be of a prepackaged or preweighed type and only the use of full units will be allowed. No part packs or on-Site batching will be allowed under any circumstances.

22

In all operations of storage, mixing and application, the Contractor shall comply with the health and safety recommendations of the manufacturer and governing authorities.

23

The injected system shall be allowed to cure for 24 h and shall be left undisturbed for this time.

24

The nipples and bands of surface sealant shall then be removed and damaged areas made good to the satisfaction of the Engineer.

25

The injection material shall be compatible with the host concrete and shall have the properties shown in Table 16.4 when tested in accordance with the relevant standards.

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Table 16.4 Property Requirement for Epoxy Crack Injection Material Method

BS 4551, BS 2782 BS 6319

Flexural strength

BS EN 12390-5

70 MPa

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Compressive strength

Minimum Value

POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE

16.7.1

General

1

Polyester resin concrete is a mixture formed from aggregates and fillers which are bound together using a polyester resin (also called Polymer concrete pipes), as defined in ISO 18672-1 or ASTM D 6783 with the amendments given below.

2

Polyester resin concrete is permitted for use in infrastructure drainage and sewage systems (pipes, manhalls, soakways).

16.7.2

Resin

1

The resin used in the pipe system and manufactured as per ISO 18672-1shall have a temperature of deflection of at least 85 °C, when tested in accordance with Method A of ISO 75-2 with the test specimen in the edgewise position. It shall also conform to the applicable requirements of EN 13121-1.

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2

The resin used in the pipe system and manufactured as per ASTM D 6783 shall have a minimum deflection temperature of 85°C when tested at 1.82 MPa following Test Method D648. The resin content shall not be less than 7 % of the weight of the sample as determined by Test Method D2584.

16.7.3

Minimum strength

1

The minimum strength classes for different pipe shapes are given below. Table 16.4

.

Minimum strength classes for pipes designated PRC-OC or PRC-TC Strength class Sc Nominal size N/mm DN PRC-TC

150 ≤ DN ≤ 500

180

180

600 ≤ DN ≤ 1000

145

1200 ≤ DN≤ 3000

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Table 16.5 Minimum strength classes for pipes designated PRC-OE or PRC-TE Strength class Sc N/mm

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Nominal width/height WN/HN

PRC-TE

300/450 ≤ WN/HN ≤ 600/900

180

180

700/1050 ≤ WN/HN ≤ 1000/1500

145

160

120

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1200/1800 ≤ WN/HN ≤ 1400/2100

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Table 16.6 — Minimum strength classes for pipes designated PRC-OK or PRC-TK Strength class Sc N/mm

Nominal size DN

PRC-OK

PRC-TK

800 ≤ DN ≤ 1000

145

160

1200 ≤ DN ≤ 1800

120

145

END OF PART

Section 02: Quality Assurance and Quality Control Part 15: Appendix B - Templates

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Section 02: Quality Assurance and Quality Control Part 15: Appendix B - Templates

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Section 02: Quality Assurance and Quality Control Part 15: Appendix B - Templates

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Section 02: Quality Assurance and Quality Control Part 15: Appendix B - Templates

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Section 02: Quality Assurance and Quality Control Part 15: Appendix B - Templates

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Section 02: Quality Assurance and Quality Control Part 15: Appendix B - Templates

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Section 02: Quality Assurance and Quality Control Part 15: Appendix B - Templates

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Section 02: Quality Assurance and Quality Control Part 15: Appendix B - Templates

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Section 02: Quality Assurance and Quality Control Part 15: Appendix B - Templates

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CONTRACTORS INSPECTION AND TEST PLAN TEMPLATE

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QUALITY NON-CONFORMANCE TEMPLATE

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END OF PART

Page 17

QCS 2014

Section 02: Quality Assurance and Quality Control Part 02: Submittals

Page 1

SUBMITTALS .......................................................................................................... 2

2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7

GENERAL ............................................................................................................... 2 Project Quality Plan 2 Quality Organisation Plan 3 Inspection and Test Plans 4 Quality Checklists 5 Key Performance Indicators 5 Method Statements 6 Commissioning Plan 6

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Page 2

SUBMITTALS

2.1

GENERAL

2.1.1

Project Quality Plan

1

The Contractor shall prepare the necessary Contract specific Project Quality Plan as specified in this Section, the Contract Documents and as a minimum meeting the requirements ISO 9001 and ISO 10005 and submit them to the Engineer for review and approval within 30 days of the award of Contract. The Contractor is not permitted to Work on the worksite until such time as the plan has been approved by the Engineer.

2

The Contractor shall regularly review the suitability of the Project Quality Plan. The Contractor shall undertake a full formal review of the quality plans annually with reference to the date of award of the Contract and submit the findings of the review to the Engineer within 14 days of that date along with an amended plan should any amendments be required.

3

The Project Quality Plan shall describe the Contractor’s Quality Management System that will be used throughout the Contract and the contents shall include but not be limited to the following: Front Cover

(b)

Table of Contents

(c)

Project Scope, Requirements and Quality Objectives

(d)

Quality Policy and ISO 9001 Certificate (if applicable)

(e)

Control of Project Quality Plan

(f)

Reference Documentation

(g)

Project Management, Planning and Resources

(h)

Management, Organisation and Responsibilities

(i)

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Contract Review Project Deliverables

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(k)

Communication with the Engineer

(l)

Management of Documents, Data and Records

(m)

Design (Including Temporary Works)

(n)

Procurement of Services, Equipment and Materials

(o)

Method Statements

(p)

Inspection and Test

(q)

Product Identification and Traceability

(r)

Owner Supplied Product

(s)

Handling, Storage, Packaging and Delivery

(t)

Non-conformance, Corrective and Preventative Action

(u)

Control of Inspection, Measuring and Test Equipment

QCS 2014

Section 02: Quality Assurance and Quality Control Part 02: Submittals Audits

(w)

Training

(x)

Key Performance Indicators and Continual Improvement

(y)

Management Review

(z)

Quality Meetings

(aa)

Monthly Quality Report

(bb)

Commissioning

(cc)

Interface Management

(dd)

Project Completion and Handover

(ee)

Appendices

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And include as a minimum:

a detailed description of procedures, instructions, and reports to be used to ensure compliance with the Project Documentation

(b)

a detailed description of procedures for reviewing shop drawings, samples, certificates and other submittals necessary for compliance with the Project Documentation

(c)

a detailed description of procedures used to identify, report and resolve problems

(d)

a description of the services provided by outside organisations such as testing laboratories, architects, and consulting engineers

(e)

a detailed description of inspections and tests required

(f)

copies of forms and reports to be used to document quality assurance operations

(g)

the names of personnel responsible for each part of the Works

(h)

a submittal status log listing required submittals and action required by the Contractor and Engineer

(i)

a detailed description of document and submittal control procedures

(j)

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an inspection and test schedule keyed to the construction programme procedures to identify and control the use of items and materials

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5

No construction shall begin and no requests for payment from the Contractor shall be processed until the Contractor’s Project Quality Plan is approved.

6

A Contractors Project Quality Plan Template with guidance notes is included in Part 15 Appendix B of this Section. The format of the Contractors Project Quality Plan must follow this template including all clauses contained within.

2.1.2

Quality Organisation Plan

1

The Contractor shall submit a Quality Organisation Plan to the Engineer for approval no later than thirty (30) days from the start of the Contract.

2

The Quality Organisation Plan shall provide the names, qualifications, experience and skills of all the QA/QC Team including Corporate QA/QC Manager, Quality Management Representative and key support staff.

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Section 02: Quality Assurance and Quality Control Part 02: Submittals

Page 4

The Quality Organisation Plan shall show the organisation of Contractor’s quality team and shall include, but not be limited to, the following: (a)

an organisation chart identifying all personnel responsible for quality

(b)

Identify the quality team showing that the team is independent of the job supervisory staff with clear lines of authority to top tier management.

(c)

Indicate and describe the area of responsibility and authority of each individual in the quality assurance team.

The Quality Organisation Plan should also define quality responsibilities of any of the Contractors team with responsibilities under the Contractors Project Quality Plan.

5

The Contractor’s Quality staff shall have relevant educational and professional qualifications, and training as defined in 3.1.7 (1). The Contractor is not permitted to execute any form of the works at the worksite until such time as approved quality personnel have been deployed on a fulltime basis to the worksite. The Contractor shall not remove or replace the appointed quality personnel without prior approval from the Engineer.

6

The Quality Organisation Plan may form part of the Project Quality Plan or be prepared as a standalone document and cross-referenced within the Project Quality Plan.

2.1.3

Inspection and Test Plans

1

As part of the Project Quality Plan the Contractor shall submit an Inspection and Test Plan Schedule to the Engineer for approval no later than thirty (30) days from the start of the Contract.

2

The Inspection and Test Plan schedule shall define the Inspection and Test Plans to be prepared for the Works and the target dates for their submission to the Engineer for his approval.

3

The Inspection and Test Plans shall consider the requirements of each Section of the Specification and shall identify, as a minimum, the following:

(b)

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(c)

the required inspection and testing frequency

(d)

the acceptance/rejection criteria

(e)

whom from the Contractors team is responsible and qualified to perform the inspection or test

(f)

Quality Records to be generated

(g)

Hold, Witness, surveillance and Record Review points of the Contractors team, the Engineer and any other agencies having jurisdictional authority over the work relating to each inspection and test to be performed.

Details each activity, inspection and test to be performed Reference to specifications, standards etc.

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Each inspection and test shall have a unique reference number.

5

Inspection and Test Plans are required to address the Contractors on and off site Work and preparation, submission and approval of related documentation.

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Section 02: Quality Assurance and Quality Control Part 02: Submittals

Page 5

Inspection and Test Plans are required for all operations including major temporary works and commissioning.

7

No work covered by the Inspection and Test Plan shall begin until the plan has been approved by the Engineer.

8

A Contractors Inspection and Test Plan Template with guidance notes is included in Appendix B of this Section and must be used by the Contractor

2.1.4

Quality Checklists

1

The Contractor shall develop specific quality checklists for all activities to be checked as per the Inspection and Test Plans and submit to the Engineer for the approval with the Inspection Test Plans submission prior to the start of the activity.

2

The Contractor shall inspect the work and sign off the relevant checklist and Inspection Request prior to the final inspection with the Engineer.

3

The checklist shall be attached with the Inspection Request and other relevant attachments and submitted to the Engineer.

2.1.5

Key Performance Indicators

1

The Contractor shall develop and report Key Performance Indicators (KPI’s). KPI’s are a set of quantifiable measures that are used to gauge performance of the Contractors Performance.

2

The KPI’s shall be defined in the Contractors Project Quality Plan and be subject to Engineers approval.

3

The Contractor is responsible for developing his own KPI’s for all elements of his contract (Contractual, Commercial, Safety etc.) but as a minimum shall address the following KPI’s.

Time between opening and closure of Nonconformance Reports (NCR) and Corrective Action Requests (CAR).

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(c)

NCR and CAR statistics per areas, sections, discipline, subcontractor etc.

(d)

Percentage of reoccurring NCR’s and CAR’s – Trends on NCR’s and CAR’s.

(e)

Approval status of critical documentation for the progress of the works (Method Statements, ITPs etc.).

(f)

Statistical data from inspections as per the Inspection & Test Plans (Pass vs failed, pass first time, etc.).

(g)

Completion packages (As-Built folders) progress.

Reporting of the KPI’s shall include a graphical bar chart representation on a month by month basis from the start of the Contract.

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Page 6

Method Statements

1

Contractor shall ensure that Method Statements address quality issues. Refer to Section 11 Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in particular section 2.4

2.1.7

Commissioning Plan

1

The Contractor shall submit a Commissioning Plan to the Engineer for approval no later than sixty (60) days unless agreed otherwise with the engineer before the start of the commissioning of the Works or any part thereof.

2

The Commissioning Plan shall consider the requirements of each Section of the Specification in turn and shall identify the following:

.

2.1.6

all required commissioning work required by that Section of the Specification

(b)

any prerequisites to commissioning

(c)

a list of the commissioning procedure

(d)

a detailed description of the duties and responsibilities on the personnel involved in the commissioning process

(e)

a detailed list of the tests/checks/activities that will be performed, linked to the relevant construction activities and referenced to any links/documents to the ITPs performed during the construction

(f)

specific reference to the witness/hold and review points of the engineer

(g)

a detailed list of the standards /specifications/regulatory requirements that need to be performed

(h)

a detailed description of the interactions/communication organization/public service or other legal/regulatory institutions

(i)

a detailed description of the test/activities of the maintenance needed during the life time of the project, with reference to any special requirements/qualifications of the personnel involved in the maintenance activities

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a detailed description of any spare parts/equipment/fixtures and other type of the of consumables that might be needed, with an estimation of quantities, for the life time of the project

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(k)

a detailed description of the as built project file that will be created after the commission phase

(l)

a procedure for up-date and revision of the commissioning plan

No work covered by the Commissioning Plan shall begin until the plan has been approved. END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 03: Contractor’s Quality Personnel

Page 1

CONTRACTOR’S QUALITY PERSONNEL ............................................................. 2

3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8

INTRODUCTION ..................................................................................................... 2 General 2 Quality Assurance Manager 2 Quality Control Manager 2 Quality Engineer 2 Quality Inspector 3 Personnel Qualifications 3 Quality Staff Requirement 3 Quality Training for Contractor’s Employees and Labour 5

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Section 02: Quality Assurance and Quality Control Part 03: Contractor’s Quality Personnel

Page 2

CONTRACTOR’S QUALITY PERSONNEL

3.1

INTRODUCTION

3.1.1

General

1

Contractor shall, throughout the execution and completion of the Works and the remedying defects therein have on his staff at the Site office(s) a dedicated Quality Team dealing only with matters regarding the quality and protection against damage before, during and after execution of Works as specified in this section. This team shall be qualified and experienced in their work and shall have the authority to issue instructions and shall take protective measures to prevent execution of Works that do not comply with the Specifications.

2

The Contractor shall notify the Engineer in writing prior to re-assigning or replacement of any of the quality team designated in the Quality Organisation Plan.

3

The Contractor shall have adequate quality personnel on the site during all production operations, including adequate coverage during night shift operations and off site work.

4

The Contractor's quality team shall have the authority to stop any portion of the work which does not comply with the requirements of the Project Documentation.

5

Minimum qualifications and experience of the Contractors Quality Personnel shall be as defined in the Contract.

3.1.2

Quality Assurance Manager

1

Where required by this section, the Contractor shall designate and assign a full time Quality Assurance Manager who shall be responsible for overseeing the implementation and operation of the Project Quality Plan at all levels. The Quality Assurance Manager shall report directly to Top Tier Management and be independent of the Contractors organisation responsible for construction.

3.1.3

Quality Control Manager

1

Where required by this section, the Contractor shall designate and assign a full time Quality Control Manager who reports directly to the Quality Assurance Manager and shall be responsible for supervision of the construction quality control management activities and ensuring compliance with the Contractors Inspection and Test Plans and associated specification and contract documentation.

3.1.4

Quality Engineer

1

Where required by this section, the Contractor shall designate and assign a Quality Engineer who reports directly to the Quality Assurance Manager or Quality Control Manager and shall be responsible for assisting them with their day to day responsibilities and may be assigned to cover several locations or areas of work relating to the Contract. Where a Quality Assurance Manager or Quality Control Manager are not required by this section the Quality Engineer shall be assigned all the responsibilities defined in clause 3.1.2, 3.13, and 3.1.7.

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Section 02: Quality Assurance and Quality Control Part 03: Contractor’s Quality Personnel

Page 3

Quality Inspector

1

The Contractor shall designate and assign a Quality Inspector for each shift for each location where work is being performed. Each Quality Inspector shall be qualified by training and experience in all the construction or fabrication activities being conducted at the location of work and is directly responsible for ensuring compliance with the Contractors Inspection and Test Plans and associated specification and contract documentation.

3.1.6

Personnel Qualifications

1

The Contractor shall identify activities requiring qualified production, inspection, and test personnel and establish their minimum competence level.

2

The Contractor shall maintain records of personnel qualifications as quality records.

3.1.7

Quality Staff Requirement

1

Unless otherwise specified by the Engineer the Contractor shall employ fulltime qualified quality personnel for the Work as per below tables.

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3.1.5

No of workers on Worksite

Requirement

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Quality Staff Requirement

1 Quality Inspector (Part time, 15 hours of duty per week)

Less than 10

2.

More than 11 but less than 50

3.

More than 51 but less than 500

4.

More than 501 but less than 1500

1 Quality Assurance Manager and 1 Quality Engineer per 500 workers and 1 Quality Inspector per 100 workers

More than 1501

1 Quality Assurance Manager and 1 Quality Control Manager and 1 Quality Engineer per 500 workers and 1 Quality Inspector per 100 workers

1 Quality Inspector

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1 Quality Engineer and 1 Quality Inspector per 100 workers

QCS 2014

Section 02: Quality Assurance and Quality Control Part 03: Contractor’s Quality Personnel

Page 4

Quality Management and Control staff Qualifications & Experience Matrix Minimum Qualifications Required

Position

Minimum Years of Experience

Minimum Key Competencies

Degree in relevant 12 years, 5 of which at Engineering discipline and Management Level and 3 related training in Quality years Regional experience Management Techniques. Internationally recognised Lead Auditor Certificate

Qualified Professional who can manage a Quality Management System and coordinate specialised activities. Excellent written & verbal communication skills in English

Quality Control Manager

Degree in relevant 12 years, 5 of which at Excellent written & verbal Engineering discipline and Management Level and 3 communication skills in related training in Quality years Regional experience English Management Techniques. Internationally recognised Lead Auditor Certificate

Quality Engineer

Degree in relevant Engineering discipline. Internationally recognised Lead Auditor Certificate

Quality Inspector

Certificate or Diploma in the appropriate engineering discipline

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Quality Assurance Manager

Good written & verbal communication skills in English

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10 years’ experience in related Quality Control Activities and 3 years Regional experience

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5 years’ experience in Good written & verbal related Quality Control and communication skills in Materials Testing activities English along with 2 years Regional Experience

The Contractor shall appoint deputy quality personnel who are capable of performing all the duties of the quality personnel in the event of their absence.

3

The Contractor shall appoint support staff in sufficient numbers to ensure the effective function of the quality related work within the Contractor’s organisation.

4

The Contractor shall ensure that every Sub-contractor employed on the Worksite appoints suitably qualified quality staff to ensure the effective function of the quality related issues within the Sub-contractor’s organisation. The Sub-contractor shall appoint and deploy fulltime on the Worksite one Quality Inspector for every 100 workers that they employ at the Worksite. Any Sub-contractor that employs more than 100 workers will appoint a Quality Engineer. This shall be in addition to the Contractor’s Quality Team.

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Section 02: Quality Assurance and Quality Control Part 03: Contractor’s Quality Personnel

Page 5

Quality Training for Contractor’s Employees and Labour

1

The Contractor shall conduct quality training including Contract specific induction, pre-work briefings, skills training, tool box talks and formal training conducted by training professionals or agencies for all the Contractor’s employees. The Contract specific induction will be at least 1 hour duration, approved by the Engineer and provided for all persons involved in the Works. Such induction training will be reviewed, revised and repeated at intervals not exceeding 12 months throughout the duration of the Work. All training shall be provided in the languages preferred by the recipients of the training. Training shall focus on improving competency and skill for those performing activities that impact quality.

2

The Contractor must conduct regular tool box talks to his Labour workforce Such training should include as a minimum Health and Safety issues and Construction Method best practice.

3

The Owner may organise quality related training, meetings, seminars, workshops or similar events at any time throughout the Contract Period. The Contractor is required to participate in such events when requested at his own expense.

4

The Contractor shall maintain records of all training conducted including details of the training given and a list of attendees, including attendee’s signature and ID numbers.

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3.1.8

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END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 04: Document & Data Control

Page 1

DOCUMENT & DATA CONTROL ............................................................................ 2

4.1 4.1.1 4.1.2 4.1.3

INTRODUCTION ..................................................................................................... 2 General 2 Document and Data Approval and Issue 2 Document and Data Changes 2

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Section 02: Quality Assurance and Quality Control Part 04: Document & Data Control

Page 2

DOCUMENT & DATA CONTROL

4.1

INTRODUCTION

4.1.1

General

1

The Contractor shall establish and maintain documented procedures to control all documents and data that relate to the requirements of the Specification. Documents and data can be in the form of any type of media, such as hard copy or electronic media.

2

The Contractor shall maintain up to date copies of all industry codes and standards that apply to the Contract.

4.1.2

Document and Data Approval and Issue

1

The documents and data shall be reviewed and approved for adequacy by authorised personnel prior to issue. A master list or equivalent document control procedure identifying the current revision status of documents shall be established and be readily available to preclude the use of invalid and/or obsolete documents. This control shall ensure that:

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4

The pertinent issues of appropriate documents are available at all locations where operations essential to the effective functioning of the quality system are performed

(b)

Invalid and/or obsolete documents are promptly removed from all points of issue or use, or otherwise assured against unintended use

(c)

Any obsolete documents retained for legal and/or knowledge preservation purposes are suitably identified

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(a)

Document and Data Changes

1

Where practicable, the nature of the change shall be identified in the document or appropriate attachments.

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4.1.3

END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 05: Quality Records

Page 1

QUALITY RECORDS..................................................................................... 2

5.1 5.1.1

INTRODUCTION ........................................................................................... 2 General 2

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Section 02: Quality Assurance and Quality Control Part 05: Quality Records

Page 2

QUALITY RECORDS

5.1

INTRODUCTION

5.1.1

General

1

The Contractor shall establish and maintain documented procedures for identification, collection, indexing, access, filing, storage, maintenance and disposition of quality records.

2

The Contractor shall supplement these quality records as necessary to monitor quality throughout the Contract period.

3

Quality records shall be maintained to demonstrate conformance of materials and equipment to specified technical requirements and the effective operation of the quality system.

4

All quality records shall be legible and shall be stored and retained in such a way that they are readily retrievable in facilities that provide a suitable environment to prevent damage or deterioration and to prevent loss.

5

As a minimum, the quality record for any particular item shall include: name of item

(b)

item number

(c)

item description

(d)

suppliers name

(e)

serial number or other identification (where applicable)

(f)

Specification reference (where applicable)

(g)

verification of receipt of all required supporting documentation

(h)

quantity of items

(i)

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location and installation of item inspection/test procedure reference

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(k)

non-conformance number (if applicable)

(l)

Observations / comments.

(m)

Signatures of responsible person

END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 06: Quality Audits

Page 1

QUALITY AUDITS ................................................................................................... 2

6.1 6.1.1 6.1.2

GENERAL ............................................................................................................... 2 Contractor’s Quality Audit 2 Engineer’s Quality Audit 2

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Section 02: Quality Assurance and Quality Control Part 06: Quality Audits

Page 2

QUALITY AUDITS

6.1

GENERAL

6.1.1

Contractor’s Quality Audit

1

The Contractor shall establish and maintain documented procedures in line with ISO 190011 for planning and implementing internal quality audits to verify whether quality activities and related results comply with planned arrangements and to determine the effectiveness of the quality system.

2

Internal quality audits shall be scheduled on the basis of the status and importance of the activity to be audited and shall be carried out by personnel independent of those having direct responsibility for the activity being audited. Unless otherwise agreed with the Engineer in writing, the Contractor shall carry out a full system quality audit every three months.

3

The results of the audits shall be recorded and brought to the attention of the personnel having responsibility in the area audited. The management personnel responsible for the area shall take timely corrective action on deficiencies found during the audit.

4

Follow-up audit activities shall verify and record the implementation and effectiveness the corrective action taken.

5

The results of the Contractor’s quality audits shall be made available for review by the Engineer. The Contractor shall implement any recommendations made by the Engineer based on the results of the internal audit.

6

The Contractor shall allow the Engineer to observe the Contractor’s internal audit upon request.

7

Quality audits must be undertaken by suitably qualified personnel with an internationally recognized audit qualification to recognized standards.

6.1.2

Engineer’s Quality Audit

1

The Engineer may undertake a quality audit of any of the Contractor’s activities at any time during the course of the Contract. The Contractor shall make all personnel and facilities available to the Engineer as necessary to undertake quality audits.

2

The Engineer shall make the results of his quality audit available to the Contractor for review. The Contractor shall implement any recommendations made by the Engineer based on the results of the Engineer’s quality audit.

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END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 07: Inspection and Test

Page 1

INSPECTION AND TEST ........................................................................................ 2

7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7

INTRODUCTION ..................................................................................................... 2 General 2 Inspections and Tests 2 Inspection and Test Status 3 Inspections by the Engineer during construction 3 Inspections by the Engineer during Defects Liability Period 4 Workmanship 4 Measuring and Test Equipment 4

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7

Section 02: Quality Assurance and Quality Control Part 07: Inspection and Test

Page 2

INSPECTION AND TEST INTRODUCTION

7.1.1

General

1

The Contractor shall provide equipment, instruments, qualified personnel, and facilities necessary to inspect the work and perform the tests required by the Project Documentation.

2

The Contractor shall repeat tests and inspections after correcting non-conforming work until all work complies with the requirements. All re-testing and re-inspections shall be performed at no additional cost to the Client.

3

The Engineer may elect to perform additional inspections and tests at the place of the manufacture or the shipping point to verify compliance with applicable Specifications. Inspections and tests performed by the Engineer shall not relieve the Contractor of his responsibility to meet the Specifications. Inspections and tests by the Engineer shall not be considered a guarantee that materials delivered at a later time will be acceptable. All costs associated with the foregoing shall be borne by the Contractor.

4

Inspections and tests conducted by persons or agencies other than the Contractor, shall not in any way relieve the Contractor of his responsibility and obligation to meet all Specifications and referenced standards.

7.1.2

Inspections and Tests

1

All inspections and tests shall be conducted in accordance with written test procedures as detailed in the Project Quality Plan and Inspection and Test Plans that have been reviewed and approved by the Engineer.

2

Mandatory Products and Materials Sampling and Testing Frequencies are included in Part 14, Appendix A of this section. The Contractor shall follow the Sampling and Testing Frequencies stipulated in Appendix A unless otherwise stated in the Contract. The table in Appendix A shall be read and understood in tandem with the footnotes in Appendix A.

3

Inspection and test procedures submitted for approval shall include, but not be limited to, the following:

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7.1

(a)

inspection/test procedure reference

(b)

references to Clauses of this Specification and other standards along with applicable inspection/test levels specified therein

(c)

prerequisites for the given inspection/test

(d)

required tools, equipment

(e)

necessary environmental conditions

(f)

acceptance criteria

(g)

data to be recorded

(h)

reporting forms

(i)

Identification of items inspected and tested.

(j)

Contractors and Engineers Hold, Witness, Surveillance and Record Review Points

QCS 2014

Section 02: Quality Assurance and Quality Control Part 07: Inspection and Test

Page 3

Approved procedures and instructions shall be readily available and used by inspection and test personnel at the time of inspection or test. All revisions to these procedures and instructions shall be approved prior to being used to inspect or test the work. No deviations from the approved procedures and instructions shall be allowed without written authorisation from the Engineer.

5

Inspection and testing work shall be performed by personnel designated by the Contractor. Such personnel shall not be the same as those performing the work.

6

The Contractor shall furnish the Engineer with a signed inspection report for each item of work inspected and tested. The report shall indicate whether the item of work, material and/or equipment complies with all the inspection/test criteria. The Contractor shall submit inspection/test results to the Engineer prior to incorporating the item(s) into the work. Inspection/test failures shall be reported to the Engineer immediately.

7

Inspection and test reports shall, as a minimum, identify the following: inspection/test procedure reference

(b)

name of inspector/tester

(c)

observations/comments

(d)

specified requirements

(e)

acceptability

(f)

deviations/non-conformance

(g)

corrective action

(h)

evaluation of results

(i)

authorised signature

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4

The Contractor shall clearly document and identify the inspections and test status of all materials and equipment throughout construction. Identification may be by means of stamps, tags, or other control devices attached to, or accompanying, the material or equipment.

7.1.3

Inspection and Test Status

1

The inspection and test status of materials, equipment and construction work shall be identified by suitable means, which indicates the conformance or non-conformance of materials, equipment and construction work with regard to inspection and tests performed. The identification of inspection and test status shall be maintained, as defined in the Quality Assurance Plan and/or documented procedures, throughout the course of construction to ensure that only materials, equipment and construction work that have passed the required inspections and tests are used or installed.

7.1.4

Inspections by the Engineer during construction

1

The Contractors Inspection and Test Plans will define Hold, Witness, Surveillance and Record Review points for the Engineer during construction. The contractor shall prepare, document and implement a Request for Inspection system that defines how the Engineer will be given sufficient notice to inspect the works in accordance with the Inspection and Test Plans.

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Section 02: Quality Assurance and Quality Control Part 07: Inspection and Test

Page 4

Inspections by the Engineer during Defects Liability Period

1

The Engineer will give the Contractor due notice of his intention to carry out any inspections during the defects liability period.

2

The Contractor shall arrange for a responsible representative to be present at the times and dates named by the Engineer.

3

The Contractor’s representative shall render all necessary assistance and take note of all matters to which his attention is directed by the Engineer

7.1.6

Workmanship

1

The Contractor shall comply with industry standards except when more restrictive tolerances or specified requirements indicate more rigid standards or more precise workmanship.

2

Only persons qualified to produce workmanship of the required quality shall perform works

3

The Contractor shall comply with manufactures’ published installation instructions / guides in full, including each step in sequence. Should instructions conflict with project documentation, the Contractor shall request clarification from the Engineer before proceeding.

7.1.7

Measuring and Test Equipment

1

The Contractor shall establish and maintain documented procedures which conform to accepted and approved national or international standards to control, calibrate and maintain inspection, measuring and test equipment used by the Contractor to demonstrate the conformance of materials, equipment and/or construction work with the requirements of the Project Documentation.

2

Inspection, measuring and test equipment shall be used in a manner which ensures that the measurement uncertainty is known and is consistent with the required measurement capability

3

The Contractor shall establish a unique identification number for each item of measuring and test equipment. This unique identification number shall be permanently affixed to each item of measuring and test equipment

4

The Contractor shall ensure that each item of inspection, measuring and test equipment is calibrated at intervals recommended by the manufacturer. Valid calibration certificates for measuring and testing equipment shall be present and available for inspection during inspections and tests.

5

The Contractor shall establish a log of all measuring and test equipment and record:

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7.1.5

(a)

equipment description

(b)

identification number

(c)

date of the last calibration

(d)

date that the next calibration is due.

QCS 2014

Page 5

The Contractor shall assess and record the validity of the previous measuring results when the equipment is subsequently found not to confirm to requirements. The Contractor shall take appropriate action on the equipment and any product affected.

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END OF PART

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QCS 2014

Section 02: Quality Assurance and Quality Control Part 08: Materials

Page 1

MATERIALS .................................................................................................. 2

8.1 8.1.1 8.1.2 8.1.3

GENERAL ...................................................................................................... 2 Plant, Materials, Goods and Workmanship 2 Handling and Storage of Materials 2 Identification and Control of Items and Materials 2

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Section 02: Quality Assurance and Quality Control Part 08: Materials

Page 2

MATERIALS

8.1

GENERAL

8.1.1

Plant, Materials, Goods and Workmanship

1

All Plant, materials, goods and workmanship shall be of the respective kinds described in the Contract with necessary approvals from the concerned authorities and in accordance with the Engineer's instructions and shall be subjected from time to time to such tests as the Engineer may direct at the place of manufacture or fabrication or on the Site or at all or any such places. The Contractor shall provide such assistance, instruments, machines, labour and material as are normally required for examining, measuring and testing any work and the quality, weight or quantity of any materials used and shall supply samples of materials before incorporation in the Works for testing as may be selected and required by the Engineer.

8.1.2

Handling and Storage of Materials

1

The Contractor shall establish procedures for handling and storage of materials and equipment.

2

The Contractor’s storage and handling procedures shall be designed to prevent damage, deterioration, distortion of shape or dimension, loss, degradation, loss of identification, or substitution.

3

The handling procedures shall address the use, inspection and maintenance of special devices such as crates, boxes, containers, dividers, slings, material handling and transportation equipment and other facilities.

4

The Contractor shall identify equipment and/or material requiring special handling or storage.

8.1.3

Identification and Control of Items and Materials

1

The Contractor shall establish control procedures to ensure that equipment and materials are properly used and installed.

2

The Contractor shall identify all items and materials so that they are traceable throughout all inspections, test activities, and records. For stored items, the identification method shall be consistent with the expected duration and type of storage.

3

The Contractor shall record equipment and material identifications and ensure that they are traceable to the location where they are incorporated into the Works.

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END OF PART

QCS 2014

Section 02: Quality Assurance and Quality Control Part 09: Nonconformance Monitoring

Page 1

NONCONFORMANCE MONITORING .................................................................... 2

9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6

INTRODUCTION ..................................................................................................... 2 General 2 Review and Disposition of Nonconforming Items 2 Corrective Action 3 Identification of Nonconforming Items 3 Acceptance and Approval of Nonconforming items 4 Nonconformance Records 4

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Section 02: Quality Assurance and Quality Control Part 09: Nonconformance Monitoring

Page 2

9

NONCONFORMANCE MONITORING

9.1

INTRODUCTION

9.1.1

General

1

The Contractor shall ensure that product which does not conform to Specification requirements is identified and controlled to prevent its unintended use or delivery. A documented procedure shall be established to define the controls and relate responsibilities and authorities for dealing with nonconforming product: by taking action to estimate the detected nonconformity

(b)

by authorizing its use, release or acceptance under concession by the Engineer

(c)

by taking action to preclude its original intended use or application

(d)

by taking action appropriate to the effects, or potential effects, of the nonconformity when nonconformity product is detected after delivery or use has started .

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(a)

When Conforming product is corrected it shall be subject to re-verification to demonstrate conformity to requirements.

3

Records of the nature of nonconformities and any subsequent actions taken, including concessions obtained by the engineer, shall be maintained.

4

The monitoring system shall apply to material and equipment as well as installation and construction which fail to conform to the Contract.

5

A Contractors Quality Nonconformance Template is included in Part 15 Appendix B of this Section and must be used for recording Nonconformance.

9.1.2

Review and Disposition of Nonconforming Items

1

The responsibility for review and authority for the disposition of nonconforming items shall be defined in the Quality Plan.

2

Nonconforming items shall be reviewed in accordance with documented procedures. A nonconforming item may be:

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(a)

reworked to meet the specified requirements

(b)

accepted with or without repair if agreed in writing by the Engineer

(c)

re-graded for alternative applications

(d)

rejected or scrapped.

3

The proposed use or repair of an item which does not conform to the requirements of the Project Documentation shall be reported to the Engineer. The description of the nonconformity and of repairs shall be recorded to denote the actual condition.

4

Repaired and/or reworked products shall be inspected in accordance with the Quality Assurance Plan and/or documented procedures

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Section 02: Quality Assurance and Quality Control Part 09: Nonconformance Monitoring

Page 3

9.1.3

Corrective Action

1

The Contractor shall take action to eliminate the causes of nonconformities in order to prevent recurrence. Corrective actions shall be appropriate to the effects of the nonconformity encountered. A documented procedure shall be established to define requirements for: Reviewing nonconformities (including Engineer complaints)

(b)

Determining the causes of nonconformities

(c)

Evaluating the need for action to ensure that conformities do not occur

(d)

Determining and implementing actions needed

(e)

Records of the results of action taken and

(f)

Reviewing the effectiveness of the corrective action taken

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Any corrective or preventive action taken to eliminate the causes of actual or potential nonconformities shall be to a degree appropriate to the magnitude of problems and commensurate with the risks encountered.

3

The Contractor shall implement and record any changes to the documented procedures for implementing corrective and preventive action.

4

The Contractor shall take prompt action to identify the causes of each nonconformance and the corrective action necessary prevent recurrence. The results of failure and discrepancy report summaries, Contractor evaluations, and any other pertinent applicable data shall be used for determining corrective action. Information developed during construction, tests, and inspections that support the implementation of required improvements and corrections shall be used to support the adequacy of corrective action taken.

5

The procedures for preventive action shall include:

determination of the steps needed to deal with any problems requiring preventive action

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(b)

the use of appropriate sources of information such as processes and work operations which affect product quality, concessions, audit results, quality records and service reports to detect, analyse and eliminate potential causes of nonconformities

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(c)

initiation of preventive action and application of controls to ensure that it is effective

(d)

ensuring that relevant information on actions taken is submitted for management review

9.1.4

Identification of Nonconforming Items

1

The Contractor shall clearly identify each nonconforming item with a status tag or other distinguishing mark. The Contractor shall establish procedures for installing, monitoring, and removing these status tags and identify personnel authorised to remove status tags.

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Section 02: Quality Assurance and Quality Control Part 09: Nonconformance Monitoring

Page 4

9.1.5

Acceptance and Approval of Nonconforming items

1

Acceptance of the Contractors proposed disposition of Nonconforming items should be his obtained in writing from the Engineer prior to the undertaking of any remedial works by the his Contractor.

2

Close out of Nonconforming items must be agreed in writing by the Engineer.

9.1.6

Nonconformance Records

1

The Contractor shall provide the Engineer with the following information for each nonconformance:

(b)

description of nonconformance

(c)

evaluation of nonconformance to establish the cause

(d)

recommended corrective action

(e)

date nonconformance was identified

(f)

date corrective action was completed

(g)

description of final corrective action.

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identification of nonconformance

unique sequential reference number

(b)

date issued

(c)

originator

(d)

description of item deemed to be in nonconformance

(e)

description of nonconformance

(f) (g)

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The Contractor shall establish and maintain a nonconformance log. The log shall contain the following information as a minimum:

Contractors recommended and final disposition Engineers acceptance of Contractors recommended and final disposition

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(a)

(h)

date closed

(i)

remarks, as applicable

END OF PART

QCS 2014

Section 03: Ground Investigation Part 01: General

Page 1

GENERAL ............................................................................................................... 2

1.1 1.1.1 1.1.2 1.1.3

INTRODUCTION ..................................................................................................... 2 Scope 2 References 2 Definitions 2

1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7

SUBMITTALS .......................................................................................................... 3 Programme of Works 3 Preliminary Logs 3 Exploratory Hole Logs 4 Preliminary Laboratory Test Results 5 Digital Data 5 Form of Report 5 Approval of Report 6

1.3

QUALITY ASSURANCE .......................................................................................... 6

1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.4.10 1.4.11 1.4.12 1.4.13 1.4.14 1.4.15 1.4.16

GENERAL PROJECT/SITE CONDITIONS .............................................................. 7 General 7 Working Areas 7 Turf and Topsoil 7 Paved Areas 7 Paving Slabs and Blocks 7 Claims for Damage 8 Geotechnical and Environmental Personnel 8 Location of Exploratory Holes 8 Ground Elevation of Exploratory Holes 8 Exploratory Work 8 Methods of Investigation 8 Safety and Management 9 Anomalous Conditions 9 Surface Water Control 9 Photographs 9 Facilities for the Engineer 10

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QCS 2014

Section 03: Ground Investigation Part 01: General

Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

General requirements and information for the execution of ground investigations.

2

Related Sections are as follows:

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Section 1 ......... General Section 2 ......... Quality Assurance and Quality Control Section 4 ......... Foundations and Retaining Structures Section 6 ......... Roadworks Section 8 ......... Drainage Works Section 12 ....... Earthworks Related to Buildings References

1

The following standards and other documents are referred to in this Part:

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BS 5930......................Code of practice for site investigations BS EN 1997................Ground Investigation and testing

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes

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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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Deere D. U. et al., Design of surface and near-surface construction in rock. Proc. 8th US symposium on rock mechanics. AIME, New York, 1967

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Code of Practice and Specifications for Road Openings in the Highway issued by the Government. Definitions

1

Topsoil: the surface layer of earth that contains organic material and can also support vegetation.

2

Soil: earthen material not classified herein as topsoil or hard stratum.

3

Hard stratum and obstruction: The words 'hard stratum' and 'obstruction' shall mean natural or artificial material, including rock, which cannot be penetrated except by the use of chiselling techniques, rotary drilling, blasting or powered breaking tools. The term 'hard stratum' shall apply during boring, where it is shown that condition (1) or condition (2) below are fulfilled, provided that the boring rig involved is in good working order and is fully manned:

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1.1.3

(a)

Condition (1) 100 mm diameter undisturbed sample tubes cannot be driven more than 300 mm

(b)

Condition (2) a standard penetration resistance test shows a resistance in excess of 35 blows/75 mm.

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Section 03: Ground Investigation Part 01: General

Page 3

Fill: deposits or embankments which have been formed by persons, as distinct from geological agencies.

5

Exploratory Hole/Trench/Excavation: any boring, pit trench, ditch or shaft formed for the purpose of ground investigation.

6

Boring: hole in earth, excavated by either percussion or auger equipment.

7

Drilling: any hole in rock, excavated by rotary equipment.

8

Borehole: exploratory hole excavated by boring or drilling techniques.

1.2

SUBMITTALS

1.2.1

Programme of Works

1

The Geotechnical Investigation Contractor shall prepare a programme of works for the investigation which will give a detailed schedule showing proposed time schedule for all aspect of the work, details of all plant and equipment to be used in addition to a list of personnel who will work on the project.

1.2.2

Preliminary Logs

1

The Geotechnical Investigation Contractor shall prepare a preliminary log of each exploratory hole. For trial pits and trenches, a trial pit or trench map showing each face of the pit or trench shall be provided, as appropriate. Preliminary logs shall be submitted to the Engineer in duplicate within seven working days of completion of the explorations to which they refer to, and shall contain the information required for the exploratory hole logs.

2

Geotechnical Investigation Contractor activities shall fully comply with Ministry of Environment (MOE) requirements and/or those of other Government Departments, Ministries and Statutory Organizations.

3

The Geotechnical Investigation Contractor shall obtain all necessary work permits and security permits prior to commencement of Geotechnical investigation of the site.

4

The investigation shall provide detailed information on the nature of the sub-strata, superficial deposits and ground water table at the site together with general recommendations for designing foundations and earthworks, new road pavements, culverts, retaining walls, etc.

5

The geotechnical investigation Exploratory Boreholes shall be spaced as mentioned in Section 2.

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Section 03: Ground Investigation Part 01: General

Page 4

The geotechnical investigation Exploratory Boreholes depths shall be as mentioned in Table 1.1. Table 1.1: Minimum Depth of Boreholes No of floors

Depth of Boreholes (m)

3 or Less

6

4

8

5

9

6

10

7

12

8

13 0.7

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2m below the inverted level; 1.5width of excavation. 2D (D=Diameter or equivalent diameter of the tunnel/underground structure.

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For trenches, pipeline and Tunnels, the depth of Boreholes shall be the larger value of:

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Notes:  The depth of boreholes is measured from foundation level.  S is the number of floors.  For structures small in plan area, exploration should be made at a minimum of three points, unless other reliable information is available in the immediate vicinity. Where a structure consists of a number of adjacent units, one exploration point per unit may suffice.  For piles the depth of Boreholes is at least below the depth of pile tip by 5m or 5D (D is the diameter of the pile at the toe) whichever is greater.  For roads, the depth of Boreholes shall be greater than 2m below the proposed formation Level.

Exploratory Hole Logs

1

The exploratory hole logs shall be prepared and presented to a suitable vertical scale. The logs shall include all the information that follows, such information having been updated as necessary in the light of laboratory testing and further examination of samples and cores.

2

Information for exploratory hole logs:

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Drilling

Pit and Trench

Static and Dynamic Probing









National grid co-ordinates









Ground level related to the datum









Elevation of each stratum referred to the datum







()

Rotary Borehole

All the designated information

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Section 03: Ground Investigation Part 01: General

Page 5

Drilling

Pit and Trench

Static and Dynamic Probing







()

Details of groundwater observations







()

Symbolic legend of strata in accordance with BS 5930







()

Rotary Borehole Description of each stratum in accordance with BS 5930 and initials of person who carried out the logging (and responsible Supervisor if under training)

Core recovery as percentage of each core run



Rock Quality Designation, RQD (Deere et al. 1967)



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_____ Note:  means information required; () means information required if applicable. Preliminary Laboratory Test Results

1

Laboratory test results shall be submitted to the Engineer in batches at the completion of each week's testing. Legible photocopies of work sheets are acceptable.

1.2.5

Digital Data

1

Data from the investigation shall be provided in digital form to the approval of the Engineer.

1.2.6

Form of Report

1

The report shall comprise of a factual or interpretative or both types of reports as required by the Employer or Engineer. Reports shall begin with a cover page showing the name of the Contract and the names of the Employer, Engineer and Geotechnical Investigation Contractor. Report pages shall be numbered consecutively.

2

The factual report shall contain, as a minimum, the following information: A statement from the Engineer on the purpose and rationale of the investigation.

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1.2.4

(b)

A description of the work carried out, including reference to specification and standards adopted and any deviations from them.

(c)

Exploratory hole logs.

(d)

In-situ test records.

(e)

Laboratory test results.

(f)

Plan with locations of exploratory holes.

(g)

Site location plan.

(h)

Geological cross-sections (if appropriate).

The plans shall be to a stated scale and shall include a north arrow. Additional information shall be provided as designated.

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Section 03: Ground Investigation Part 01: General

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The interpretative report shall contain the following information: (a)

A written appraisal of the ground and water conditions.

(b)

Analysis and recommendations as designated.

When so designated, the Geotechnical Investigation Contractor shall supply the calculations and analyses on which recommendations are based. Approval of Report

1

A draft copy of the factual report and the interpretative report shall be submitted to the Engineer for approval before submission of the final report.

1.3

QUALITY ASSURANCE

1

Only Geotechnical Investigation Contractors holding a current approval certificate from the Central Materials Laboratory shall be permitted to carry out ground investigations.

2

The work shall be carried out in accordance with the relevant British Standards or equivalent.

3

Where specifically designated, all work shall be carried out in accordance with a quality management system established in accordance with Section 2 Quality Assurance and Quality Control of the QCS. Records to indicate compliance with quality management shall be made available to the Engineer on request.

4

The Geotechnical Investigation Contractor shall provide full time professional attendance on site. The professional attendant shall be approved by the Engineer, and shall be responsible for the technical direction of all fieldwork.

5

The Geotechnical Investigation Contractor’s geotechnical and environmental personnel employed on the Contract shall be competent to undertake the work required. Categories of personnel who may be required by the Contract are as follows:

(b)

Graduate Engineer/Geologist/Environmental Scientist. Graduate Engineer/Geologist/Environmental Scientist with at least three years of

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Technician.

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1.2.7

relevant experience since graduation.

(d)

Professional Engineer/Geologist/Environmental Scientist with at least five years of relevant experience.

(e)

6

Professional Engineer/Geologist/Environmental Specialist with at least ten years of relevant experience.

All drillers employed on the Contract shall be experienced and competent in percussion or auger boring or rotary drilling, to the complete satisfaction of the Engineer. One competent drilling supervisor per site shall be permanently on the Site during borehole operations.

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Section 03: Ground Investigation Part 01: General

Page 7

GENERAL PROJECT/SITE CONDITIONS

1.4.1

General

1

Geotechnical Investigation Contractor shall only use access routes to and between exploration sites that are approved by the Engineer.

2

Where the presence of underground services is likely, exploratory holes shall be started by means of a hand excavated inspection pit.

3

In addition to any designated notice, at least one working day's notice of the intended time of entry shall be given to the land owner and occupier of the exploration site.

4

All work shall be carried out with the least possible damage to the Site and its environs.

5

All barriers breached or otherwise disturbed during the execution of site operations shall be immediately repaired or replaced to the same standard.

6

Working hours shall be restricted to those designated.

7

Daily allocation sheets detailing the work carried out shall be submitted in duplicate at the end of each day’s work.

1.4.2

Working Areas

1

Operations shall be confined to the minimum area of ground required for the Works. Unless otherwise designated, on completion of each exploration all equipment, surplus material and rubbish of every kind shall be cleared away and removed from the Site. Damage to land or property in the vicinity of the exploratory hole and on access routes shall be made good. The whole of the Site and any ancillary works shall be left in a clean and tidy condition.

1.4.3

Turf and Topsoil

1

Turf and topsoil shall be stripped from the site of each exploration and stockpiled for future replacement. Vegetation and topsoil adjacent to the exploration which may be damaged by the operations shall either be removed and stockpiled as above, or otherwise protected from damage. After completion of the exploration all topsoil shall be replaced and the Site restored to its original condition.

1.4.4

Paved Areas

1

Pavement from paved areas (other than paving slabs and blocks) shall be broken out to the minimum extent necessary for each exploration. After completion of the exploration and backfill of the excavation, the disturbed subgrade shall be compacted and the paving replaced.

2

Restoration of highway pavement shall be in accordance with the current Code of Practice and Specification for Road Openings in the Highway issued by the Government.

1.4.5

Paving Slabs and Blocks

1

Paving slabs and blocks shall be removed from the Site, as required for each exploration, and stored for reuse.

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1.4

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Section 03: Ground Investigation Part 01: General

Page 8

Contiguous paving slabs and blocks which are liable to be damaged by the operations shall either be removed and stored as above or otherwise protected from damage.

3

After completion of the exploration and backfill of the excavation, the disturbed subgrade shall be compacted and the paving slabs and blocks relayed.

1.4.6

Claims for Damage

1

Any damage, or claim for compensation for damage by owners or occupiers of the Site, shall be reported to the Engineer.

1.4.7

Geotechnical and Environmental Personnel

1

In addition to the provision of the designated personnel by the Geotechnical Investigation Contractor, the Engineer may specifically require the services of geotechnical and environmental personnel for advice, assistance or preparation of interpretative reports. The form of interpretative reports shall be agreed with the Engineer. Details of the qualifications and experience of the personnel shall be supplied to the Engineer.

1.4.8

Location of Exploratory Holes

1

The location of each exploratory hole shall be measured from an approved grid co-ordinate system, and shall be accurate to within 1 m, and the position recorded on a plan as

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designated.

Ground Elevation of Exploratory Holes

1

The elevation of the ground at each exploratory hole shall be established, on the basis of the Qatar National Datum unless otherwise designated or approved by the Engineer, to the nearest 0.05 m.

1.4.10

Exploratory Work

1

The location and depth of each exploratory hole shall be as designated. The Engineer may, after consultation with the Geotechnical Investigation Contractor, vary the location and depth of any exploratory hole and the sequence or quantity of in-situ testing depending on the actual ground conditions encountered. When the position of an exploratory hole has been varied, the Geotechnical Investigation Contractor shall take all necessary measurements and shall inform the Engineer of the revised co-ordinates and ground elevation or other measurements required to locate the exploratory hole.

1.4.11

Methods of Investigation

1

The Engineer will have the option to require any of the following methods of investigation. These options will comprise, but not necessarily be limited to, the following:

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1.4.9

(a)

Desk study.

(b)

Geological mapping.

(c)

Topographic survey.

(d)

Aerial photographs.

or any other methods described in this Section.

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Section 03: Ground Investigation Part 01: General

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Safety and Management

1

The Geotechnical Investigation Contractor shall submit detailed Job Hazard Analysis (JHA) to all site activities including but not limited to potential hazard, who/what might be harmed, control/ recovery measure, responsible person…etc.

2

The presence and nature of known areas of hazardous or contaminated ground are designated, based on available records. If evidence of further hazardous or contaminated ground is encountered, the Geotechnical Investigation Contractor shall immediately so inform the Engineer. If required by the Engineer, the Geotechnical Investigation Contractor’s work plan shall be revised appropriately to take into account the nature and level of contamination encountered. Where contaminated land is present or suspected the Geotechnical Investigation Contractor shall take the appropriate health and safety precautions as directed by the Engineer and where appropriate by the Civil Defence Department of the Government. Care shall be taken to avoid contaminating the egress from the Site.

3

A method statement indicating the safety procedures to be followed during the investigation of hazardous or contaminated ground shall be provided by the Geotechnical Investigation Contractor before beginning the investigation in the hazardous or contaminated ground.

4

Traffic safety and management measures shall be provided, in accordance with the provisions of traffic control of Section 1, General. Where the circumstances of any particular case are not designated, proposals for dealing with such situations shall be submitted to the Engineer for approval.

1.4.13

Anomalous Conditions

1

Where anomalous or unexpected features are revealed, the Geotechnical Investigation Contractor shall immediately inform the Engineer.

1.4.14

Surface Water Control

1

Surface water or other water shall be prevented from entering the exploratory hole, except as permitted by the Engineer.

1.4.15

Photographs

1

Colour photographs shall be taken and supplied by the Geotechnical Investigation Contractor as designated. Each photograph shall clearly show all necessary details, and shall have its scale identified.

2

A single gloss colour print (size 150 mm by 100 mm) copy of each photograph shall be submitted to the Engineer for his approval, within seven working days of the photography. In the event that the photographs are of a quality unacceptable to the Engineer, they shall be retaken.

3

On acceptance of the quality of the photograph, two complete sets of prints of all the photographs shall be presented, annotated and submitted in bound volumes, together with the original photograph digital format with the factual report.

4

Particular requirements for photographs of cores and pits and trenches are given in Parts 3 and 4

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1.4.16

Facilities for the Engineer

1

When required by the particular contract documentation, facilities to the designated standard shall be provided for the use of the Engineer, as described in Section 1.

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END OF PART

QCS 2014

Section 03: Ground Investigation Part 02: Boreholes

Page 1

BOREHOLES .......................................................................................................... 2

2.1 2.1.1 2.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

2.2 2.2.1 2.2.2 2.2.3

BOREHOLES GENERALLY .................................................................................... 2 Method and Diameter 2 Addition of Water to the Borehole 3 Backfilling 3

2.3 2.3.1

PERCUSSION BORING .......................................................................................... 3 Hard Stratum or Obstruction in Percussion Boring 3

2.4 2.4.1 2.4.2 2.4.3

AUGER BORING ..................................................................................................... 3 Hand Auger 3 Continuous Flight Auger Boring 3 Hollow Stem Flight Auger 3

2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6

ROTARY DRILLING ................................................................................................ 3 General 3 Drilling Fluid 4 Rotary Drilling with Core Recovery 4 Rotary Drilling without Core Recovery 6 Backfilling 6 Photographs 6

2.6

BOREHOLES OVERWATER .................................................................................. 6

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Section 03: Ground Investigation Part 02: Boreholes

Page 2

2

BOREHOLES

2.1

GENERAL

2.1.1

Scope

1

Advancement of boreholes by percussion boring, auger boring, and rotary drilling.

2

Related Sections and Parts are as follows: This Section

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Section 4, ........ Foundations and Retaining Structures Section 6, ........ Roadworks Section 8, ........ Drainage Works Section 12, ...... Earthworks Related to Buildings

.

Part 1 ............... General

References

1

The following standards and other documents are referred to in this Part:

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BS 5930 ......................Code of practice for site investigations.

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BS EN 1997 ................Ground Investigation and testing

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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Engineering Group of the Geological Society Working Party Report The logging of rock cores for engineering purposes (1970).

BOREHOLES GENERALLY

2.2.1

Method and Diameter

1

The method of advancement and the diameter of a borehole shall be such that the boring can be completed and logged to the designated depth, and samples of the designated diameter can be obtained, in-situ testing carried out and instrumentation installed.

2

The following methods may be employed for advancement of a borehole unless otherwise designated:

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(a)

Percussion boring.

(b)

Auger boring (If hollow stem augering is proposed, the Contractor shall satisfy the Employer that the SPT values obtained are not effected by disturbance of the soil by the auger head, or the presence of material within the hollow stem.).

(c)

Rotary drilling.

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Section 03: Ground Investigation Part 02: Boreholes

Page 3

Addition of Water to the Borehole

1

Jetting with water shall not be used to assist the advance of the borehole, except where approved by the Engineer. Where the borehole penetrates below the water table and disturbance of the soils is likely, a positive hydraulic head shall be maintained in the borehole.

2.2.3

Backfilling

1

The Contractor shall backfill boreholes in such a manner as to minimise subsequent depression at the ground surface due to settlement of the backfill. In some circumstances, grout or special infilling may be required by the Engineer. Where artesian or other water conditions make normal backfilling impracticable, the Contractor shall consult and agree with the Engineer a procedure for sealing the borehole.

2.3

PERCUSSION BORING

2.3.1

Hard Stratum or Obstruction in Percussion Boring

1

In a borehole where percussion boring is employed and a hard stratum or obstruction is encountered, the Contractor shall employ chiselling techniques for a period of up to 1 h.

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Should this not penetrate through the hard stratum or obstruction the Contractor shall inform the Engineer, who may instruct the use of one or more of the following: continuation of chiselling techniques

(b)

rotary or other approved drilling until the stratum is penetrated

(c)

abandonment of the borehole.

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AUGER BORING

2.4.1

Hand Auger

1

Hand auger boring may be appropriate in suitable self-supporting strata.

2.4.2

Continuous Flight Auger Boring

1

Where continuous flight auger boring is used, it shall be carried out under the full-time supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) who shall produce, as boring proceeds, a record of the material and groundwater encountered.

2.4.3

Hollow Stem Flight Auger

1

Where hollow stem flight auger boring is used, the equipment used shall be such as to bore and recover samples as designated. Sampling shall be carried out through the hollow stem.

2.5

ROTARY DRILLING

2.5.1

General

1

Rotary drilling may be required for the recovery of cores, or for the advancement of a hole in rock, with or without core recovery.

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Section 03: Ground Investigation Part 02: Boreholes

Page 4

Drilling Fluid

1

The drilling fluid shall normally be clean water, air or air mist. However, with the approval of the Engineer, drilling muds, additives or foam may be used.

2.5.3

Rotary Drilling with Core Recovery

1

Unless otherwise designated rotary core drilling shall be carried out by a double or triple tube coring system incorporating a removable inner liner or split tube. The triple tube system may be affected by use of a double tube barrel with an approved semi-rigid liner.

2

Rotary core drilling shall produce cores of not less than the designated diameter throughout the core length. Care shall be exercised in the drilling so as to optimise core recovery.

3

The first drill run in each hole shall not exceed 1 m in length. Subsequent drill runs shall not

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2.5.2

normally exceed 3 m in length and the core barrel shall be removed from the drill hole as

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Removal of cores and labelling of liners shall be carried out as follows: All operations entailed in recovering the cores from the ground after completion of drilling shall be carried out in a manner such as to minimise disturbance to the cores.

(b)

Core barrels or inner tube in case of wireline shall be held horizontally while the innermost liner containing the core is removed without vibration and in a manner to prevent disturbance to the core. The core should be rigidly supported at all times while it is being extruded and during subsequent handling, and the liner containing the core must not be allowed to flex

(c)

Immediately after removing the liner the top and bottom shall be marked in indelible ink. The ends of liners shall be capped and sealed using adhesive tape. Liners shall

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(a)

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often as is required to obtain the best possible core recovery or alternatively the core samples shall be retrieved by means of wireline. The Engineer may designate in-situ testing between drill runs.

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be cut to the length of the enclosed core. Alternatively, should a metallic split tube be used, the samples shall be placed in half cut PVC pipes sealed with the second half after core samples description with marking of the core run on the PVC tube and the core box.

5

(d)

Where the length of core recovered from any single core run is such that it cannot be accommodated in one channel of the core box, the liner shall be cut to coincide, if possible, with existing fractures. The liner either side of the cut shall be marked 'cut' and the ends capped as above.

(e)

Each section of liner shall be marked with the contract title, exploratory hole reference number, date and the depths of the top and bottom of the drill run.

(f)

Core obtained without a liner and that from within the core catcher but not inside the liner shall be wrapped in two layers of plastic cling film and labelled to indicate the depth and exploratory hole reference number.

Core boxes, packing, labelling, storing shall be carried out as follows: (a)

Core boxes shall be soundly constructed and fitted with stout carrying handles, fastenings and hinged lids. The total weight of the cores and box shall together not exceed 60 kg.

QCS 2014

Section 03: Ground Investigation Part 02: Boreholes

Page 5

Cores shall be rigidly and securely packed at the site of drilling and during all subsequent handling and storage the cores shall remain packed unless required for examination or testing. Cores shall be placed in the box, in their liners where used, with the shallowest core to the top left hand corner, the top being considered adjacent to the hinged section. Cores from the core catcher shall also be placed in the core boxes at the correct relative depth.

(c)

Depth shall be indicated on the core box by durable markers at the beginning and end of each drill run. Rigid core spacers shall be used to indicate missing lengths. The contract title, exploratory hole reference number and the depth of coring contained in each bore shall be clearly indicated in indelible ink inside, on top and on the right-hand end of the box and on the inside of the box lid.

(d)

Core boxes containing core shall be kept horizontal and moved and handled with care at all times. Cores shall be protected from direct sunlight. At the end of each day's work, core boxes shall be stored secure from interference and protected from the weather.

Cores shall be prepared for examination as follows: (a)

Cores shall be prepared for examination by the removal of sealing materials and splitting of liners in such a way as not to damage the cores. Plastic liners shall be cut lengthways such that at least half the core circumference is exposed. If half PVC is used, care should be taken while removing and replacing the split half.

(b)

Before examination of the core, the Contractor shall photograph the cores. The time between beginning preparation and the examination of the prepared and photographed cores shall be minimised to prevent loss of moisture from the core samples.

(c)

Cores shall be examined and described on site by a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) in accordance with BS 5930 or ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society Working Party Report The logging of rock cores for engineering purpose (1970).

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(b)

When the examination of the cores has been completed, the Contractor may be required to retain separately designated core sub-samples for possible laboratory testing. The Contractor shall cut the liner and cap and seal the core sub-samples in such a way as to prevent loss of moisture and sample disturbance. They shall be clearly labelled so that the location, depth and origin of the sub-samples can be readily identified. Cores in their liners remaining after the designated sub-samples have been removed shall be end-capped and resealed and replaced in the original core box location. Rigid spacers shall be placed in the spaces in the cores boxes previously occupied by the core sub-samples to prevent movement of adjacent cores and these shall be labelled identically to the core sub-samples that they replace. The core sub-samples shall be retained in separate core boxes clearly marked to indicate the origin of the cores contained within.

8

The Contractor shall protect all cores and transport them including loading and unloading to

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(a)

The Contractor's premises.

(b)

For a number of selected cores, to the designated address.

After submittal of the approved final report, the Contractor shall retain cores, other than those delivered to the designated address, for a period of time required by the Engineer. The Engineer's written permission shall be obtained before disposal of the cores, but the required retention period will normally not exceed three months.

QCS 2014

Section 03: Ground Investigation Part 02: Boreholes

Page 6

2.5.4

Rotary Drilling without Core Recovery

1

Rotary blind bit or rotary percussive drilling may be used to advance a hole. The hole diameter shall be as designated.

2

When used for the purpose of locating mineral seams, mineworkings, adits, shafts, other cavities or anomalous conditions, drilling shall be under the full-time supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c). As drilling proceeds a systematic record shall be made of the drilling methods, rate of penetration, loss of flushing medium, the material penetrated and any cavities or broken ground encountered. Backfilling

1

Except where otherwise designated, the Contractor shall backfill rotary drill holes with clean, well graded aggregate. The aggregate size and gradation shall be approved by the Engineer. Under special circumstances grout may be required to backfill the holes. The grout shall consist of equal portions by weight of ordinary Portland cement and bentonite mixed by machine or hand to a uniform colour and consistency before placing, with a moisture content not greater than 250 %. The grout shall be introduced at the bottom of the hole by means of

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a tremie pipe, which shall be raised but kept below the grout surface as the filling proceeds. Where artesian water conditions or voids make normal grouting impracticable, the Contractor shall consult and agree with the Engineer a procedure for sealing the drill hole.

2.5.6

Photographs

1

In addition to the requirements of Part 1, the Contractor shall photograph cores where required in a fresh condition before logging and ensure that the following criteria are fulfilled:

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A graduated scale in centimetres is provided.

(b)

Labels and markers are clearly legible in the photograph.

(c)

A clearly legible reference board identifying the project title, exploratory hole number, date, and depth of drill runs shall be included in each photograph.

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Core boxes are evenly and consistently lit.

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(a)

(e)

The length of the core box in each photograph fills the frame.

(f)

The focal plane of the camera and the plane of the core box are parallel.

(g)

The camera is placed in the same position with respect to the core box in every photograph.

(h)

The resolution of the camera is not less than 8Mpixels.

(i)

The photograph taken should be in focus along all the core samples length.

2.6

BOREHOLES OVERWATER

1

When boreholes are required overwater the method of drilling and sampling shall comply in general with the other requirements given in this Section, with the exception of backfilling.

2

Overwater boreholes shall be undertaken by the use of overwater staging, work over platform (WOP) jack-up vessels, anchored floating vessels or any other methods agreed with the Engineer.

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Control of the elevation related to the borehole/seabed surface or varying stratums shall be related to the top of the casing installed. Anchored floating vessels will keep a constant record of tidal movement between the vessel and the fixed casing elevation and make any allowances necessary.

4

Boring or drilling operations will cease when the wave height exceeds the designated maximum value relating to standing time due to inclement weather, if this item is applicable to the Contract under the contract specific documentation.

5

An accurate method of measuring wave height from trough to crest will be installed on the drilling vessel or platform and calibrated and approved by the Engineer before beginning drilling operations.

6

All overwater operations will comply with all local government regulations related to such work and will also comply fully with any Safety of Lives at Sea (SOLAS) regulations in force at the time.

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QCS 2014

Section 03: Ground Investigation Part 03: Pits and Trenches

Page 1

PITS AND TRENCHES ........................................................................................... 2

3.1 3.1.1 3.1.2 3.1.3

GENERAL ............................................................................................................... 2 Scope 2 References 2 Quality Assurance 2

3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

PITS AND TRENCHES GENERALLY ..................................................................... 2 Pit and Trench Dimensions 2 Contaminated Ground 2 Groundwater 3 Protection to Pits and Trenches Left Open 3 Backfilling and Restoration 3 Photographs 3

3.3 3.3.1 3.3.2 3.3.3

INSPECTION PITS .................................................................................................. 3 Excavation Method 3 Services 3 Sidewall Stability 4

3.4 3.4.1 3.4.2 3.4.3 3.4.4

TRIAL PITS AND TRENCHES ................................................................................ 4 Excavation Method 4 Services 4 Sidewall Stability 4 Trial Pits Examination 4

3.5 3.5.1 3.5.2 3.5.3

OBSERVATION PITS AND TRENCHES ................................................................. 4 Excavation Method 4 Services 5 Sidewall Stability 5

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Section 03: Ground Investigation Part 03: Pits and Trenches

Page 2

3

PITS AND TRENCHES

3.1

GENERAL

3.1.1

Scope

1

Inspection pits, trial pits and trenches, observation pits and trenches.

2

Related Sections and Parts are as follows: This Section

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Section 1, ....... General Section 4, ....... Foundations and Retaining Structures Section 6, ....... Roadworks Section 8, ....... Drainage Works Section 12, ..... Earthworks Related to Buildings.

.

Part 1, .............. General

References

1

The following standards and other documents are referred to in this Part:

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BS 5930 ...................... Code of practice for site investigations

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes

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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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Code of Practice and Specifications for Road Openings in the Highway issued by the Government. Quality Assurance

1

Trial pits and trenches and observation pits and trenches shall be examined and described by a geotechnical person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c) and photographed, if required.

3.2

PITS AND TRENCHES GENERALLY

3.2.1

Pit and Trench Dimensions

1

Unless otherwise designated

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2.

(a)

Trial pits and observation pits shall have a minimum base area of 1.5 m

(b)

Trial trenches and observation trenches shall not be less than 1 m wide.

3.2.2

Contaminated Ground

1

Ground that is suspected of being contaminated shall be described by an environmental or geotechnical person, as appropriate, meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c).

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Page 3

Groundwater

1

The Contractor shall divert surface water runoff from entering pits and trenches.

2

Groundwater shall be controlled by the use of wellpoints or sump pumps to permit continuous work if required.

3.2.4

Protection to Pits and Trenches Left Open

1

Where pits and trenches are required to be left open and unattended, the Contractor shall provide fencing together with all necessary lighting and signing.

2

Precautions shall be taken to protect the pits and trenches from the adverse effects of weather during this period.

3.2.5

Backfilling and Restoration

1

Pits and trenches shall be backfilled as soon as practicable and reinstated to their original condition.

2

The backfill shall be placed in lifts of 150 mm thickness and compacted in such a manner as to minimise any subsequent settlement of the ground surface.

3

The use of sand backfill compacted by flooding may be permitted, but this method requires the approval of the Engineer.

4

In paved areas, the pavement shall be restored.

3.2.6

Photographs

1

In addition to the requirements of Part 1, photographs shall clearly show details of the ground conditions in the pit and trench with any support in place and shall contain a graduated scale.

2

Material derived from the excavation shall be photographed, when directed by the Engineer. Artificial lighting shall be used where necessary.

3

Unless directed otherwise by the Engineer, three photographs will normally be required at every pit and trench.

3.3

INSPECTION PITS

3.3.1

Excavation Method

1

Inspection pits for the location of underground services shall be excavated by hand to a depth of 1.2 m unless otherwise designated.

2

Hand-operated power tools may be used to assist excavation where necessary.

3.3.2

Services

1

The locations, depths and dimensions of all services encountered shall be measured and recorded in the daily report with other designated information.

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3.2.3

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Page 4

Sidewall Stability

1

Due care shall be exercised to ensure the stability of the sides of the excavation at all times.

3.4

TRIAL PITS AND TRENCHES

3.4.1

Excavation Method

1

Trial pits and trenches shall be excavated by hand to a maximum depth of 1.2 m or by machine to the required depth to enable visual examination and sampling from outside the pit or trench as required.

2

Where dewatering is required, the pumping equipment used shall be adequate to lower the water table to the required level.

3.4.2

Services

1

The locations, depths and dimensions of all services encountered shall be measured and recorded in the daily report with other designated information.

3.4.3

Sidewall Stability

1

Excavations deeper than 1.2 m shall be braced if necessary.

3.4.4

Trial Pits Examination

1

All recovered materials from the Trial Pits shall be examined in accordance with BS 5930 or ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society Working Party.

2

Disturbed samples shall be obtained from the trial pits for laboratory testing and geological description purposes. The samples shall be taken to be representative of the actual site conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories for examination and testing.

3

Color photographs shall be taken for each excavated trial pit with a metric scale laid into the pit after cleaning it, indicating the pits details such as trial pit number, date and depth.

3.5

OBSERVATION PITS AND TRENCHES

3.5.1

Excavation Method

1

Observation pits and trenches shall be excavated by hand or machine and shall be adequately supported to enable personnel to enter safely and to permit in-situ examination, soil sampling and testing as required. In areas where dewatering is required, the equipment and methods proposed must be approved by the Engineer before beginning the work.

2

All recovered materials from the pit/trench shall be examined in accordance with BS 5930 or ASTM D 2488.

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3.3.3

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Page 5

Disturbed samples shall be obtained for laboratory testing and geological description purposes (if required). The samples shall be taken to be representative of the actual site conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories for examination and testing.

4

Color photographs shall be taken for each excavated pit with a metric scale laid into the pit after cleaning it, indicating the pits details such as trial pit number, date and depth.

3.5.2

Services

1

The locations, depths and dimensions of all services encountered shall be measured and recorded in the daily report with other designated information.

3.5.3

Sidewall Stability

1

Due care shall be exercised to ensure the stability of the sides of the excavation at all times.

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END OF PART

QCS 2014

Section 03: Ground Investigation Part 04: Soil Sampling

Page 1

SOIL SAMPLING ..................................................................................................... 2

4.1 4.1.1 4.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5

SAMPLING GENERALLY ........................................................................................ 2 Sampling and Testing Frequency 2 Recording depths of samples 3 Description of samples 3 Labelling, Protection and Transportation of Samples 3 Retention and Disposal of Samples 3

4.3 4.3.1 4.3.2 4.3.3 4.3.4

SOIL SAMPLES....................................................................................................... 3 Small Disturbed Samples 3 Bulk Disturbed Samples 3 Open Tube and Piston Samples 4 Standard Penetration Test Samples 4

4.4

GROUNDWATER SAMPLES .................................................................................. 4

4.5

SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS ................................................................ 4

4.6

GAS SAMPLING...................................................................................................... 5

4.7

SPECIAL SAMPLING .............................................................................................. 5

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Section 03: Ground Investigation Part 04: Soil Sampling

Page 2

4

SOIL SAMPLING

4.1

GENERAL

4.1.1

Scope

1

Taking of samples of soil, groundwater, gas and contaminants. Sample handling, transportation, storage, retention and disposal.

2

Related Sections and Parts are as follows: This Section

References

1

The following documents are referred to in this Part:

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Part 1, .............. General Part 2, .............. Boreholes Part 3, .............. Pits and Trenches.

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes

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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure) BS 5930 ......................Code of practice for site investigations

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BSI –DD 175 ..............Code of practice for the identification of potentially contaminated land and its investigation (draft for development).

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BS EN 1997--- ............ Ground Investigation and testing

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ICE et al, Soil Investigation Steering Group (SISG) Publication, Soil investigation in construction, Part 4, Guidelines for the safe investigation by drilling of landfills and contaminated land, Thomas Telford, (1993).

SAMPLING GENERALLY

4.2.1

Sampling and Testing Frequency

1

The frequency of sampling and in-situ testing is dependent on the ground conditions. In the absence of designated requirements the intervals observed shall be as follows:

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4.2

(a)

(b)

in boreholes (i)

first open tube sample (generally in clay soils) or standard penetration test (SPT) (generally in granular soils) at 0.5 m depth, the next at 1.0 m depth, thereafter at 1 m intervals to 5 m depth then at 1.5 m intervals.

(ii)

small disturbed samples shall be taken from the topsoil, at each change in soil

(iii)

type or consistency and midway between successive open tube samples or SPT’s.

(iv)

Bulk disturbed samples shall be taken of each soil type.

in pits and trenches

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Section 03: Ground Investigation Part 04: Soil Sampling

Page 3

(i)

Small disturbed samples shall be taken of the topsoil, at each change in soil type or consistency and between successive bulk disturbed samples.

(ii)

Bulk disturbed samples shall be taken at 1 m depth intervals, with at least one large bulk disturbed sample of each soil type.

Recording depths of samples

1

The depths below ground level at which samples are taken shall be recorded. For open tube and piston samples the depth to the top and bottom of the sample, and the length of sample obtained shall be given. For bulk samples the limits of the sampled zone shall be recorded.

4.2.3

Description of samples

1

All samples shall be examined and described by a geotechnical person meeting the requirements of Part 1, Clause 1.3.1, Paragraph 5 Item (c) in accordance with BS 5930. Samples of suspected contaminated ground and leachate shall be described by an environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c) in accordance with DD 175. Descriptions shall include colour and smell with reference to specific inclusions.

4.2.4

Labelling, Protection and Transportation of Samples

1

Samples shall be clearly labelled in accordance with BS 5930. Samples of fill, groundwater, leachate or contaminated ground suspected to be toxic or hazardous shall be tagged with a red label.

2

Samples shall be protected from direct heat and sunlight.

3

Samples shall be transported to the Contractor's premises. Where required by the Engineer, selected samples shall be delivered to the designated address.

4.2.5

Retention and Disposal of Samples

1

Samples shall be kept for the designated period after submission of the approved final report. This period shall not exceed three months, unless specifically designated otherwise. The Contractor shall ultimately dispose of all samples other than those delivered to the designated address.

4.3

SOIL SAMPLES

4.3.1

Small Disturbed Samples

1

Small disturbed samples shall weigh not less than 0.5 kg. They shall be placed immediately in airtight containers, which they should sensibly fill.

4.3.2

Bulk Disturbed Samples

1

Bulk disturbed samples shall be representative of the zone from which they have been taken.

2

Normal bulk disturbed samples shall weigh not less than 10 kg.

3

Large bulk disturbed samples shall weigh not less than 30 kg.

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4.2.2

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Page 4

Open Tube and Piston Samples

1

Open tube and piston samples shall be taken using the sampling equipment and procedures as described in BS 5930. The diameter shall be 100 mm unless otherwise designated.

2

Before an open tube or piston sample is taken, the bottom of the hole shall be carefully cleared of disturb materials and where a casing is being used the sample shall be taken below the bottom of the casing. Following a break in the work exceeding one hour, the borehole shall be advanced by 250 mm before open tube or piston sampling is resumed.

3

Where an attempt to take an open tube or piston sample is unsuccessful the hole shall be cleaned out for the full depth to which the sampling tube has penetrated and the recovered soil saved as a bulk disturbed sample. A fresh attempt shall then be made from the level of the base of the unsuccessful attempt. Should this second attempt also prove unsuccessful the Contractor shall agree with the Engineer as to alternative means of sampling.

4

The samples shall be sealed immediately to preserve their natural moisture content and in such a manner as to prevent the sealant from entering any voids in the sample.

5

Soil from the cutting shoe of an open tube shall be retained as an additional small disturbed sample.

4.3.4

Standard Penetration Test Samples

1

When a standard penetration test (SPT) is made, the sample from the split barrel sampler shall be retained as a small disturbed sample.

4.4

GROUNDWATER SAMPLES

1

Groundwater samples shall be taken from each exploratory hole where groundwater is encountered. Where more than one groundwater level is found, each one shall be sampled separately. Where water has been previously added, the hole shall be bailed out before

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sampling so that only groundwater is present. The sample volume shall be not less than 0.25 l.

SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS

1

Samples of suspected contaminated ground, groundwater and leachate shall be taken in accordance with DD 175 and the SISG publication under the supervision of an environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c).

2

The size and type of sample and container, method of sampling and time limitations for carrying out specific analyses shall be commensurate with the range of analyses to be carried out or as designated.

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Page 5

GAS SAMPLING

1

Samples of gas for chromatographic analysis shall be obtained from exploratory holes or standpipes in accordance with DD 175 and the SISG publication. The sampling method shall relate to the volume of gas available and the type of laboratory analysis. The sampler receptacle shall be airtight and may include lockable syringes, Teflon-lined bags or gas bombs.

4.7

SPECIAL SAMPLING

1

The Engineer may require special sampling. This work will normally require supervision on site by a geotechnical person and shall be carried out in accordance with BS 5930 or as designated.

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END OF PART

QCS 2014

Section 03: Ground Investigation Part 05: In-Situ Testing, Instrumentation and Monitoring

Page 1

IN-SITU TESTING, INSTRUMENTATION AND MONITORING............................... 2

5.1 5.1.1 5.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

5.2 5.2.1 5.2.2

TESTING, INSTRUMENTATION AND MONITORING GENERALLY ...................... 2 Testing 2 Instrumentation and Monitoring 3

5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6

TESTS ..................................................................................................................... 3 Tests in accordance with BS 1377 or BS EN 1997 3 Tests in accordance with BS 5930 4 Geophysical Methods of Investigation 4 Special In-Situ Testing 4 Hand Penetrometer and Hand Vane for Shear Strength 5 Self-boring Pressuremeter 5

5.4 5.4.1 5.4.2 5.4.3

INSTRUMENTATION AND MONITORING .............................................................. 6 Groundwater 6 Installation of Standpipes and Piezometers 6 Installation of Gas Monitoring Standpipes 6

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Section 03: Ground Investigation Part 05: In-Situ Testing, Instrumentation and Monitoring

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5

IN-SITU TESTING, INSTRUMENTATION AND MONITORING

5.1

GENERAL

5.1.1

Scope

1

Testing of soils in place, and provision of instrumentation and monitoring of groundwater and subsurface gases.

2

Related Sections and Parts are as follows: This Section

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Part 1 ............... General Part 2 ............... Boreholes Part 3 ............... Pits and Trenches. References

1

The following standards and other documents are referred to in this Part:

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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BS 1377......................Methods of tests for soils for civil engineering purposes BS 5930......................Code of practice for site investigations

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BS 7022......................Geophysical logging of boreholes for hydrogeological purposes

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BS EN 1997................Ground Investigation and testing

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The Geological Society Engineering Group Working Party Report on Engineering Geophysics, Quarterly Journal of Engineering Geology, 21, pp. 207-271, 1988.

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Clarke B.G. and Smith A., A model specification for radial displacement measuring pressuremeters, Ground Engineering, Volume 25, No. 2, March, 1992.

TESTING, INSTRUMENTATION AND MONITORING GENERALLY

5.2.1

Testing

1

The following information shall be submitted for each test record to be included in the daily report, preliminary log and factual report:

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5.2

(a)

Date of test.

(b)

Project name, exploratory hole number and location.

(c)

Depth and location of test or depths covered by test.

(d)

Information on water levels in exploratory hole during testing.

(e)

Original ground level at test site.

(f)

Soil type and description as identified from the sample.

All results shall be reported in SI units.

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Page 3

Where load, displacement or other measuring equipment is used which necessitates regular calibration, then this shall be carried out in accordance with the relevant standard (the preferred method) or the manufacturer's instructions, by a calibration service approved by the Central Materials Laboratory. Evidence of calibrations and copies of calibration charts shall be supplied to the Engineer prior to commencing work and when otherwise requested.

5.2.2

Instrumentation and Monitoring

1

The top of each standpipe, gas monitoring standpipe and piezometer tube shall be protected by a cover. The type of protective cover shall be approved by the Engineer.

2

When instructed by the Engineer, the Contractor shall install a protective fence around the top of a standpipe or piezometer. The fence shall be constructed of corrosion treated angle iron, galvanised wire, and corrosion resistant wire mesh fencing suitable for use in the climate of Qatar or a fence as a agreed upon with the Engineer.

3

Daily readings of depths to water in groundwater monitoring standpipes and piezometers shall be made by the Contractor, with an instrument approved by the Engineer.

4

Where the presence of gas is suspected or when directed by the Engineer, gas measurements, using an approved in-situ meter, shall be made by the Contractor during construction of exploratory holes and in gas monitoring standpipes. The depth to water and barometric pressure shall be measured immediately after each gas measurement.

5

Unless otherwise designated, piezometers, and standpipes protection shall not be removed from the site.

6

Other instrumentation and monitoring shall be carried out as designated.

5.3

TESTS

5.3.1

Tests in accordance with BS 1377 or BS EN 1997

1

The following in-situ tests shall be carried out and reported in accordance with BS 1377 or BS EN 1997: in-situ density by

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(i)

Small pouring cylinder method.

(ii)

Large pouring cylinder method.

(iii)

Water replacement method.

(iv)

Core cutter method.

(v)

Nuclear method.

(b)

Static cone penetration test (CPT), capacity to suit scheduled depths unless otherwise designated

(c)

Dynamic probing (DPH or DPSH).

(d)

Standard penetration test (SPT).

(e)

Plate loading test.

(f)

Shallow pad maintained load test.

QCS 2014

Section 03: Ground Investigation Part 05: In-Situ Testing, Instrumentation and Monitoring

(g)

California bearing ratio (CBR).

(h)

Vane shear strength.

(i)

Apparent resistivity of soil.

(j)

Redox potential.

(k)

Pressurementer or Self-boring Pressuremeter (PMT)

(l)

Pocket Penetrometer.

Page 4

5.3.2

Tests in accordance with BS 5930

1

The following in-situ tests shall be carried out where applicable and reported in accordance with BS 5930:

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Constant head permeability test. Variable head permeability test. Packer permeability test.

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Geophysical Methods of Investigation

1

Geophysical testing shall be carried out as designated. The Contractor shall submit to the Engineer a full description of equipment and procedure for each geophysical method required.

2

The equipment and procedure, and information to be submitted for the following geophysical methods of investigation, shall be as described in BS 5930, BS 7022 and the Geological Society Engineering Group Working Party Report on Engineering Geophysics:

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electrical resistivity method

(b)

seismic refraction and reflection method

(c)

magnetic method

(d)

gravity method

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electromagnetic method

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Ground conductivity.

(ii)

Transient electromagnetic.

(iii)

Ground probing radar (optional).

(f)

Borehole geophysical logging.

(g)

Cross-hole seismic method.

(h)

Multi Channel Analysis of Surface Waves (MASW)

(i)

Refraction Microtremor (ReMi)

5.3.4

Special In-Situ Testing

1

Special in-situ testing shall be carried out as designated.

2

The Contractor shall allow for the excavation of boreholes, trenches or trial pits necessary for the execution of inspection tests.

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Section 03: Ground Investigation Part 05: In-Situ Testing, Instrumentation and Monitoring

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Inspection tests shall be decided as directed by the Engineer. These tests shall include but not limited to those in Table 3.2. Table 3.2: Quality Assurance Tests for Completed Work Recommended Test per Layer Deep Fill (boreholes)

In-situ CBR

Field density

Plate load Test

Layer Thickness

Field density

DCP Test

Layer Thickness

SPT

DCP Test

Pressure meter

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1

Hand penetrometer and hand vane tests shall be carried out where required to give a preliminary estimate of undrained shear strength of the soil tested.

2

Hand (or pocket) penetrometer equipment shall be of an approved proprietary make with 2 stainless steel tip of end area 31 mm with an engraved penetration line 6 mm from the tip.

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5.3.5

Hand vane equipment shall be of an approved proprietary make with stainless steel vanes having a length of 19 mm or 33 mm and a length-to-diameter ratio of 2:1. The scale shall be

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The scale shall be suitably graduated. The procedure for the test shall be in accordance with the manufacturer's instructions. Both unconfined compressive strength and estimated shear strength shall be reported for the soil tested.

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suitably graduated. The procedure for test shall be in accordance with BS 5930 and the manufacturer's instructions. Peak shear strength and residual shear strength shall be

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The reported shear strengths for the hand penetrometer and handvane shall be the average of 3 tests in close proximity. Tests giving inconsistent results shall be reported and comments on the relevance of the tests noted.

5.3.6

Self-boring Pressuremeter

1

The equipment shall be of the Cambridge type (soft ground) self-boring pressuremeter (SBP) unless otherwise designated. The instruments, calibration, operator, installation, testing procedure, on-site data processing and analysis, information to be submitted, report data processing and analysis and information to be submitted in the report shall be as described by Clarke and Smith (1992) and as designated..

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5.4

INSTRUMENTATION AND MONITORING

5.4.1

Groundwater

1

When groundwater is encountered in exploratory holes, the depth from ground level of the point of entry shall be recorded together with depth of any casing. Exploratory hole operations shall be stopped and the depth from ground level to water level recorded with an approved instrument at 5 minutes intervals for a period of 20 minutes. If at the end of the

.

period of 20 minutes the water level is still rising, this shall be recorded together with the depth to water below ground level, unless otherwise instructed by the Engineer, and the exploratory hole shall then be continued. If casing is used and this forms a seal against the entry of groundwater, the Contractor shall record the depth of casing at which no further entry or only insignificant infiltration of water occurred. Water levels shall be recorded as required by the Contract and at the beginning and end of each shift. On each occasion when groundwater levels are recorded, the depth of the exploratory hole, the depth of any casing and the time shall also be recorded.

3

Where artesian conditions are encountered, the Contractor shall immediately inform the Engineer and agree a method for dealing with the conditions.

5.4.2

Installation of Standpipes and Piezometers

1

Standpipes for monitoring groundwater levels and changes in groundwater levels shall be installed in exploratory holes, as instructed by the Engineer. They shall be to the designated form and detail, and appropriate dimensions and depths shall be recorded at the time of installation.

2

Standpipe piezometers for monitoring groundwater levels in exploratory holes shall be installed as instructed by the Engineer. They shall be to the designated form and detail, and appropriate dimensions. The installation details of the standpipe piezometers shall be recorded.

3

The Contractor shall install piezometers of the hydraulic, electrical or pneumatic type described in BS 5930 or as designated by the Engineer.

5.4.3

Installation of Gas Monitoring Standpipes

1

Standpipes for monitoring gas concentration in exploratory holes shall be installed as instructed by the Engineer. Warning signs or other safety measures required by the Civil Defence Department of the Government shall be complied with. Standpipes shall be of the designated form and detail. All dimensions and depths shall he recorded at the time of installation.

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END OF PART

QCS 2014

Section 03: Ground Investigation Part 06: Laboratory Testing

Page 1

LABORATORY TESTING ........................................................................................ 2

6.1 6.1.1 6.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

6.2

SCHEDULE OF TESTS ........................................................................................... 2

6.3 6.3.1 6.3.2 6.3.3 6.3.4

TESTING PROCEDURES ....................................................................................... 3 General 3 Geotechnical Testing on Contaminated Samples 3 Soil Testing 3 Rock Testing 3

6.4 6.4.2 6.4.3

CHEMICAL TESTING FOR CONTAMINATED GROUND ....................................... 4 Laboratory Testing On Site 6 Special Laboratory Testing 6

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Section 03: Ground Investigation Part 06: Laboratory Testing

Page 2

6

LABORATORY TESTING

6.1

GENERAL

6.1.1

Scope

1

Geotechnical tests and testing procedures carried out in the laboratory or, when designated, on site.

2

Related Sections and Parts are as follows: This Section

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Part 1, .............. General Part 3, .............. Soil Sampling

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Section 6, ........ Roadworks Section 8, ........ Drainage Works Section 12, ...... Earthworks Related to Buildings References

1

The following standards and other documents are referred to in this Part:

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6.1.2

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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction Purposes

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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)

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ASTM SP 402.............Special Technical Publications No. 402

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BS 1377 ......................Methods of tests for soils for civil engineering purposes BS 1881 ......................Analysis of hardened concrete

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BS 812 ........................Testing aggregates

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BS EN 1997--------- .....Ground Investigation and testing

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Brown E.T. (Editor). Rock characterisation testing and monitoring. International Society for Rock Mechanics Suggested Methods. 1981. Pergamon Press. C2 through C25 and C27 through C31, Methods for examination of waters and associated materials, HMSO IRSM Commission on Testing Methods. Suggested method for determining Point Load Strength (revised version). Int. J. Rock Mech. Min. Sci. and Geomech. Abst., 22, 51-60 (1985).

6.2

SCHEDULE OF TESTS

1

The Contractor shall prepare a schedule of tests for approval by the Engineer. It may be necessary to designate additional testing after the results of the original tests are available. Unless otherwise agreed, testing schedules are to be provided within six working days of the receipt by the Engineer of the relevant preliminary logs. The Contractor shall inform the Engineer within six working days from the receipt of the approved testing schedule if a sample referred to in the schedule is not available for testing.

QCS 2014

Section 03: Ground Investigation Part 06: Laboratory Testing

Page 3

TESTING PROCEDURES

6.3.1

General

1

Where applicable, all preparation, testing and reporting shall be in accordance with the relevant Qatar National Standard or British Standards or ASTM Standards. Where tests are not covered by these Standards, they shall be performed in accordance with the procedures in the references or as designated.

2

Calibration of load-displacement or other measuring equipment shall be carried out in accordance with the relevant standard (the preferred method) or the manufacturer’s instructions by a calibration service approved by the Central Materials Laboratory. Evidence of current calibrations shall be supplied to the Engineer.

6.3.2

Geotechnical Testing on Contaminated Samples

1

Where geotechnical testing is required on samples of suspected contaminated material, indicative chemical testing shall be carried out and a safe method of working approved by the Engineer before any such work is started. It should be noted that this may include but is not limited to the safe storage, transportation and handling of all suspect material.

6.3.3

Soil Testing

1

Soil testing shall be carried out and reported in accordance with BS 1377 or ASTM Standards unless otherwise designated.

6.3.4

Rock Testing

1

Rock testing shall be carried out and reported in accordance with the following references and as designated: Classification.

Natural water content - Brown (1981).

(ii)

Porosity/density - Brown (1981).

(iii)

Void index - Brown (1981).

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6.3

(b)

(c)

(d)

(iv)

Carbonate content - BS 1881.

(v)

Petrographic description -Brown (1981).

Durability. (i)

Slake durability index - Brown (1981).

(ii)

Soundness by solution of magnesium sulphate - BS 812.

Hardness. (i)

Shore sclerometer -Brown (1981).

(ii)

Schmidt rebound hardness - Brown (1981).

Aggregates. (i)

Aggregate crushing value - BS 812.

(ii)

Ten percent fines - BS 812.

(iii)

Aggregate impact value - BS 812.

(iv)

Aggregate abrasion value - BS 812.

(v)

Polished stone value - BS 812.

(vi)

Aggregate frost heave - BS 812.

Strength. (i)

Uniaxial compressive strength - Brown (1981).

(ii)

Deformability in uniaxial compression -Brown (1981).

(iii)

Tensile strength-Brown (1981).  

Direct tensile strength. Indirect tensile strength by the Brazilian method.

Undrained triaxial compression without measurement of porewater pressureBrown (1981).

(v)

Direct shear strength - Brown (1981).

(vi)

Swelling pressure - Brown (1981).

(vii)

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Swelling pressure index under conditions of zero volume change. Swelling strain index for a radially confined specimen with axial surcharge. Swelling strain developed in an unconfined rock specimen.

Point load test - IRSM Commission on Testing Methods (1985).

Geophysical. Seismic velocity-Brown (1981).

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(iv)

   (f)

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Section 03: Ground Investigation Part 06: Laboratory Testing

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CHEMICAL TESTING FOR CONTAMINATED GROUND

1

Chemical testing for contaminated ground shall be carried out and reported in accordance with the following references and as designated:

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Primary contaminants in soil. Arsenic total - C4.

(ii)

Cadmium total - C2.

(iii)

Chromium total - C2.

(iv)

hexavalent chromium (undertaken if total chromium content >25 mg/kg dry

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Mass) -C2.

(v)

Lead total - C2.

(vi)

Mercury total - C3.

(vii)

Selenium total - C4.

(viii)

Boron, water-soluble - C5.

(ix)

Copper total - C2.

(x)

Nickel total - C2.

(xi)

Zinc total - C2.

(xii)

Cyanide total (alkali extraction methods) - C6.

(xiii)

Cyanide complex - C6.

(xiv) Cyanide free - C6. (xv)

Thiocyanate - C6.

QCS 2014

Section 03: Ground Investigation Part 06: Laboratory Testing

Page 5

(xvi) (Tests xiii, xiv and xv undertaken if total cyanide >25 mg/kg dry mass. Methods shall follow alkali extraction.) (xvii) Phenols total - C7. (xviii) Sulphide - C8. (xix) Sulphate - total, acid, soluble - C9. (xx)

Sulphate - water soluble, 2 : 1 extract - C9.

(xxi) Sulphur free - C10. (xxii) PH value - C9. (xxiii) Toluene extractable matter - Cl1.

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(xxiv) Coal tar/polyaromatic hydrocarbons (undertaken if toluene extractable matter> 2000 g/kg dry mass of soil) - C12.

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Antimony total - C13.

(ii)

Barium total - C13.

(iii)

Beryllium total - C15.

(iv)

Vanadium total - C13.

(v)

Cyclohexane extractable matter - C14.

(vi)

Freon extractable matter - C15.

(vii)

Mineral oils - C31.

(viii)

Chloride - C9.

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(i)

Contaminants in water.

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(c)

Secondary contaminants in soil.

(i)

Arsenic - C4.

(ii)

Cadmium - C2 and C23. Chromium - C2 and C24.

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(iii)

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(b)

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(xxv) Asbestos. Asbestos content determination shall be carried out by visual examination and polarised light microscopy.

Hexavalent chromium - C2.

(v)

Lead - C2 and C25.

(vi)

Mercury - C3.

(vii)

Selenium - C4.

(viii)

Boron - C5 and C6.

(ix)

Copper - C2 and C27.

(x)

Nickel - C2 and C28.

(xi)

Zinc - C2 and C29.

(xii)

Cyanide total - C6.

(xiii)

Cyanide complex - C6.

(xiv)

Cyanide free - C6.

(xv)

Thiocyanate - C6.

(xvi)

Phenols total - C7.

(xvii)

Sulphide - C8.

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Page 6

Sulphate - C9.

(xix)

Sulphur free - C10.

(xx)

PH value - C9.

(xxi)

Polyaromatic hydrocarbons - C 12.

(xxii)

Antimony-C13.

(xxiii)

Barium-C13.

(xxiv)

Beryllium-C15.

(xxv)

Vanadium - C 13.

(xxvi)

Chloride - C9.

(xxvii)

Ammoniacal nitrogen - C16.

(xxviii)

Nitrate nitrogen - Cl7.

(xxix)

Chemical oxygen demand - C18.

(xxx)

Biochemical oxygen demand - C19.

(xxxi)

Total organic carbon - C20.

(xxxii)

Volatile fatty acids - C21.

(xxxiii)

Iron - C22.

(xxxiv)

Manganese - C22.

(xxxv)

Calcium - C31.

(xxxvi)

Sodium - C31.

(xxxvii)

Magnesium - C31.

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(xviii)

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Constituents of gas samples. Carbon dioxide - C30.

(ii)

Hydrogen - C30.

(iii)

Hydrogen sulphide - C30.

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(xxxviii) Potassium - C21.

Methane - C30.

(v)

Nitrogen - C30.

(vi)

Oxygen - C30.

(vii)

Ethane- C30.

(viii)

Propane- C30.

(ix)

Carbon monoxide - C30.

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6.4.2

Laboratory Testing On Site

1

When designated, tests listed under laboratory testing shall be carried out on site.

6.4.3

Special Laboratory Testing

1

When designated, special laboratory testing shall be carried out. END OF PART

QCS 2014

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 1

GENERAL REQUIREMENTS FOR PILING WORK ................................................. 2

1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 General Contract Requirements 2 Submittals 3 Records 3

1.2 1.2.1 1.2.2

GROUND CONDITIONS ......................................................................................... 3 Ground Investigation Reports 3 Unexpected Ground Conditions 4

1.3 1.3.1 1.3.2 1.3.3

MATERIALS AND WORKMANSHIP........................................................................ 4 General 4 Sources of Supply 4 Rejected materials 5

1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6

INSTALLATION TOLERANCES .............................................................................. 5 Setting Out 5 Position 6 Verticality 6 Rake 6 Tolerance Variations 6 Forcible Corrections to Pile 6

1.5 1.5.1 1.5.2 1.5.3 1.5.4

NUISANCE AND DAMAGE ..................................................................................... 6 Noise and Disturbance 6 Damage to Adjacent Structures 7 Damage to Piles 7 Temporary Support 7

1.6 1.6.1 1.6.2 1.6.3

SAFETY .................................................................................................................. 7 General 7 Life-Saving Appliances 7 Driving 7

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Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 2

GENERAL REQUIREMENTS FOR PILING WORK

1.1

GENERAL

1.1.1

Scope

1

This Part is concerned with all works associated with installation of piles by any of the recognised techniques.

1.1.2

References

1

The following standards and codes of practice are referred to in this Part:

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Part I, Code of practice for basic information and procedures for noise control Part IV, Code of practice for noise and vibration control applicable to piling operations

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BS 8008......................Safety precautions and procedures for the construction and descent of machine-bored shafts for piling and other purposes

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BS EN 1997................Eurocode 7, Geotechnical Design.

General Contract Requirements

1

The following matters, where appropriate, are described in the contract specific documentation for the Works: general items related to Works Nature of the Works.

(ii)

Classes of loads on piles.

(iii)

Contract drawings.

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(b)

(iv)

Other works proceeding at the same time.

(v)

Working area.

(vi)

Order of the Works.

(vii)

Datum.

(viii)

Offices for the Engineer's Representative.

(ix)

Particular facilities and attendance items where not included in this section.

(x)

Details of soil investigation reports.

specific items related to particular type of pile (i)

Soil sampling, laboratory testing and in-situ soil testing.

(ii)

Designed concrete or grout mixes, grades of concrete or grout, type of cement and aggregate, grout or concrete admixtures, concreting of piles.

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 3

Grades and types of reinforcement and prestressing tendons.

(iv)

Pile dimensions, length and marking of piles.

(v)

Type and quality of pile shoe/splice.

(vi)

Type and quality of permanent casing.

(vii)

Specified working loads.

(viii)

Sections of proprietary types of pile, grades of steel, minimum length to be supplied, thickness of circumferential weld reinforcement.

(ix)

Surface preparation, types and thickness of coatings.

(x)

Test piles, driving resistance or dynamic evaluation and penetration.

(xi)

Detailed requirements for driving records.

(xii)

Acceptance criteria for piles under test.

(xiii)

Disposal of cut-off lengths.

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QCS 2014

(xiv) Preboring. Submittals

1

The Contractor shall supply for approval all relevant details of the method of piling and the plant he proposes to use. Any alternative method to that specified shall be subject to approval.

2

The Contractor shall submit to the Engineer on the first day of each week, or at such longer periods as the Engineer may from time to time direct, a progress report showing the current rate of progress and progress during the previous period on all important items of each section of the Works.

3

The Contractor shall inform the Engineer each day of the intended programme of piling for the following day and shall give adequate notice of his intention to work outside normal hours and at weekends.

1.1.5

Records

1

The Contractor shall keep records, as indicated by an asterisk in Table 1.1, of the installation of each pile and shall submit two signed copies of these records to the Engineer not later than noon of the next working day after the pile is installed. The signed records will form a record of the work. Any unexpected driving or boring conditions shall be noted briefly in the records.

1.2

GROUND CONDITIONS

1.2.1

Ground Investigation Reports

1

Factual information and reports on site investigations for the Works and on the previous known uses of the Site will be provided by the Engineer where they exist as part of the specific contract documentation. However, even if a full report is given, including interpretations, opinions or conclusions, no responsibility is accepted by the Engineer for any opinions or conclusions which may be given in the reports.

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Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 4

Before the start of work the Contractor shall be given a copy of any subsequent information which may have been obtained relating to the ground conditions and previous uses of the Site.

1.2.2

Unexpected Ground Conditions

1

The Contractor shall report immediately to the Engineer any circumstance which indicates that in the Contractor's opinion the ground conditions differ from those reported in or which could have been inferred from the site investigation reports or test pile results.

1.3

MATERIALS AND WORKMANSHIP

1.3.1

General

1

All materials and workmanship shall be in accordance with the appropriate British Standards, codes of practice and other approved standards current at the date of tender except where the requirements of these standards or codes of practice are in conflict with this Section in which case the requirements of this Section shall take precedence.

1.3.2

Sources of Supply

1

The sources of supply of materials shall not be changed without prior approval.

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Table 1.1

Driven segmental concrete piles

Driven cast-in-place concrete piles

Bored cast-in-place concrete piles

Continuous flight auger concrete or grout piles

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

Nominal cross-sectional dimensions or diameter

*

*

*

*

*

Nominal diameter of underream/base

-

-

-

*

-

Length of preformed pile

*

*

-

-

-

Standing groundwater level from direct observation or given site investigation data.

-

-

*

*

*

Date and time of driving, redriving or boring

*

*

*

*

*

Date of concreting

-

-

*

*

*

Ground level/sea bed level at pile position at commencement of installation of pile (commencing surface)

*

*

*

*

*

Working elevation of pile driver

*

*

*

*

*

Depth from ground level at pile position to pile tip

*

*

*

*

*

Tip elevation

*

*

*

*

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Driven steel, precast concrete and steel sheet piles

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Records to be Kept (Indicated by an Asterisk)

Contract

Pile type

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Pile reference number (location)

Bored cast-in-place concrete piles

Continuous flight auger concrete or grout piles

Pile head elevation, as constructed

*

*

*

*

*

Pile cut-off elevation

*

*

*

*

*

Length of temporary casing

-

-

*

*

-

Length of permanent casing

-

-

*

*

-

Type, weight, drop and mechanical condition of hammer and equivalent information for other equipment

*

*

*

-

-

Number and type of packings used and type and condition of dolly used during driving of the pile

*

*

-

-

*

*

-

-

*

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Set of pile or pile tube in millimetres per 10 blows or number of blows per 25 mm of penetration

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Data

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Driven cast-in-place concrete piles

Page 5

Driven segmental concrete piles

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work Driven steel, precast concrete and steel sheet piles

QCS 2014

*

*

*

-

-

If required, temporary compression of ground and pile from time of a marked increase in driving resistance until pile reached its final level

*

*

*

-

-

*

*

*

-

-

Soil samples taken and in-situ tests carried out during pile installation

*

*

*

*

*

Length and details of reinforcements

-

-

*

*

*

Concrete mix

-

-

*

*

*

-

-

*

*

*

*

*

*

*

*

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If required, the sets taken at intervals during the last 3 m of driving

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If required, driving resistance taken at regular intervals over the last 3 m of driving

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Volume of concrete supplied to pile obstructions

delays

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All information regarding interruptions to the work

and

other

1.3.3

Rejected materials

1

Rejected materials are to be removed promptly from the Site.

1.4

INSTALLATION TOLERANCES

1.4.1

Setting Out

1

Setting out of the main grid lines shall be by the Contractor. The installation of marker pins at pile positions, as required by the Contract, shall be located by the Contractor from the main grid lines of the proposed structure. Before installation of the pile, the pile position relative to the main grid lines shall be verified.

QCS 2014

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 6

Position

1

For a pile cut off at or above ground level the maximum permitted deviation of the pile centre from the centre-point shown on the drawings shall be 75 mm in any direction. An additional tolerance for a pile head cut off below ground level will be permitted in accordance with Clauses 1.4.3 and 1.4.4.

1.4.3

Verticality

1

At the commencement of installation, the pile, or pile-forming equipment in the case of a driven pile, or the relevant equipment governing alignment in the case of the bored pile, shall be made vertical to a tolerance of within 1 in 100. The maximum permitted deviation of the finished pile from the vertical is 1 in 75.

1.4.4

Rake

1

As in clause 1.4.3, the pile, or driving or other equipment governing the direction and angle of rake shall be set to give the correct alignment of the pile to within a tolerance of 1 in 50. The piling rig shall be set and maintained to attain the required rake. The maximum permitted deviation of the finished pile from the specified rake is 1 in 25 for piles raking up to 1:6 and 1 in 15 for piles raking more than 1:6.

1.4.5

Tolerance Variations

1

In exceptional circumstances where these tolerances are difficult to achieve, the tolerances of Clauses 1.4.2, 1.4.3 and 1.4.4 may be relaxed by the Engineer, subject to consideration of the implications of such action.

1.4.6

Forcible Corrections to Pile

1

Forcible corrections to concrete piles to overcome errors of position or alignment shall not be made. Forcible corrections may be made to other piles only if approved and where the pile shaft is not fully embedded in the soil.

1.5

NUISANCE AND DAMAGE

1.5.1

Noise and Disturbance

1

The Contractor shall carry out the work in such a manner and at such times as to minimise noise, vibration and other disturbance in order to comply with current environmental legislation.

2

The Contractor shall endeavour to ascertain the nature and levels of noise produced by the mechanical equipment and plant that will be used. He shall than take steps to reduce either the level or the annoying characteristics, or both, of the noise. Reference should be made to BS 5228 Part 1 for prediction of noise level due to different types of mechanical equipment and plant, and to BS 5228 Part 4 for noise and vibration control techniques applicable to piling operations.

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1.4.2

QCS 2014

Section 04: Foundations and Retaining Structures Part 01: General Requirements for Piling Work

Page 7

Damage to Adjacent Structures

1

If in the opinion of the Contractor, damage will be, or is likely to be, caused to mains, services or adjacent structures, he shall submit to the Engineer his proposals for making preconstruction surveys, monitoring movements or vibrations, and minimising or avoiding such damage.

1.5.3

Damage to Piles

1

The Contractor shall ensure that during the course of the work, displacement or damage which would impair either performance or durability does not occur to completed piles.

2

The Contractor shall submit to the Engineer his proposed sequence and timing for driving or boring piles, having the intent of avoiding damage to adjacent piles.

1.5.4

Temporary Support

1

The Contractor shall ensure that where required, any permanently free-standing piles are temporarily braced or stayed immediately after driving to prevent loosening of the piles in the ground and to ensure that the pile will not be damaged by oscillation, vibration or ground movement.

1.6

SAFETY

1.6.1

General

1

A competent person, properly qualified and experienced, should be appointed to supervise the piling operations. This person should be capable of recognising and assessing any potential dangers as they arise; e.g., unexpected ground conditions that may require a change in construction technique, or unusual smells which may indicate the presence of noxious or dangerous gases.

2

Safety precautions throughout the piling operations shall comply with BS 8008 and BS EN 1997. Refer Section 1 for general safety standards to be adopted at a construction site.

1.6.2

Life-Saving Appliances

1

The Contractor shall provide and maintain on the Site sufficient, proper and efficient lifesaving appliances to the approval of the Engineer. The appliances must be conspicuous and available for use at all times.

2

Site operatives shall be instructed in the use of safety equipment and periodic drills shall be held to ensure that all necessary procedures can be correctly observed.

1.6.3

Driving

1

Before any pile driving is started, the Contractor shall supply the Engineer with two copies of the code of signals to be employed, and shall have a copy of the code prominently displayed adjacent to the driving control station on the craft, structure or site from which the piles will be driven.

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1.5.2

END OF PART

QCS 2014

Section 04: Foundations and Retaining Structures Part 02: Concrete Works for Piling

Page 1

CONCRETE WORKS FOR PILING ......................................................................... 2

2.1 2.1.1 2.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5

MATERIALS ............................................................................................................ 2 Cementitious 2 Aggregate 2 Water 2 Admixtures 2 Steel Reinforcement and Prestressing Steel 2

2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5

CONCRETE MIXES FOR PILING WORK ............................................................... 3 General 3 Grade Designation 3 Designed Mix 3 Durability 3 Exposure Classes 3

2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7

PLACING CONCRETE ............................................................................................ 3 General 3 Inspection 4 Cleanliness of Pile Bases 4 Workability of Concrete 4 Compaction 4 Placing Concrete in Dry Borings 5 Placing Concrete under Water or Drilling Fluid 5

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QCS 2014

Section 04: Foundations and Retaining Structures Part 02: Concrete Works for Piling

CONCRETE WORKS FOR PILING

2.1

GENERAL

2.1.1

Scope

1

This part applies to cast in-situ as well as precast concrete work.

2

Related Sections and Parts are as follows:

Section 5

Concrete.

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This Section Part 1, Part 3 Part 4 Part 5

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2

Page 2

References

1

The following Standards are referred to in this Part:

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All Standards mentioned in Section 5

MATERIALS

2.2.1

Cementitious

1

All cementitious materials shall comply with the requirements of Section 5, Part 3.

2

All cementitious materials shall be stored in separate containers according to type in waterproof stores or silos.

2.2.2

Aggregate

1

Aggregates shall comply with the requirements of Section 5, Part 2.

2.2.3

Water

1

If water for the Works is not available from a public supply, approval shall be obtained regarding the source of water. For quality of water refer to Section 5, Part 4.

2.2.4

Admixtures

1

Admixtures shall comply with the requirements of Section 5, Part 5

2.2.5

Steel Reinforcement and Prestressing Steel

1

Steel reinforcement shall be stored in clean and dry conditions. It shall be clean, and free from loose rust and loose mill scale when installed in the Works. For requirements of steel reinforcement refer to Section 5, Part 11.

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The number of joints in longitudinal steel bars shall be kept to a minimum. Joints in reinforcement shall be such that the full strength of each bar is effective across the joint and shall be made so that there is no detrimental displacement of the reinforcement during the construction of the pile.

3

For requirements of prestressing steel refer to Section 5, Part 18.

2.3

CONCRETE MIXES FOR PILING WORK

2.3.1

General

1

For general requirements of concrete mixes, trial mixes, batching, mixing and transportation of fresh concrete and testing of hardened concrete refer to Section 5.

2.3.2

Grade Designation

1

Grades of concrete shall be as given in Section 5, Part 6.

2.3.3

Designed Mix

1

The Contractor shall be responsible for selecting the mix proportions to achieve the required strength and workability..

2

Complete information on the mix and sources of aggregate for each grade of concrete and the water/cementitious ratio and the proposed degree of workability shall be approved before work commences.

3

Where low-alkali, sulphate-resisting cement to BS EN 197 is specified, the alkali content (equivalent sodium oxide) of the cement shall not exceed 0.6 % by weight.

4

The Contractor shall submit the slump value for approval before work commences.

2.3.4

Durability

1

For piles exposed to aggressive ground or groundwater, approved measures shall be taken to ensure durability. Reference shall be made to Section 5, Part 6.

2.3.5

Exposure Classes

1

The minimum cementitious content and type and the concrete grades shall be specified based on the exposure classes as given in Table 6.8, Section 5, Part 6.

2.4

PLACING CONCRETE

2.4.1

General

1

The workability and method of placing and vibrating the concrete shall be such that a continuous monolithic concrete shaft of the full cross-section is formed.

2

The concrete shall be placed without such interruption as would produce a cold joint in the pile. The method of placing shall be approved.

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3

The Contractor shall take all precautions in the design of the mix and placing of the concrete to avoid arching of the concrete in a temporary casing. No soil, liquid or other foreign matter which would adversely affect the performance of the pile shall be permitted to contaminate the concrete.

2.4.2

Inspection

1

Each pile bore which does not contain standing water or drilling fluid shall be inspected directly or indirectly before to concrete is placed in it. This inspection shall be carried out from the ground surface in the case of piles of less than 750 mm diameter. Torches or other approved means of lighting, measuring tapes, and a means of measuring verticality shall be provided. For piles of 750 mm diameter or larger, equipment shall be provided by the

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Contractor to enable his representatives and the Engineer to descend into the bore for the purpose of inspection. Any method of descent and the equipment used shall comply with the requirements of BS 8008. Cleanliness of Pile Bases

1

On completion of boring and where inspection of a dry pile bore indicates the necessity, loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain water or drilling fluid, a cleaning process shall be employed before concrete is placed, or the concrete shall be placed by tremie method. Large debris or accumulated sediment, or both of them, shall be removed using appropriate approved methods, which shall be designed to clean while at the same time minimising ground disturbance below the pile bases. Water or drilling fluid shall be maintained at such levels throughout and following the cleaning operation that stability of the bore is preserved.

2.4.4

Workability of Concrete

1

Slump measured at the time of discharge into the pile bore shall be in accordance with the standards shown in Table 2.1.

2.4.5

Compaction

1

Internal vibrators may be used to compact concrete, with the approval of the Engineer obtained in advance for each specific use.

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Piling mix workability

Table 2.1 Standards for Concrete Slump Slump Minimum

Range

mm

mm

Typical conditions of use

A

75

75-150

Placed into water-free unlined or permanently lined bore of 600 mm diameter or over, or where concrete is placed below temporary casing, and where reinforcement is widely spaced leaving ample room for free movement of concrete between bars.

B

100

100-200

Where reinforcement is not spaced widely, where concrete is placed within temporary casings, where pile bore is water-free, and the diameter less than 600 mm

C

150

150 or more

Where concrete is to be placed by tremie under water or drilling mud, or by pumping

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Placing Concrete in Dry Borings

1

Approved measures shall be taken to ensure that the structural strength of the concrete placed in all piles is not impaired through grout loss, segregation or bleeding.

2

Concrete shall be placed by “elephant trunk”, and the free fall shall not exceed 1.2 m.

2.4.7

Placing Concrete under Water or Drilling Fluid

1

Before placing concrete, measures shall be taken in accordance with Clause 2.4.3 to ensure that there is no accumulation of silt or other material at the base of the boring, and the Contractor shall ensure that heavily contaminated bentonite suspension, which could impair the free flow of concrete from the tremie pipe, has not accumulated in the bottom of the hole.

2

Concrete to be placed under water or drilling fluid shall be placed by tremie and shall not be discharged freely into the water or drilling fluid. Pumping of concrete may be approved where appropriate.

3

A sample of the bentonite suspension shall be taken from the base of the boring using an approved sampling device. If the specific gravity of the suspension exceeds 1.20 the placing of concrete shall not proceed. In this event the Contractor shall modify or replace the bentonite as approved to meet the specification.

4

The concrete shall be a rich, coherent mix and highly workable, and cement content shall be in accordance with Clause 2.3.5.

5

The concrete shall be placed in such a manner that segregation does not occur.

6

The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall extend to the base of the bore and a sliding plug or barrier shall be placed in the pipe to prevent direct contact between the first charge of concrete in the tremie and the water or drilling fluid. The pipe shall at all times penetrate the concrete which has previously been placed and shall be withdrawn at a rate such that there shall be a minimum concrete cover of 2 m over the end of the tremie pipe, until completion of concreting. A sufficient quantity of

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concrete shall be maintained within the pipe to ensure that the pressure from it exceeds that from the water or drilling fluid. The internal diameter of the tremie pipe shall be not less than 150 mm, and the maximum sized aggregate shall be 20 mm. It shall be so designed that external projections are minimised, allowing the tremie to pass within reinforcing cages without causing damage. The internal face of the pipe of the tremie shall be free from projections. END OF PART

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Page 1

SHALLOW FOUNDATIONS .................................................................................... 2

3.1 3.1.1 3.1.2 3.1.3 3.1.4

GENERAL ............................................................................................................... 2 Scope 2 Definition 2 References 2 Limit States Considerations 2

3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

DESIGN CONSIDERATIONS .................................................................................. 3 General 3 Allowable Bearing Pressure 3 Selection of Types of Shallow Foundation 3 Pad foundations 4 Strip foundations 4 Raft foundations 5

3.3 3.3.1 3.3.2 3.3.3

BASIS OF GEOTECHNICAL DESIGN .................................................................... 5 Design Requirements 5 Design Situations 7 Durability 8

3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11

GEOTECHNICAL DESIGN BY CALCULATION ...................................................... 9 General 9 Actions 10 Ground Properties 12 Geometrical Data 13 Characteristic and Representative Values of Actions 13 Characteristic Values of Geotechnical Parameters 13 Characteristic Values of Geometrical Data 14 Geotechnical Design Report 14 Actions and Design Situations 15 Design and Construction Considerations 15 Foundations on Rock; Additional Design Considerations 16

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SHALLOW FOUNDATIONS

3.1

GENERAL

3.1.1

Scope

1

The provisions of this Section apply to shallow foundations including isolated, pads, strips and rafts.

3.1.2

Definition

1

Shallow foundations are taken to be those where the depth below finished ground level is less than 3 m and include isolated, pad, strip and raft foundations. The choice of 3 m is arbitrary; shallow foundations where the depth/breadth ratio is high may need to be designed as deep foundations.

3.1.3

References

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BS 8004,.....................Code of practice for foundations.

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BS EN 1990................Eurocode 0: Basis of Structural Design BS EN 1991................Eurocode 1: Actions on structures BS EN 1992................Eurocode 2: Design of concrete structures -

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BS EN 1993................Eurocode 3: Design of steel structures

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BS EN 1994................Eurocode 4: Design of composite steel and concrete structures BS EN 1995................Eurocode 5: Design of timber structures

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BS EN 1996................Eurocode 6: Design of masonry structures

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BS EN 1997-1 ............Eurocode 7, Geotechnical design Part 1: General Rules BS EN 1997-2 ............Eurocode 7, Geotechnical design Part 2: Ground investigation and testing

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BS EN 1998................Eurocode 8: Design of structures for earthquake resistance

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BS 5930......................Code of Practice for Site Investigation Limit States Considerations

1

The following limit states shall be considered and an appropriate list shall be compiled:

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3.1.4

(a)

Loss of overall stability;

(b)

Bearing resistance failure, punching failure, squeezing;

(c)

Failure by sliding;

(d)

Combined failure in the ground and in the structure;

(e)

Structural failure due to foundation movement;

(f)

Excessive settlements;

(g)

Excessive heave due to swelling, frost and other causes;

(h)

Unacceptable vibrations.

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3.2

DESIGN CONSIDERATIONS

3.2.1

General

1

The depth to which foundations should be carried depends on two principal factors: (a)

Reaching an adequate bearing stratum;

(b)

Penetration below the zone in which trouble may be expected from seasonal weather changes.

Other factors such as ground movements, changes in groundwater conditions, long-term stability and heat transmitted from structures to the supporting ground may be important.

3

Shallow foundations are particularly vulnerable to certain soil conditions, e.g. loose waterbearing sands and soils that change structure when loaded. Specialist advice should be sought where such conditions are indicated by ground investigation.

3.2.2

Allowable Bearing Pressure

1

The center of area of a foundation or group of foundations should be arranged vertically under the centre of gravity of the imposed loading. If this is not possible, the effects on the structure of rotation and settlement of the foundation need to be considered.

2

Where foundation support is provided by a number of separate bases these should, as far as practicable, be proportioned so that differential settlement is minimal.

3.2.3

Selection of Types of Shallow Foundation

1

The selection of the appropriate type of shallow foundation will normally depend on the magnitude and disposition of the structural loads, the bearing capacity and settlement characteristics of the ground and the need to found in stable soil.

2

A pad foundation is used for the purpose of distributing concentrated loads. Unless special conditions control the design, relatively heavy column loads make it advantageous to use pad foundations.

3

Strip foundations may be more appropriate where column loads are comparatively small and closely spaced or where walls are heavy or heavily loaded.

4

Adjacent pad foundations can be combined or joined together with ground beams to support eccentric loads, to resist overturning or to oppose horizontal forces. Walls between columns may be carried on ground beams spanning between the pad foundations.

5

Where the allowable bearing pressure would result in large isolated foundations occupying the majority of the available area, it may be logical to join them to form a raft and spread the loads over the entire area. The combination of isolated foundations to form a raft sometimes results in a complex design and a large increase in the reinforcement requirement.

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In connection with the provision of foundations to an extension of an existing building, allowance should be made for differential movement of the foundations between the new and existing structure; such movement affects the structure above foundations. Where a degree of cracking and subsequent remedial work is not acceptable, provision for a joint between the extension and existing building should be considered. Where the foundations of an extension about the foundations of the existing building, the stability of the existing foundations should be ensured.

3.2.4

Pad foundations

1

For buildings such as low rise dwellings and lightly framed structures, pad foundations may be of unreinforced concrete provided that the angle of spread of load from the pier or base plate to the outer edge of the ground bearing does not exceed one (vertical) in one (horizontal) and that the stresses in the concrete due to bending and shear do not exceed tolerable limits. For buildings other than low rise and lightly framed structures, it is customary to use reinforced concrete foundations.

2

The thickness of the foundation should under no circumstances be less than 150 mm and will generally be greater than this to maintain cover to reinforcement where provided.

3

Where concrete foundations are used they should be designed in accordance with the design method appropriate to the loading assumptions.

3.2.5

Strip foundations

1

Similar considerations to those for pad foundations apply to strip foundations. On sloping sites strip foundations should be on a horizontal bearing, stepped where necessary to maintain adequate depth.

2

In continuous wall foundations it is recommended that reinforcement be provided wherever an abrupt change in magnitude of load or variation in ground support occurs. Continuous wall foundations will normally be constructed in mass concrete provided that the angle of spread of load from the edge of the wall base to the outer edge of the ground bearing does not exceed one (vertical) in one (horizontal). Foundations on sloping ground, and where regarding is likely to take place, may require to be designed as retaining walls to accommodate steps between adjacent ground floor slabs or finished ground levels. At all changes of level unreinforced foundations should be lapped at the steps for a distance at least equal to the thickness of the foundation or a minimum of 300mm. Where the height of the step exceeds the thickness of the foundation, special precautions should be taken. The thickness of reinforced strip foundations should be not less than 150mm, and care should be taken with the excavation levels to ensure that this minimum thickness is maintained. For the longitudinal spread of loads, sufficient reinforcement should be provided to withstand the tensions induced. It will sometimes be desirable to make strip foundations of inverted tee beam sections, in order to provide adequate stiffness in the longitudinal direction. At corners and junctions the longitudinal reinforcement of each wall foundation should be lapped.

3

Where the use of ordinary strip foundations would overstress the bearing strata, wide strip foundations designed to transmit the foundation loads across the full width of the strip may be used. The depth below the finished ground level should be the same as for ordinary strip foundations.

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Where the nature of the ground is such that narrow trenches can be neatly cut down to the bearing stratum, an economical foundation may be achieved by filling the trenches with concrete. When deciding the trench width, account should be taken of normal building tolerances in relation to setting out dimensions. Where the thickness of such a foundation is 500mm or more, any step should be not greater than the concrete thickness and the lap at such a step should be at least 1 m or twice the step height, whichever is the greater?

5

Where fill or other loose materials occur above the bearing stratum adequate support is required to any excavation. Consideration may be given to the use of lean mix mass concrete replacement under ordinary strip footings placed at shallow depth. This mass concrete can be poured against either permanent or recoverable shuttering. This form of foundation provides a method of dealing with local areas where deeper foundations are required.

3.2.6

Raft foundations

1

General. Suitably designed raft foundations may be used in the following circumstances.

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For lightly loaded structures on soft natural ground where it is necessary to spread the load, or where there is variable support due to natural variations, made ground or weaker zones. In this case the function of the raft is to act as a bridge across the weaker zones. Rafts may form part of compensated foundations.

(b)

Where differential settlements are likely to be significant. The raft will require special design, involving an assessment of the disposition and distribution of loads, contact pressures and stiffness of the soil and raft.

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(a)

BASIS OF GEOTECHNICAL DESIGN

3.3.1

Design Requirements

1

For each geotechnical design situation it shall be verified that no relevant limit state is exceeded.

2

When defining the design situations and the limit states, the following factors should be considered: Site conditions with respect to overall stability and ground movements;

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3

(b)

Nature and size of the structure and its elements, including any special requirements such as the design life;

(c)

Conditions with regard to its surroundings (e.g.: neighboring structures, traffic, utilities, vegetation, hazardous chemicals);

(d)

Ground conditions;

(e)

Ground-water conditions;

(f)

Regional seismicity;

(g)

Influence of the environment (hydrology, surface water, subsidence, seasonal changes of temperature and moisture).

Limit states can occur either in the ground or in the structure or by combined failure in the structure and the ground.

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Page 6

Limit states should be verified by any appropriate method such as calculation method as described in 3.4;

5

In practice, experience will often show which type of limit state will govern the design and the avoidance of other limit states may be verified by a control check.

6

Buildings should normally be protected against the penetration of ground-water or the transmission of vapor or gases to their interiors.

7

If practicable, the design results should be checked against comparable experience.

8

In order to establish minimum requirements for the extent and content of geotechnical investigations, calculations and construction control checks, the complexity of each geotechnical design shall be identified together with the associated risks. In particular, a distinction shall be made between:

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L ight and simple structures and small earthworks for which it is possible to ensure that the minimum requirements will be satisfied by experience and qualitative geotechnical investigations, with negligible risk;

(b)

Other geotechnical structures.

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(a)

For structures and earthworks of low geotechnical complexity and risk, such as defined above, simplified design procedures may be applied.

10

To establish geotechnical design requirements, three Geotechnical Categories, 1, 2 and 3, may be introduced.

11

A preliminary classification of a structure according to Geotechnical Category should normally be performed prior to the geotechnical investigations. The category should be checked and changed, if necessary, at each stage of the design and construction process.

12

The procedures of higher categories may be used to justify more economic designs, or if the designer considers them to be appropriate.

13

The various design aspects of a project can require treatment in different Geotechnical Categories. It is not required to treat the whole of the project according to the highest of these categories.

14

Geotechnical Category 1 should only include small and relatively simple structures:

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(a)

For which it is possible to ensure that the fundamental requirements will be satisfied on the basis of experience and qualitative geotechnical investigations;

(b)

With negligible risk.

15

Geotechnical Category 1 procedures should be used only where there is negligible risk in terms of overall stability or ground movements and in ground conditions, which are known from comparable local experience to be sufficiently straightforward. In these cases the procedures may consist of routine methods for foundation design and construction.

16

Geotechnical Category 1 procedures should be used only if there is no excavation below the water table or if comparable local experience indicates that a proposed excavation below the water table will be straightforward.

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17

Geotechnical Category 2 should include conventional types of structure and foundation with no exceptional risk or difficult soil or loading conditions

18

Designs for structures in Geotechnical Category 2 should normally include quantitative geotechnical data and analysis to ensure that the fundamental requirements are satisfied.

19

Routine procedures for field and laboratory testing and for design and execution may be used for Geotechnical Category 2 designs. the following are examples of conventional structures or parts of structures complying with Geotechnical Category 2: Shallow foundations;

(ii)

Pile foundations;

(iii)

Walls and other structures retaining or supporting soil or water;

(iv)

Excavations;

(v)

Bridge piers and abutments;

(vi)

Embankments and earthworks;

(vii)

Ground anchors and other tie-back systems;

(viii)

Tunnels in hard, non-fractured rock and not subjected to special water tightness or other requirements.

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Geotechnical Category 3 should include structures or parts of structures, which fall outside the limits of Geotechnical Categories 1 and 2.

21

Geotechnical Category 3 should normally include alternative provisions and rules to those in this standard. Geotechnical Category 3 includes the following examples: Very large or unusual structures;

(ii)

Structures involving abnormal risks, or unusual or exceptionally difficult ground or loading conditions;

(iii)

Structures in highly seismic areas;

(iv)

Structures in areas of probable site instability or persistent ground movements that require separate investigation or special measures.

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3.3.2

Design Situations

1

Both short-term and long-term design situations shall be considered.

2

In geotechnical design, the detailed specifications of design situations should include, as appropriate: (a)

The actions, their combinations and load cases;

(b)

The general suitability of the ground on which the structure is located with respect to overall stability and ground movements;

(c)

The disposition and classification of the various zones of soil, rock and elements of construction, which are involved in any calculation model;

QCS 2014

Section 04: Foundations and Retaining Structures Part 03: Shallow Foundations

(d)

Dipping bedding planes;

(e)

Mine workings, caves or other underground structures;

(f)

In the case of structures resting on or near rock: (i)

inter bedded hard and soft strata;

(ii)

faults, joints and fissures;

(iii)

possible instability of rock blocks;

(iv)

solution cavities, such as swallow holes or fissures filled with soft material, and continuing solution processes;

The environment within which the design is set, including the following: (i)

effects of scour, erosion and excavation, leading to changes in the geometry of the ground surface;

(ii)

effects of chemical corrosion;

(iii)

effects of weathering;

(iv)

effects of long duration droughts;

(v)

variations in ground-water levels, including, e.g. the effects of dewatering, possible flooding, failure of drainage systems, water exploitation;

(vi)

the presence of gases emerging from the ground;

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Earthquakes;

(i)

Ground movements caused by subsidence due to mining or other activities;

(j)

The sensitivity of the structure to deformations;

(k)

The effect of the new structure on existing structures, services and the local environment.

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Durability

1

At the geotechnical design stage, the significance of environmental conditions shall be assessed in relation to durability and to enable provisions to be made for the protection or adequate resistance of the materials.

2

In designing for durability of materials used in the ground, the following should be considered:

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3.3.3

(a)

For concrete: (i)

(b)

Aggressive agents in the ground-water or in the ground or fill material, such as acids or sulfate salts;

For steel: (i)

Chemical attack where foundation elements are buried in ground that is sufficiently permeable to allow the percolation of ground-water and oxygen;

(ii)

Corrosion on the faces of sheet pile walls exposed to free water, particularly in the mean water level zone;

(iii)

The pitting type of corrosive attack on steel embedded in fissured or porous concrete, particularly for rolled steel where the mill scale, acting as a cathode, promotes electrolytic action with the scale-free surface acting as an anode;

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Section 04: Foundations and Retaining Structures Part 03: Shallow Foundations For timber: (i)

(d)

Page 9

Fungi and aerobic bacteria in the presence of oxygen;

For synthetic fabrics: (i)

The ageing effects of UV exposure or ozone degradation or the combined effects of temperature and stress, and secondary effects due to chemical degradation.

Reference should be made to durability provisions in construction materials standards.

3.4

GEOTECHNICAL DESIGN BY CALCULATION

3.4.1

General

1

Design by calculation shall be in accordance with the fundamental requirements of EN 1990 and with the particular rules of this specification. Design by calculation involves:

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Actions, which may be either imposed loads or imposed displacements, e.g. from ground movements;

(b)

Properties of soils, rocks and other materials;

(c)

Geometrical data;

(d)

Limiting values of deformations, crack widths, vibrations etc;

(e)

Calculation models.

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(a)

It should be considered that knowledge of the ground conditions depends on the extent and quality of the geotechnical investigations. Such knowledge and the control of workmanship are usually more significant to fulfilling the fundamental requirements than is precision in the calculation models and partial factors.

3

The calculation model shall describe the assumed behavior of the ground for the limit state under consideration.

4

If no reliable calculation model is available for a specific limit state, analysis of another limit state shall be carried out using factors to ensure that exceeding the specific limit state considered is sufficiently improbable. Alternatively, design by prescriptive measures, experimental models and load tests, or the observational method, shall be performed.

5

The calculation model may consist of any of the following:

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(a)

An analytical model;

(b)

A semi-empirical model;

(c)

A numerical model.

6

Any calculation model shall be either accurate or err on the side of safety.

7

A calculation model may include simplifications.

8

If needed, a modification of the results from the model may be used to ensure that the design calculation is either accurate or errs on the side of safety.

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If the modification of the results makes use of a model factor, it should take account of the following: (a)

The range of uncertainty in the results of the method of analysis;

(b)

Any systematic errors known to be associated with the method of analysis.

10

If an empirical relationship is used in the analysis, it shall be clearly established that it is relevant for the prevailing ground conditions.

11

Limit states involving the formation of a mechanism in the ground should be readily checked using a calculation model. For limit states defined by deformation considerations, the deformations should be evaluated by calculation or otherwise assessed.

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NOTE: many calculation models are based on the assumption of a sufficiently ductile performance of the ground/structure system. A lack of ductility, however, will lead to an ultimate limit state characterized by sudden collapse. Numerical methods can be appropriate if compatibility of strains or the interaction between the structure and the soil at a limit state are considered.

13

Compatibility of strains at a limit state should be considered. Detailed analysis, allowing for the relative stiffness of structure and ground, may be needed in cases where a combined failure of structural members and the ground could occur. Examples include raft foundations, laterally loaded piles and flexible retaining walls. Particular attention should be paid to strain compatibility for materials that are brittle or that have strain-softening properties.

14

In some problems, such as excavations supported by anchored or strutted flexible walls, the magnitude and distribution of earth pressures, internal structural forces and bending moments depend to a great extent on the stiffness of the structure, the stiffness and strength of the ground and the state of stress in the ground.

15

In these problems of ground-structure interaction, analyses should use stress-strain relationships for ground and structural materials and stress states in the ground that are sufficiently representative, for the limit state considered, to give a safe result.

3.4.2

Actions

1

The definition of actions shall be taken as:

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(a)

Set of forces (loads) applied to the structure (direct action);

(b)

Set of imposed deformations or accelerations caused for example, by temperature changes, moisture variation, uneven settlement or earthquakes (indirect action).

The values of actions shall be taken from EN 1991 or equivalent international standard, where relevant. 2

The values of geotechnical actions to be used shall be selected, since they are known before a calculation is performed; they may change during that calculation. NOTE: Values of geotechnical actions may change during the course of calculation. In such cases they will be introduced as a first estimate to start the calculation with a preliminary, known value.

3

Any interaction between the structure and the ground shall be taken into account when determining the actions to be adopted in the design.

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In geotechnical design, the following should be considered for inclusion as actions: the weight of soil, rock and water;

(b)

stresses in the ground;

(c)

earth pressures and ground-water pressure;

(d)

free water pressures, including wave pressures;

(e)

ground-water pressures;

(f)

seepage forces;

(g)

dead and imposed loads from structures;

(h)

surcharges;

(i)

mooring forces;

(j)

removal of load or excavation of ground;

(k)

traffic loads;

(l)

movements caused by mining or other caving or tunneling activities;

(m)

swelling and shrinkage caused by vegetation, climate or moisture changes;

(n)

movements due to creeping or sliding or settling ground masses;

(o)

movements due to degradation, dispersion, decomposition, self-compaction and solution;

(p)

movements and accelerations caused by earthquakes, explosions, vibrations and dynamic loads;

(q)

temperature effects, including frost action;

(r)

imposed pre-stress in ground anchors or struts;

(s)

down drag.

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Section 04: Foundations and Retaining Structures Part 03: Shallow Foundations

Consideration shall be given to the possibility of variable actions occurring both jointly and separately.

6

The duration of actions shall be considered with reference to time effects in the material properties of the soil, especially the drainage properties and compressibility of fine-grained soils.

7

Actions, which are applied repeatedly, and actions with variable intensity shall be identified for special consideration with regard to, e.g. continuing movements, liquefaction of soils, change of ground stiffness and strength.

8

Actions that produce a dynamic response in the structure and the ground shall be identified for special consideration.

9

Actions in which ground- and free-water forces predominate shall be identified for special consideration with regard to deformations, fissuring, variable permeability and erosion.

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NOTE Unfavorable (or destabilizing) and favorable (or stabilizing) permanent actions may in some situations be considered as coming from a single source. If they are considered so, a single partial factor may be applied to the sum of these actions or to the sum of their effects.

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Page 12

Ground Properties

1

Properties of soil and rock masses, as quantified for design calculations by geotechnical parameters, shall be obtained from test results, either directly or through correlation, theory or empiricism, and from other relevant data.

2

Values obtained from test results and other data shall be interpreted appropriately for the limit state considered.

3

Account shall be taken of the possible differences between the ground properties and geotechnical parameters obtained from test results and those governing the behavior of the geotechnical structure.

4

The above differences can be due to the following factors: many geotechnical parameters are not true constants but depend on stress level and mode of deformation;

(b)

soil and rock structure (e.g. fissures, laminations, or large particles) that may play a different role in the test and in the geotechnical structure;

(c)

time effects;

(d)

the softening effect of percolating water on soil or rock strength;

(e)

the softening effect of dynamic actions;

(f)

the brittleness or ductility of the soil and rock tested;

(g)

the method of installation of the geotechnical structure;

(h)

the influence of workmanship on artificially placed or improved ground;

(i)

the effect of construction activities on the properties of the ground.

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(a)

When establishing values of geotechnical parameters, the following should be considered:

the value of each geotechnical parameter compared with relevant published data and local and general experience;

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(b)

published and well recognized information relevant to the use of each type of test in the appropriate ground conditions;

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3.4.3

6

(c)

the variation of the geotechnical parameters that are relevant to the design;

(d)

the results of any large scale field trials and measurements from neighboring constructions;

(e)

any correlations between the results from more than one type of test;

(f)

any significant deterioration in ground material properties that may occur during the lifetime of the structure.

Calibration factors shall be applied where necessary to convert laboratory or field test results according to EN 1997-2 into values that represent the behavior of the soil and rock in the ground, for the actual limit state, or to take account of correlations used to obtain derived values from the test results.

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Geometrical Data

1

The level and slope of the ground surface, water levels, levels of interfaces between strata, excavation levels and the dimensions of the geotechnical structure shall be treated as geometrical data.

3.4.5

Characteristic and Representative Values of Actions

1

Characteristic and representative values of actions shall be derived in accordance with EN 1990:2002 and the various parts of EN 1991.

3.4.6

Characteristic Values of Geotechnical Parameters

1

The selection of characteristic values for geotechnical parameters shall be based on results and derived values from laboratory and field tests, complemented by well-established experience.

2

The characteristic value of a geotechnical parameter shall be selected as a cautious estimate of the value affecting the occurrence of the limit state.

3

The selection of characteristic values for geotechnical parameters shall take account of the following:

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3.4.4

geological and other background information, such as data from previous projects;

(b)

the variability of the measured property values and other relevant information, e.g. from existing knowledge;

(c)

the extent of the field and laboratory investigation;

(d)

the type and number of samples;

(e)

the extent of the zone of ground governing the behavior of the geotechnical structure at the limit state being considered;

(f)

the ability of the geotechnical structure to transfer loads from weak to strong zones in the ground.

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Characteristic values can be lower values, which are less than the most probable values, or upper values, which are greater.

5

For each calculation, the most unfavorable combination of lower and upper values of independent parameters shall be used.

6

The zone of ground governing the behavior of a geotechnical structure at a limit state is usually much larger than a test sample or the zone of ground affected in an in situ test. Consequently the value of the governing parameter is often the mean of a range of values covering a large surface or volume of the ground. The characteristic value should be a cautious estimate of this mean value.

7

If the behavior of the geotechnical structure at the limit state considered is governed by the lowest or highest value of the ground property, the characteristic value should be a cautious estimate of the lowest or highest value occurring in the zone governing the behavior.

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Page 14

When selecting the zone of ground governing the behavior of a geotechnical structure at a limit state, it should be considered that this limit state may depend on the behavior of the supported structure. For instance, when considering a bearing resistance ultimate limit state for a building resting on several footings, the governing parameter should be the mean strength over each individual zone of ground under a footing, if the building is unable to resist a local failure. If, however, the building is stiff and strong enough, the governing parameter should be the mean of these mean values over the entire zone or part of the zone of ground under the building.

9

If statistical methods are employed in the selection of characteristic values for ground properties, such methods should differentiate between local and regional sampling and should allow the use of a prior knowledge of comparable ground properties.

10

If statistical methods are used, the characteristic value should be derived such that the calculated probability of a worse value governing the occurrence of the limit state under consideration is not greater than 5%.

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NOTE : In this respect, a cautious estimate of the mean value is a selection of the mean value of the limited set of geotechnical parameter values, with a confidence level of 95%; where local failure is concerned, a cautious estimate of the low value is a 5% fractal. When using standard tables of characteristic values related to soil investigation parameters, the characteristic value shall be selected as a very cautious value.

3.4.7

Characteristic Values of Geometrical Data

1

Characteristic values of the levels of ground and ground-water or free water shall be measured, nominal or estimated upper or lower levels.

2

Characteristic values of levels of ground and dimensions of geotechnical structures or elements should usually be nominal values.

3.4.8

Geotechnical Design Report

1

The assumptions, data, methods of calculation and results of the verification of safety and serviceability shall be recorded in the Geotechnical Design Report.

2

The level of detail of the Geotechnical Design Reports will vary greatly, depending on the type of design. For simple designs, a single sheet may be sufficient.

3

The Geotechnical Design Report should normally include the following items, with crossreference to the Ground Investigation Report :

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(a)

a description of the site and surroundings;

(b)

a description of the ground conditions;

(c)

a description of the proposed construction, including actions;

(d)

design values of soil and rock properties, including justification, as appropriate;

(e)

statements on the codes and standards applied;

(f)

statements on the suitability of the site with respect to the proposed construction and the level of acceptable risks;

(g)

geotechnical design calculations and drawings;

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(h)

foundation design recommendations;

(i)

a note of items to be checked during construction or requiring maintenance or monitoring.

4

The Geotechnical Design Report shall include a plan of supervision and monitoring, as appropriate. Items, which require checking during construction or, which require maintenance after construction shall be clearly identified. When the required checks have been carried out during construction, they shall be recorded in an addendum to the Report.

5

In relation to supervision and monitoring the Geotechnical Design Report should state: the purpose of each set of observations or measurements;

(b)

the parts of the structure, which are to be monitored and the locations at which observations are to be made;

(c)

the frequency with which readings is to be taken;

(d)

the ways in which the results are to be evaluated;

(e)

the range of values within which the results are to be expected;

(f)

the period of time for which monitoring is to continue after construction is complete;

(g)

the parties responsible for making measurements and observations, for interpreting the results obtained and for maintaining the instruments.

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An extract from the Geotechnical Design Report, containing the supervision, monitoring and maintenance requirements for the completed structure, shall be provided to the owner/client.

3.4.9

Actions and Design Situations

1

Design situations shall be selected in accordance with 3.3.2.

2

The actions listed in 3.4.2(4) should be considered when selecting the limit states for calculation.

3

If structural stiffness is significant, an analysis of the interaction between the structure and the ground should be performed in order to determine the distribution of actions.

3.4.10

Design and Construction Considerations

1

When choosing the depth of a shallow foundation the following shall be considered:

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(a)

reaching an adequate bearing stratum;

(b)

the depth above which shrinkage and swelling of clay soils, due to seasonal weather changes, or to trees and shrubs, may cause appreciable movements;

(c)

the level of the water table in the ground and the problems, which may occur if excavation for the foundation is required below this level;

(d)

possible ground movements and reductions in the strength of the bearing stratum by seepage or climatic effects or by construction procedures;

(e)

the effects of excavations on nearby foundations and structures;

(f)

anticipated excavations for services close to the foundation;

(g)

high or low temperatures transmitted from the building;

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Section 04: Foundations and Retaining Structures Part 03: Shallow Foundations

Page 16

(h)

the possibility of scour;

(i)

the effects of variation of water content due to long periods of drought, and subsequent periods of rain, on the properties of volume-unstable soils in arid climatic areas;

(j)

the presence of soluble materials, e.g. limestone, clay stone, gypsum, salt rocks;

2

In addition to fulfilling the performance requirements, the design foundation width shall take account of practical considerations such as economic excavation, setting out tolerances, working space requirements and the dimensions of the wall or column supported by the foundation.

3

One of the following design methods shall be used for shallow foundations: a direct method, in which separate analyses are carried out for each limit state. When checking against an ultimate limit state, the calculation shall model as closely as possible the failure mechanism, which is envisaged. When checking against a serviceability limit state, a settlement calculation shall be used;

(b)

an indirect method using comparable experience and the results of field or laboratory measurements or observations, and chosen in relation to serviceability limit state loads so as to satisfy the requirements of all relevant limit states;

(c)

a prescriptive method in which a presumed bearing resistance is used.

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Foundations on Rock; Additional Design Considerations

1

The design of shallow foundations on rock shall take account of the following features: the deformability and strength of the rock mass and the permissible settlement of the supported structure;

(b)

the presence of any weak layers, for example solution features or fault zones, beneath the foundation;

(c)

the presence of bedding joints and other discontinuities and their characteristics (for example filling, continuity, width, spacing);

(d)

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disturbance of the natural state of the rock caused by construction activities, such as, for example, underground works or slope excavation, being near to the foundation.

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(e)

the state of weathering, decomposition and fracturing of the rock;

2

Shallow foundations on rock may normally be designed using the method of presumed bearing pressures. For strong intact igneous rocks, gneissic rocks, limestone and sandstones, the presumed bearing pressure are limited by the compressive strength of the concrete foundation.

3

The settlement of a foundation may be assessed on the basis of comparable experience related to rock mass classification. END OF PART

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Page 1

DEEP FOUNDATIONS ............................................................................................ 4

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9

PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES .................... 4 General 4 Limit States Considerations 4 Precast Reinforced and Prestressed Concrete Piles 4 Materials and components 5 Prestressing 7 Driving Piles 8 Risen Piles 10 Repair and lengthening of piles 10 Cutting off pile heads 10

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.2.10 4.2.11

PRECAST REINFORCED CONCRETE SEGMENTAL PILES............................... 10 Scope 10 References 11 Submittals 11 Quality Assurance 11 Tolerances in Pile Dimensions 11 Handling, Transportation, Storage and Acceptance of Piles 12 Materials and components 12 Driving piles 13 Risen Piles 14 Repair and lengthening of piles 15 Cutting off pile heads 15

4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6

BORED CAST IN PLACE PILES ........................................................................... 15 Scope 15 References 16 Quality Assurance 16 Materials 16 Boring 17 Extraction of casing 19

4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5

BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS ....... 21 Scope 21 Materials 21 Boring 22 Placing of concrete or grout 23 Cutting off pile heads 23

4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6

DRIVEN CAST IN PLACES PILES ........................................................................ 23 Scope 23 Submittals 24 Quality Assurance 24 Materials 24 Driving piles 25 Risen Piles 26

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Page 2

Extraction of casing

26

4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.6.8 4.6.9 4.6.10 4.6.11

STEEL PILES ........................................................................................................ 28 Scope 28 References 28 Submittals 28 Quality Assurance 28 Delivery, Storage and Handling 29 Materials 29 Acceptance Standards For Welds 30 Acceptability and inspection of coatings 31 Driving of piles 31 Risen Piles 33 Preparation of pile heads 33

4.7

MICROPILES (TO BE ADDED LATER) ................................................................. 33

4.8 4.8.1 4.8.2 4.8.3 4.8.4 4.8.5

REDUCTION OF FRICTION ON PILES ................................................................ 33 Scope 33 Submittals 33 Friction Reducing Methods 33 Inspection 34 Driving resistance 35

4.9 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5 4.9.6 4.9.7 4.9.8

PILE LOAD TESTING ........................................................................................... 35 Static Load Testing of Piles 35 Presentation of results 45 Low strain Integrity test 47 Grosshole Sonic Logging Test 48 Calliper Logging Test 48 Axial Tensile Load Test 48 Lateral Load Test 48 Alternative Methods for Testing Piles 48

4.10 4.10.1 4.10.2 4.10.3

DESIGN METHODS AND DESIGN CONSIDERATIONS ...................................... 51 Design method 51 Verification of Resistance for Structural and Ground Limit States in Persistent and Transient Situations 51 Design Considerations 51

4.11 4.11.1 4.11.2 4.11.3 4.11.4 4.11.5 4.11.6 4.11.7 4.11.8 4.11.9 4.11.10

AXIALLY LOADED PILES ..................................................................................... 52 Limit state design 52 Compressive Ground Resistance 53 Ultimate compressive resistance from static load tests 54 Ultimate compressive resistance from ground test results 55 Ultimate compressive resistance from dynamic impact tests 56 Ultimate compressive resistance by applying pile driving formulae 56 Ultimate compressive resistance from wave equation analysis 56 Ground tensile resistance 57 Ultimate tensile resistance from pile load tests 57 Ultimate tensile resistance from ground test results 57

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4.5.7

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Page 3

4.11.11 Vertical displacements of pile foundations 4.11.12 Pile foundations in compression 4.11.13 Pile foundations in tension

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TRANSVERSELY LOADED PILES ....................................................................... 58 Design method 58 Transverse load resistance from pile load tests 59 Transverse load resistance from ground test results and pile strength parameters 59 Transverse displacement 60

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4.12 4.12.1 4.12.2 4.12.3 4.12.4

58 58 58

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Page 4

DEEP FOUNDATIONS

4.1

PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES

4.1.1

General

1

The provisions of this Part apply to end-bearing piles, friction piles, tension piles and transversely loaded piles installed by driving, by jacking, and by screwing or boring with or without grouting.

4.1.2

Limit States Considerations

1

The following limit states shall be considered and an appropriate list shall be compiled:

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Loss of overall stability;

(b)

bearing resistance failure of the pile foundation;

(c)

Uplift or insufficient tensile resistance of the pile foundation;

(d)

Failure in the ground due to transverse loading of the pile foundation;

(e)

Structural failure of the pile in compression, tension, bending, buckling or shear;

(f)

combined failure in the ground and in the pile foundation;

(g)

combined failure in the ground and in the structure;

(h)

Excessive settlement;

(i)

Excessive heave;

(j)

Excessive lateral movement;

(k)

Unacceptable vibrations.

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(a)

Precast Reinforced and Prestressed Concrete Piles

1

Scope

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This Part applies to precast concrete driven piles usually supplied for use in a single length without facility for joining lengths together.

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4.1.3

(b) 2

Related Sections and Parts are as follows:

References (a)

The following Standards are referred to in this Part:

BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates BS 3100,.....................Steel castings for general engineering purposes BS 2789,.....................Spheroidal graphite or nodular graphite cast iron BS 8110,.....................Structural use of concrete. 3

Submittals (a)

The Contractor shall order the piles to suit the construction programme and seek the Engineer's approval before placing the order. When preliminary piles are specified, the approval of the piles for the main work will not necessarily be given until the results of the driving and loading tests on preliminary piles have been received and evaluated.

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Page 5

Quality Assurance (a)

5

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

After a pile has been cast, the date of casting, reference number, length and, where appropriate, the prestressing force shall be clearly inscribed on the top surface of the pile and also clearly and indelibly marked on the head of the pile. Lifting positions shall be marked at the proper locations on each pile.

Tolerances in Pile Dimensions (a)

The cross-sectional dimensions of the pile shall be not less than those specified and shall not exceed them by more than 6 mm. Each face of a pile shall not deviate by more than 6 mm from any straight line 3 m long joining two points on that face, nor shall the centre of area of the pile at any cross section along its length deviate by more

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than 1/500 of the pile length from a line joining the centres of area at the ends of the pile. Where a pile is less than 3 m long, the permitted deviation from straightness shall

Handling, Transportation and Storage of Piles

The method and sequence of lifting, handling, and storage of piles transporting and storing piles shall be such as to avoid shock loading and to ensure that the piles are not damaged. Only the designated lifting and support points shall be used. During transport and storage, piles shall be appropriately supported under the marked lifting points or fully supported along their length.

(b)

All piles within a stack shall be in groups of the same length. Packing of uniform thickness shall be provided between piles at the lifting points.

(c)

Concrete shall at no time be subjected to loading, including its own weight, which will induce a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the specified strength, whichever is the lesser. For this purpose the assessment of the strength of the concrete and of the stresses produced by the loads shall be subject to the agreement of the Engineer.

(d)

Pile may be rejected when the width of any transverse crack exceeds 0.3 mm. The

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be reduced below 6 mm on a pro rata basis in accordance with actual length.

measurement shall be made with the pile in its working attitude.

Materials and components

1

Fabricated Steel Components

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4.1.4

(a)

2

Pile Toes (a)

3

In the manufacture of precast concrete piles, fabricated steel components shall comply with BS 7613 grades 43A or 50B, cast steel components with BS 3100 grade A, and ductile iron components with BS 2789.

Pile toes shall be constructed so as to ensure that damage is not caused to the pile during installation. Where positional fixity is required on an inclined rock surface or in other circumstances, an approved shoe may be required.

Pile Head Reinforcement (a)

The head of each pile shall be so reinforced or banded as to prevent bursting of the pile under driving conditions.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 6

Main Reinforcement (a)

The main longitudinal reinforcing bars in piles not exceeding 12 m in length shall be in one continuous length unless otherwise specified. In piles more than 12 m long, lap splicing will be permitted in main longitudinal bars at 12 m nominal intervals, with no more than 25 % of the bars lapped at one location, and laps staggered by a minimum of 1.2 m. Laps in reinforcement shall be such that the full strength of the bar is effective across the joint. Lap or splice joints shall be provided with sufficient link bars to resist eccentric forces.

(c)

Sufficient reinforcement shall be provided for lifting and handling purposes.

Unless otherwise agreed by the Engineer, concrete shall be compacted with the assistance of vibrators. Internal vibrators shall be capable of producing not less than 150 Hz and external vibrators not less than 50 Hz. Internal vibrators shall operate not

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closer than 75 mm to shuttering.

Vibrators shall be operated in such a manner that neither segregation of the concrete mix constituents nor displacement of reinforcement occurs.

(c)

Immediately after compaction, concrete shall he adequately protected from the harmful effects of the weather, including wind, rain, rapid temperature changes and frost. It shall be protected from drying out by an approved method of curing.

(d)

Piles shall not be removed from formwork until a sufficient pile concrete strength has been achieved to allow the pile to be handled without damage.

(e)

The period of curing at an ambient temperature of 10 °C shall not be less than that

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(b)

shown in Table 4.1. If the temperature is greater or less than 10 °C, the periods given

When steam or accelerated curing is used the curing procedure shall be approved. Four hours must elapse from the completion of placing concrete before the temperature is raised. The rise in temperature within any period of 30 min shall not exceed 10 °C and the maximum temperature attained shall not exceed 70 °C. The rate

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shall be adjusted accordingly and shall be approved.

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(b)

of subsequent cooling shall not exceed the rate of heating. Table 4.1 Period of Curing at 10 °C Type of cement

Wet curing time after completion of placing concrete, d

Ordinary Portland

4

Sulphate-resisting Portland

4

Portland blast-furnace

4

Super-sulphated

4

Rapid-hardening Portland

3

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 7

Formwork (a)

shaped point or shoe, then the end of the pile shall be symmetrical about the longitudinal axis of the pile. Holes for handling or pitching, where provided in the pile, shall be lined with steel tubes; alternatively, approved inserts may be cast in.

(b)

Formwork shall be robust, clean and so constructed as to prevent loss of grout or aggregate from the wet concrete and ensure the production of uniform pile sections, free from defects. The piles are to be removed from the formwork carefully so as to prevent damage.

4.1.5

Prestressing

1

General Tensioning shall be carried out only when the Engineer is present, unless otherwise approved. In cases where piles are manufactured off site, the Contractor shall ensure that the Engineer is given adequate notice and every facility for inspecting the manufacturing process.

(b)

Prestressing operations shall be carried out only under the direction of an experienced and competent supervisor. All personnel operating the stressing equipment shall have been trained in its use.

(c)

The calculated extensions and total forces, including allowance for losses, shall be agreed with the Engineer before stressing is commenced.

(d)

Stressing of tendons and transfer of prestress shall be carried out at a gradual and steady rate. The force in the tendons shall be obtained from readings on a recently calibrated load cell or pressure gauge incorporated in the equipment. The extension of the tendons under the agreed total forces shall be within 5 % of the agreed calculated extension.

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Concrete Strength

The Contractor shall cast sufficient cubes, cured in the same manner as the piles, to be able to demonstrate by testing two cubes at a time, with approved intervals between pairs of cubes, that the specified transfer strength of the concrete has been reached.

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Post-Tensioned Piles (a)

4

Unless otherwise permitted, concrete shall not be stressed until two test cubes attain the specified transfer strength.

Ducts and vents in post-tensioned piles shall be grouted after the transfer of prestress.

Grouting Procedure (a)

Grout shall be mixed for a minimum of 2 min and until a uniform consistency is obtained.

(b)

Ducts shall not be grouted when the air temperature in the shade is lower than 3 °C.

(c)

Before grouting is started all ducts shall be thoroughly cleaned by means of compressed air.

(d)

Grout shall be injected near the lowest point in the duct in one continuous operation and allowed to flow from the outlet until the consistency is equivalent to that of the grout being injected.

(e)

Vents in ducts shall be provided in accordance with Clause 8.9.2 of BS 8110.

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Page 8

Grout (a)

Unless otherwise directed or agreed by the Engineer (i)

the grout shall consist only of ordinary Portland cement, water and approved admixtures; admixtures containing chlorides or nitrates shall not be used

(ii)

the grout shall have a water/cement ratio as low as possible consistent with the necessary workability, and the water/cement ratio shall not exceed 0.45 unless an approved mix containing an expanding agent is used

(iii)

the grout shall not be subject to bleeding in excess of 2 % after 3 h, or in excess of 4% maximum, when measured at 18 C in a covered glass cylinder approximately 100 mm in diameter with a height of grout of approximately 100 mm, and the water shall be reabsorbed after 24 h.

Records

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

The Contractor shall keep detailed records of times of tensioning, measured extensions, pressure gauge readings or load cell readings and the amount of pull-in at each anchorage. Copies of these records shall be supplied to the Engineer within such reasonable time from completion of each tensioning operation as may be required, and in any case not later than noon on the following working day.

(b)

The Contractor shall keep records of grouting, including the date, the proportions of the grout and any admixtures used, the pressure, details of interruption and topping up required. Copies of these records shall be supplied to the Engineer within such reasonable time after completion of each grouting operation as may be required, and in any case not later than noon on the following working day.

Driving Piles

1

Strength of Piles (a)

Piles shall not be driven until the concrete has achieved the specified strength.

At all stages during driving and until incorporation into the substructure, the pile shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling. These arrangements shall be such that damage to the pile does not occur.

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Leaders and Trestles

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2

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4.1.6

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as

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ta

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(a)

3

4

Performance of Driving Equipment (a)

The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where designated, dynamic evaluation and analysis shall be provided.

(b)

Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile unless otherwise approved by the Engineer. For other types of hammer the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft or damage to the pile.

Length of Piles (a)

The length of pile to be driven in any location shall be approved prior to the commencement of driving.

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Page 9

Driving Procedure and Redrive Checks (a)

The driving of each pile shall be continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can subsequently be driven to the specified depth or resistance (set), or both, without damage. A follower shall not be used unless approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(b)

The Contractor shall inform the Engineer without delay if an unexpected change in driving characteristics is noted. A detailed record of the driving resistance over the full length of the nearest available pile shall be taken if required.

(c)

At the start of the work in a new area or section, a detailed driving record shall be made over the full length of the first pile and during the last 3 m of subsequent piles

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until consistency of behaviour is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the locations of such piles being

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specified by the Engineer.

The Contractor shall give adequate notice and provide all necessary facilities to enable the Engineer to check driving resistance. A set or resistance measurement shall be taken only in the presence of the Engineer unless otherwise approved.

(e)

Redrive checks, if required, shall be carried out to an approved procedure.

as

Final Set (a)

When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per 10 blows or as the number of blows required to produce a penetration of 25 mm.

(b)

When a final set is being measured, the following requirements shall be met:

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6

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(d)

The exposed part of the pile shall be in good condition without damage or distortion.

(ii)

The helmet, dolly and any packing shall be in sound condition.

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(i)

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(iii)

7

(iv)

The hammer shall be in good condition, delivering adequate energy per blow, and operating correctly.

(v)

The temporary compression of the pile shall be recorded, if required.

Preboring (a)

8

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis, and the head of the pile protected against damage from hammer impact.

If preboring is specified, the diameter and depth of prebore shall be as designated.

Jetting (a)

Jetting shall be carried out only when the Contractor's detailed proposals have been approved.

QCS 2014

Page 10

Risen Piles Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral displacement of the ground.

(b)

When required, levels and measurements shall be taken to determine the movement of the ground or of any pile resulting from the driving process.

(c)

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile is unimpaired. If required, the Contractor shall make proposals for correcting detrimentally affected piles and for avoidance or control of heave effects in subsequent work.

4.1.8

Repair and lengthening of piles

1

Repair of Damaged Pile Heads

rw

If it is necessary to repair the head of a pile during driving, the Contractor shall carry out such repair in an approved way which allows the pile-driving to be completed without further damage. If the driving of a pile has been accepted but sound concrete of the pile is below the required cut-off level, the pile shall be made good to the cut-off level, using an approved method so that it will safely withstand the imposed design load.

as

Lengthening of Reinforced and Prestressed Concrete Piles Any provision for lengthening piles incorporated at the time of manufacture shall be as designed or approved.

(b)

If no provision for lengthening piles was incorporated at the time of manufacture, any method for lengthening shall be such that splices are capable of safely resisting the stresses during driving and under service load and shall be subject to approval.

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(a)

Driving Repaired or Lengthened Piles Repaired or lengthened piles shall not be driven until the added concrete has reached the specified strength of the concrete of the pile.

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4.1.7

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Cutting off pile heads

1

Unless otherwise directed by the Engineer, when the driving of a pile has been approved the concrete of the head of the pile shall be cut off to the designated level. The length of splice reinforcing bars projecting above this level shall be as designated.

2

Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section at the cut-off level.

4.2

PRECAST REINFORCED CONCRETE SEGMENTAL PILES

4.2.1

Scope

1

This Part applies to piles made of elements cast at a precasting works away from the site, where work cannot normally be closely supervised by the Engineer. The elements are joined together as necessary on site during driving using special proven steel joints incorporated into the pile elements when cast.

m

4.1.9

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2

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 11

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 5,

Concrete.

4.2.2

References

1

The following Standards are referred to in this Part: Eurocode 7, EN1997-1, Section 7 Pile foundation BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates BS 3100,.....................Steel castings for general engineering purposes

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BS 2789,.....................Spheroidal graphite or nodular graphite cast iron

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BS 8110,.....................Structural use of concrete. Submittals

1

The Contractor shall order the piles to suit the construction programme and seek the Engineer's approval before placing the order. When preliminary piles are specified the approval for the piles for the main work will not necessarily be given until the results of the driving and tests on preliminary piles have been received and evaluated.

4.2.4

Quality Assurance

1

A certificate of quality from the pile manufacturer shall be provided to the Engineer when required stating that the designated requirements have been fulfilled during manufacture.

2

Each pile element shall be marked in such a manner that it can be identified with the records of manufacture, which shall state the date of casting, the cement type, concrete grade, element length and any other relevant data. On delivery, the pile elements shall be accompanied by records of manufacture.

4.2.5

Tolerances in Pile Dimensions

1

The cross-sectional dimensions of the pile shall be not less than those designated.

2

The head of a pile element or the end of the pile upon which the hammer acts shall be square to the pile axis within a tolerance of 1 in 50.

3

Each pile joint shall be square to the axis of the pile within a tolerance of 1 in 150. The centroid of the pile joint shall lie within 5 mm of the true axis of the pile element.

4

Each face of a pile element shall not deviate by more than 6 mm from any straight line 3 m long joining two points on that face, nor shall the centre of area of the pile at any crosssection along its length deviate by more than 1/500 of the pile length from a line joining the centres of area at the ends of the element. Where a pile element is less than 3 m long the permitted deviation from straightness shall be reduced below 6 mm on a pro rata basis in accordance with actual length.

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4.2.3

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Page 12

Handling, Transportation, Storage and Acceptance of Piles

1

The method and sequence of lifting, handling, transporting and storing piles shall be such as to avoid shock loading and to ensure that the piles are not damaged. Only designed lifting and support points shall be used. During transport and storage, piles shall be appropriately supported under the marked lifting points or fully supported along their length.

2

All pile elements within a stack shall be in groups of the same length. Packing of uniform thickness shall be provided between piles at the lifting points.

3

Concrete shall at no time be subjected to loading, including its own weight, which will induce a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the specified strength, whichever is the less. For this purpose the assessment of the strength of the concrete and of the stresses produced by the loads shall be subject to the approval of the Engineer.

4

A pile element shall be rejected when the width of any transverse crack exceeds 0.3 mm. The measurement shall be made with the pile in its working attitude.

4.2.7

Materials and components

1

Fabricated Steel Components

ta qa

In the manufacture of jointed precast concrete segmental piles, fabricated steel components shall comply with BS 7613 grades 43A or 50A, cast steel components with BS 3100 grade A, and ductile iron components with BS 2789.

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Pile Splices (a)

The splice joints shall be close-fitting face to face and the locking method shall be such as to hold the faces in intimate contact. The design and manufacture of the splicing system shall be approved by the Engineer prior to the commencement of the Contract.

(b)

A spliced pile shall be capable of withstanding the same driving stresses or service axial loads, moments and shear stresses as a single unspliced pile of the same crosssectional dimensions and materials.

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4.2.6

(c)

3

Pile Toes (a)

4

Pile toes shall be constructed so as to ensure that damage is not caused to the pile during installation. Where fixity is required or socketing into rock, or in other circumstances, an approved shoe may be required.

Pile Head Reinforcement (a)

5

The welding of a joint to main reinforcement in lieu of a lapped connection with projecting bars affixed to the joint will not be permitted.

Where the pile head is not furnished with a joint, it shall be so reinforced or banded as to prevent bursting of the pile under driving conditions.

Main Reinforcement (a)

The main longitudinal reinforcing bars shall be in one continuous length. Splicing of bars will not be permitted except at element ends.

QCS 2014

Page 13

(b)

Concrete cover to steel reinforcement shall be in accordance with the requirements of BS 8110.

(c)

In very aggressive ground or exposure conditions, cover greater than 25 mm may be required, but alternative protection methods may be approved.

Formwork (a)

If a pile is constructed with a shaped point or shoe, then the end of the pile shall be symmetrical about the longitudinal axis of the pile.

(b)

Holes for handling or pitching, where provided in the pile, shall be lined with steel tubes; alternatively, approved inserts may be cast in.

(c)

Formwork shall be robust, clean and so constructed as to prevent loss of grout or aggregate from the wet concrete and ensure the production of uniform pile sections. The piles are to be removed from the formwork carefully so as to prevent damage.

Driving piles

1

Strength of Piles

Leaders and Trestles

At all stages during driving and until incorporation into the substructure, the pile shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling. These arrangements shall be such that damage to the pile does not occur.

Performance of Driving Equipment

The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where required in the particular specification, dynamic evaluation and analysis shall be provided. Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile at the moment of driving unless otherwise approved by the Engineer. For other types of hammer, the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft or damage to the pile.

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(b)

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(a)

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(a)

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2

Piles shall not be driven until the concrete has achieved the specified characteristic strength.

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(a)

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4.2.8

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4

Length of Piles (a)

The length of pile supplied to be driven in any location and any additional lengths to be added during driving shall he approved prior to the commencement of pile-driving. During the execution of the Works, any changes to the supplied lengths shall be approved.

QCS 2014

Page 14

Driving Procedure and Redrive Checks (a)

Except when making field splices, the driving of each pile shall he continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can subsequently be driven to the specified depth or resistance (set), or both, without damage. A follower shall only be used when approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(b)

The Contractor shall inform the Engineer without delay if an unexpected change in driving characteristics is noted. A detailed record of the driving resistance over the full length of the nearest available pile shall be taken if required.

(c)

At the start of the work in a new area or section a detailed driving record shall be made over the full length of the first pile and during the last 3 m of subsequent piles until consistency of behaviour is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the positions of such piles being specified by the Engineer.

(d)

The Contractor shall give adequate notice and provide all necessary facilities to enable the Engineer to check driving resistance. A set or resistance measurement shall be taken only in the presence of the Engineer unless otherwise approved.

(e)

Redrive checks, if required, shall be carried out to an approved procedure.

as

Final Set

When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm.

(b)

When a final set is being measured, the following requirements shall be met:

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(a)

The exposed part of the pile shall be in good condition, without damage or distortion.

(ii)

The helmet, dolly and any packing shall be in sound condition.

(iii)

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis.

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(i)

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

7

(v)

The temporary compression of the pile shall be recorded if required.

If preboring is specified, the diameter and depth of prebore shall be as designated.

Jetting (a)

4.2.9

The hammer shall be in good condition, delivering adequate energy per blow, and operating correctly.

Preboring (a)

8

(iv)

Jetting shall be carried out only when the Contractor's detailed proposals have been approved.

Risen Piles (a)

Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral displacement of the ground.

QCS 2014

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 15

(b)

When required, levels and measurements shall be taken to determine the movement of the ground or of any pile resulting from the driving process.

(c)

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile is unimpaired. If required, the Contractor shall make proposals for correcting piles detrimentally affected and for avoidance or control of heave effects in subsequent work.

4.2.10

Repair and lengthening of piles

1

Repair of Damaged Pile Heads If it is necessary to repair the head of a pile during driving, the Contractor shall carry out such repair in an approved way which allows the driving of the pile to be completed without further damage. If the driving of a pile has been accepted but sound concrete of the pile is below the required cut-off level, the pile shall be made good to the cut-off level, using an approved method so that it will safely withstand the imposed design load.

Where piles are required to be driven to depths exceeding those expected, leaving insufficient projection for bonding into the following works, the piles shall be extended or replaced as required by the Engineer using approved materials and methods.

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(a)

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Lengthening of Piles

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(a)

Cutting off pile heads

1

Unless otherwise specified, when the driving of a pile has been approved the concrete of the head of the pile shall be cut off to the designated level. The length of splice reinforcing bars projecting above this level shall be as designated.

2

Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section at the cut-off level.

4.3

BORED CAST IN PLACE PILES

4.3.1

Scope

1

This Part applies to bored piles in which the pile bore is excavated by rotary or percussive means, or both, using short augers, buckets, grabs or other boring tools to advance the open bore. Where the open bore is unstable, temporary or permanent casing or bentonite suspension may be used to support the wall of the bore prior to concreting.

2

Related Sections and Parts are as follows:

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4.2.11

This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 3, Ground Investigation Section 5, Concrete

QCS 2014

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4.3.2

References

1

The following codes of practice are referred to in this Part:

Page 16

BS 5573,.....................Code of practice for safety precautions in the construction of large diameter boreholes for piling and other purposes BS 5930,.....................Code of practice for site investigation. 4.3.3

Quality Assurance

1

Inspection Each pile bore which does not contain standing water or drilling fluid shall be inspected directly or indirectly prior to concrete being placed in it. This inspection shall be carried out from the ground surface in the case of piles of less than 750 mm diameter. Torches or other approved means of lighting, measuring tapes, and a means of measuring verticality shall be provided. For piles of 750 mm diameter or larger, equipment shall be provided, by the Contractor to enable his representatives and the Engineer to descend into the bore for the purpose of inspection. Any method of descent and the equipment used shall comply with the requirements of BS 5573.

Cleanliness of pile bases

On completion of boring and where inspection of a dry pile bore indicates the necessity, loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain water or drilling fluid, a cleaning process shall be employed before concrete is placed. Large debris and accumulated sediment shall be removed using appropriate approved methods, which shall be designed to clean while at the same time minimising ground disturbance below the pile bases. Water or drilling fluid shall be maintained at such levels throughout and following the cleaning operation that stability of the bore is preserved.

Samples and Testing

The taking of samples and all subsequent handling, transporting and testing shall be carried out in accordance with Section 3, Ground Investigation.

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(b)

If required in the Contract, soil, rock or groundwater samples shall be taken or soil tests carried out in-situ while the pile is being bored. The samples shall be taken to an approved laboratory for testing as specified.

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(a)

4.3.4

Materials

1

Permanent Casings (a)

2

Permanent casings shall be as specified.

Drilling Fluid Supply (a)

A certificate shall be obtained by the Contractor from the manufacturer of the bentonite powder showing the properties of each consignment delivered to the Site. This certificate shall be made available to the Engineer on request. The properties to be given by the manufacturer are the apparent viscosity range (in Pascal seconds) and the gel strength range (in Pascal) for solids in water.

QCS 2014

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Page 17

Drilling Fluid Mixing (a)

Bentonite shall be mixed thoroughly with clean fresh water to make a suspension which will maintain the stability of the pile bore for the period necessary to place concrete and complete construction. The temperature of the water used in mixing the bentonite suspension, and of the suspension when supplied to the borehole, shall be not lower than 5 C.

(b)

Where saline or chemically contaminated groundwater occurs, special precautions shall be taken to modify the bentonite suspension or prehydrate the bentonite in fresh water so as to render it suitable in all respects for the construction of piles.

Drilling Fluid Tests (a)

The frequency of testing drilling fluid and the method and procedure of sampling shall be proposed by the Contractor for approval prior to the commencement of the work. The frequency may subsequently be varied as required, depending on the consistency of the results obtained, subject to approval.

(b)

Control tests shall be carried out on the bentonite suspension, using suitable apparatus. The density of freshly mixed bentonite suspension shall be measured daily as a check on the quality of the suspension being formed. The measuring device shall be calibrated to read to within 0.005 g/ml. Tests to determine density, viscosity, shear strength and pH value shall be applied to bentonite supplied to the pile bore. For average soil conditions the results shall generally be within the ranges in Table 4.2.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Table 4.2.Tests on Bentonite

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Viscosity

Less than 1.10 g/ml

Mud density balance

30 - 90 s or less than 0.020 Pa • s

Marsh cone method

1.4-10 Pa Or 4-40 Pa

Shear meter

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9.5 - 12

Fann viscometer*

Fann viscometer pH indicator paper strips or electrical pH meter

Where the Fann viscometer is specified, the fluid sample should be screened by a number 52 sieve (300 m) prior to testing.

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*

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Shear strength (10 minute gel strength) pH

Test method

se

Density

Range of results at 20 C

as

Property to be measured

(c)

The tests shall be carried out until a consistent working pattern has been established account being taken of the mixing process, any blending of freshly mixed bentonite suspension and previously used bentonite suspension, and any process which may be used to remove impurities from previously used bentonite suspension. When the results show consistent behaviour, the tests for shear strength and pH value may be discontinued, and tests to determine density and viscosity shall be carried out as agreed with the Engineer. In the event of a change in the established working pattern, tests for shear strength and pH value shall be reintroduced for a period if required.

4.3.5

Boring

1

Boring Near Recently Cast Piles (a)

Piles shall not be bored so close to other recently completed piles as to damage them.

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Page 18

Temporary Casings (a)

Temporary casing of approved quality or an approved alternative method shall be used to maintain the stability of a pile bore which might otherwise collapse.

(b)

Temporary casings shall be free from significant distortion. They shall be of uniform cross-section throughout each continuous length. During concreting they shall be free from internal projections and encrusted concrete which might adversely affect the proper formation of piles.

(c)

The use of a vibrator to insert and withdraw temporary casing may be permitted by the Engineer subject to compliance with Noise and Disturbance and Damage to Adjacent Structures of this section and to the method not causing disturbance of the ground which would adversely affect the construction or the capacity of piles.

(d)

Where piles are bored under water or bentonite suspension in an unlined state, the insertion of a full-length loosely fitting casing to the bottom of the bore prior to placing concrete will not be permitted.

(e)

Where permanent casing is specified to ensure the integrity of a pile, the Contractor shall submit for approval his proposals regarding the method of installation.

ta qa

Stability of Pile

Where boring takes place through unstable water-bearing strata, the process of excavation and the depth of temporary casing employed shall be such that soil from outside the area of the pile is not drawn into the pile section and cavities are not created outside the temporary casing as it is advanced.

(b)

Where the use of drilling fluid is specified or approved for maintaining the stability of a bore, an adequate temporary casing shall be used in conjunction with the method so as to ensure stability of the strata near ground level until concrete has been placed. During construction the level of drilling fluid in the pile excavation shall be maintained within the cased or stable bore so that it is not less than 1.0 m above the level of external standing groundwater at all times.

(c)

In the event of a rapid loss of drilling fluid from a pile excavation, the bore shall be backfilled without delay and the instructions of the Engineer shall be obtained before boring at that location is resumed.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Spillage and Disposal of Drilling Fluid (a)

5

Pumping from Pile Bores (a)

6

All reasonable steps shall be taken to prevent the spillage of bentonite suspension on the Site in areas outside the immediate vicinity of boring. Discarded bentonite shall be removed from the Site without undue delay. Any disposal of bentonite shall comply with the regulations of the local controlling authority.

Pumping from pile bores shall not be permitted unless the bore has been sealed against further water entry by casing or unless the soil is stable and will allow pumping to take place without ground disturbance below or around the pile.

Continuity of Construction (a)

For a pile constructed in a stable cohesive soil without the use of temporary casing or other form of support, the pile shall be bored and the concrete shall be placed without such delay as would lead to significant impairment of the soil strength.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Enlarged Pile Bases (a)

A mechanically formed enlarged base shall be no smaller than the dimensions specified and shall be concentric with the pile shaft to within a tolerance of 10 % of the shaft diameter. The sloping surface of the frustum forming the enlargement shall make an angle to the axis of the pile of not more than 35 .

4.3.6

Extraction of casing

1

Workability of Concrete (a)

Temporary casings shall be extracted while the concrete within them remains sufficiently workable to ensure that the concrete is not lifted. During extraction the motion of the casing shall be maintained in an axial direction relative to the pile.

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Concrete Level

When the casing is being extracted, a sufficient quantity of concrete shall be maintained within it to ensure that pressure from external water, drilling fluid or soil is exceeded and that the pile is neither reduced in section nor contaminated.

(b)

The concrete level within a temporary casing shall be topped up where necessary during the course of casing extraction in such a way that the base of the casing is always below the concrete surface until the casting of the pile has been completed.

(c)

Adequate precautions shall be taken in all cases where excess heads of water or drilling fluid could occur as the casing is withdrawn because of the displacement of water or fluid by the concrete as it flows into its final position against the walls of the pile bore. Where two or more discontinuous lengths of casing (double casing) are used in the construction the proposed method of working shall be approved.

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(a)

For piles cast in dry bores using temporary casing and without the use of a permanent lining, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.3, but shall not be above the original ground level. No pile shall be cast with its head below standing water level unless approved measures are taken to prevent inflow of water causing segregation of the concrete as temporary casing is extracted, and, where approved by the Engineer, the groundwater level for each pile shall be treated as the cut-off level for the purpose of calculating tolerance.

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Pile Head Casting Level Tolerances

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(b)

For piles cast in dry bores within permanent lining tubes or permanent casings, or where their cut-off levels are in stable ground below the base of any casing used, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.4, but shall not be above the original ground level.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 20

(c)

For piles cast under water or drilling fluid, the pile heads shall be cast to a level above the specified cut-off so that, after trimming to remove all debris and contaminated concrete, a sound concrete connection with the pile can be made. The casting level shall be within the tolerance above the cut-off level shown in Table 4.4, but shall not be above the commencing surface level. Cut-off levels may be specified below the standing groundwater level, and where this condition applies the borehole fluid level shall not be reduced below the standing groundwater level until the concrete has set.

(d)

Where the cut-off level of piles lies at depths greater than 10 m below the original ground level, then the tolerances given in Tables 4.3, 4.4 and 4.5 will be varied after discussion with the Contractor and before the commencement of the piling to take account of the special conditions which apply. Table 4.3

Casting tolerance above cut-off level, m

rw

Cut-off distance below commencing surface, H, m

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Casting Tolerance above Cut-off Level for Piles Cast In Dry Bores Using Temporary Casing and Without the Use of a Permanent Lining

ta

0.3 + H/12 + C/8 where C = length of temporary casing below the commencing surface*

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0.15-10.00 *

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If H is greater than C, then this tolerance is no longer applicable and the tolerances in Table 4.4 will apply.

Table 4.4

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Casting Tolerance above Cut-off Level for Piles Cast in Dry Bores within Permanent Lining Tubes or Permanent Casings, or Where Their Cut-Off Levels is in Stable Ground below the Base of Any Casing Used

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Cut-off distance below commencing surface, H, m

0.3 + H/10

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0.15-10.00

Casting tolerance above cut-off level, m

m

Table 4.5 Casting Tolerance above Cut-off Level for Piles Cast Under Water or Drilling Fluid** Cut-off distance below commencing surface, H, m

0.15-10.00

** 4

Casting tolerance above cut-off level, m

1.0 + H /12 + C/8 where C = length of temporary casing below the commencing surface

In cases where a pile is cast so that the cut-off is within a permanent lining tube, the appropriate tolerance is given by deletion of the casing term C/8 in the table.

Water levels (a)

During extraction of temporary casings, where circumstances are such that newly placed unset concrete is brought into contact with external groundwater, precautions shall be taken to ensure that the internal concrete pressure at all levels within the pile exceeds the external groundwater pressure.

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5

After each pile has been cast, any empty bore remaining shall be protected and shall be carefully backfilled as soon as possible with approved materials.

Disposal of excavated material (a)

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Temporary backfilling above pile casting level (a)

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Disposal of excavated material shall be carried out by the Contractor as necessary to facilitate the Works and to the satisfaction of the Engineer.

Cutting off pile heads (a)

When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section at the cut-off level

BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS

4.4.1

Scope

1

This Part applies to bored piles which employ a continuous flight auger for both advancing the bore and maintaining its stability. The spoil-laden auger is not removed from the ground until concrete or grout is pumped into the pile bore from the base of the hollow-stemmed auger to replace the excavated soil.

2

Related Sections and Parts are as follows:

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This Section

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Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling

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Section 3, Ground Investigation. Section 5, Concrete Materials

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Concrete Mix Design and Workability

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4.4.2

(a)

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Where not otherwise stated in this Part, the concrete shall comply with Section 5. The design and workability of concrete to be used in the formation of a pile shall produce a mix which is suitable for pumping. It shall have a minimum slump of 150 mm unless 3 otherwise approved and a minimum cement content of 340 kg/m . The mix shall be designed so that segregation does not occur during the placing process, and bleeding of the mix shall be minimised.

Grout Mix Design and Workability (a)

Mix design of grout shall be subject to approval. Cement, water and aggregates for grout shall be according to Section 5. Course aggregate to be used shall be of 6 mm nominal size and shall be rounded and evenly graded.

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(b)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

The workability of grout mixes, where used, shall be measured by a suitable and approved means. The procedure for monitoring the suitability of grout throughout the Works shall be stated in writing to the Engineer before beginning of the Works and shall be subject to approval.

(c)

Additives to the grout shall require prior approval of the Engineer.

Reinforcement All reinforcement shall be placed with the minimum delay after the completion of the concreting or grouting operation. It shall be designed and fabricated in cages to permit it to be placed in the correct position and to the depth specified through the concrete or grout of the pile. Suitable approved spacers shall be provided to maintain the specified concrete or grout cover to steel.

(b)

The transverse reinforcement of any reinforcing cage shall be approved and may consist of either spirals, hoops or links.

(c)

Longitudinal main steel reinforcement shall be continuous over the specified length. Where splices are necessary, the number of laps shall be kept to a minimum and bars shall be welded or joined together in an approved manner.

(d)

Reinforcement shall be supported and centred so that it will provide the required projection above the cut-off level, and the proper concrete cover.

Boring

1

General

During uncased boring with continuous flight auger, the feed forward and speed (revolutions per minute) are to be adjusted according to the soil conditions in a way that the excavation of soil will be limited to a quantity that the lateral support of the uncased borehole wall will be ensured.

Boring Near Recently Cast Piles

Removal of Augers from the Ground

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Piles shall not be bored so close to other piles which have recently been cast as to damage them.

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(a)

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Depth of Piles (a)

5

Augers shall not be extracted from the ground during the boring or construction of a pile in such a way that an open unsupported bore or inflow of water into the pile section would result. While withdrawing the continuous flight auger, the auger shall be rotated in the same direction as during drilling into the soil or shall be withdrawn without rotation.

Any failure of a pile to reach the designated depth shall be reported to the Engineer without delay and a full statement of the reasons given.

Suitability of Boring Equipment (a)

The piles shall be bored using approved and suitable equipment capable of penetrating the ground without drawing surrounding soils laterally into the pile bore.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4.4.4

Placing of concrete or grout

1

Equipment for Supply of Concrete or Grout to Piles (a)

Grout or concrete shall be supplied to the pile through suitable tubing and the hollow auger stem. All pipe fitments and connections shall be so constructed that grout does not leak during the injection process.

Commencement of Concrete or Grout Supply to Each Pile (a)

The base of the auger stem shall be fitted with a suitable means of sealing it against ingress of water and soil until concrete or grout placing begins.

(b)

At the beginning of concrete or grout placement this sealing device shall be removed by the application of concrete or grout pressure. Care shall be taken to ensure that the auger is lifted only sufficiently to initiate the flow of concrete or grout, and that water inflow and soil movement at the base of the auger are minimised. The technique and equipment used to initiate and maintain the concrete or grout flow shall be such that a pile of the full specified cross-section is obtained from the maximum depth of boring to the final pile cut-off level.

The concrete or grout shall be supplied to the pile at a sufficient rate during auger withdrawal to ensure that a continuous monolithic shaft of the full specified crosssection is formed, free from debris or any segregated concrete or grout.

(b)

The rate of withdrawal of the auger, the injection pressures and the rate of supply of concrete or grout shall be measured and recorded throughout the phase of auger withdrawal for each pile.

(c)

The Contractor shall submit proposals for his method of monitoring construction for approval before beginning the Works.

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Completion of Piles

If the concrete or grout placing in any pile cannot be completed in the normal manner, then the pile shall be rebored before concrete has hardened and shall be completely replaced.

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Rate of Supply of Concrete or Grout

Casting Level of Pile Head Concrete or grout shall be cast to the original ground level in all cases, and the reinforcing cage set, as appropriate.

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4.4.5

Cutting off pile heads

1

When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any laitance, or contaminated, cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section up to the cut-off level.

4.5

DRIVEN CAST IN PLACES PILES

4.5.1

Scope

1

This Part applies to piles for which a permanent casing of steel or concrete is driven, reinforcement placed within it if required, and the casing filled with concrete. It also applies to piles in which a temporary casing is driven, reinforcement placed within it and the pile formed in the ground by filling the temporary casing with concrete before and during its extraction.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 24

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 5, Concrete Section 3, Ground Investigation. Submittals

1

Where the Contractor wishes to form a pile with an enlarged base, details of the proposed method of forming the base and the materials to be used shall be submitted at the time of tendering.

4.5.3

Quality Assurance

1

Before placing concrete in a pile casing, the Contractor shall check in an approved manner that the casing is undamaged, and free from water or other foreign matter. In the event of water or foreign matter having entered the pile casing, either the casing shall be withdrawn, repaired if necessary and re-driven, or other action shall be taken as may be approved to continue the construction of the pile.

4.5.4

Materials

1

Permanent Casings

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Permanent casings shall be as specified. Where a permanent casing is to be made from a series of short sections it shall be designed and placed so as to produce a continuous water-free shaft. The dimensions and quality of the casing shall be adequate to withstand the stresses caused by handling and driving without damage or distortion.

Temporary casings shall be free from significant distortion. They shall be of uniform external cross-section throughout each continuous length. During concreting they shall be free from internal projections and encrusted concrete which might prevent the proper formation of piles.

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Pile Shoes (a)

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Pile shoes shall be manufactured from durable material capable of withstanding the stresses caused by driving without damage, and shall be designed to give a watertight joint during construction.

Reinforcement (a)

This type of pile shall normally be reinforced over its full length unless permanently cased. The use of shorter reinforcement in piles which are not permanently cased shall be subject to the approval of the Engineer.

(b)

The number of splices in longitudinal steel bars shall be kept to a minimum. The full strength of each bar shall be effective across each splice, which shall be made so that there is no detrimental displacement of the reinforcement during the construction of the pile.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4.5.5

Driving piles

1

Piling Near Recently Cast Piles (a)

2

Casings shall not be driven or piles formed so close to other piles which have recently been cast as to damage them.

Performance of Driving Equipment (a)

The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment

(b)

Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft.

Length of Piles

Driving Procedure (a)

Each pile casing shall be driven continuously until the specified or approved depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided on resumption the casing can be driven to the specified depth or resistance (set), or both, without damage.

(b)

The Contractor shall inform the Engineer without delay if an unexpected change in driving characteristics is encountered. A detailed record of the driving resistance over the full length of the nearest available subsequent pile shall be taken if required.

(c)

At the start of the work in a new area or section a detailed driving record shall be made over the full length of the first pile to be installed and over the last 3 m of the driving of subsequent piles until consistency of behaviour is established. Where required, detailed driving records shall also be made for 5 % of the piles driven, the positions of such piles being specified by the Engineer.

(d)

The Contractor shall give adequate notice and provide all facilities to enable the Engineer to check driving resistance. A set shall be taken only in the presence of the Engineer unless otherwise approved.

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Final Set

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The length of pile to be driven in any location shall be approved.

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(a)

Where piles are driven to a set, the final set of each pile, pile shell or casing shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm.

(b)

When a final set is being measured, the following requirements shall be met: (i)

The exposed part of the pile casing shall be in good condition, without damage or distortion.

(ii)

The dolly, helmet and packing, if any, shall be in sound condition.

(iii)

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis.

(iv)

The hammer shall be in good condition, delivering adequate energy per blow, and operating correctly.

(v)

Temporary compression of the pile casing shall be recorded if required.

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6

If preboring is specified the pile casing shall be pitched after preboring to the designated depth and diameter.

Jetting (a)

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Preboring (a)

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Jetting shall be carried out only when the Contractor's detailed proposals have been approved by the Engineer

Internal Drop Hammer Where a casing for a pile without an enlarged base is to be driven by an internal drop hammer, a plug consisting of concrete grade 20 with a water/cement ratio not exceeding 0.25 shall be placed in the pile. This plug shall have a compacted height of not less than 2.5 times the diameter of the pile. Fresh concrete shall be added to ensure that this height of driving plug is maintained in the casing throughout the period of driving, and in any event a plug of fresh concrete shall be added after 1.5 h of normal driving or after 45 min of hard driving, or, should the driving of a pile be interrupted for 30 min or longer, fresh concrete shall be added prior to driving being resumed.

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Risen Piles

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Piles shall be driven in an approved sequence to minimise any detrimental effects of heave and lateral displacement of the ground.

2

When required, levels and measurements shall be taken to determine the movement of the ground or any pile resulting from the driving process.

3

When a pile has risen with detrimental effects as a result of adjacent piles being driven the Contractor shall, if required, submit to the Engineer his proposals for correcting or compensating for this and for avoidance or control of heave effects in subsequent work.

4.5.7

Extraction of casing

1

Workability of Concrete

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(a)

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3

Temporary casings shall be extracted while the concrete within them remains sufficiently workable to ensure that the concrete is not lifted.

Concrete Level (a)

When the casing is being extracted, a sufficient quantity of concrete shall be maintained within it to ensure that pressure from external water or soil is exceeded and that the pile is neither reduced in section nor contaminated.

(b)

Concrete shall be topped up as necessary while the casing is extracted until the required head of concrete to complete the pile in a sound and proper manner has been provided. No concrete is to be placed once the bottom of the casing has been lifted above the top of the concrete.

Vibrating Extractors (a)

The use of vibrating casing extractors will be permitted subject to Part 1 (Noise and Disturbance) and (Damage to Adjacent Structures).

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Page 27

Concrete Casting Tolerances (a)

For piles constructed without the use of a rigid permanent lining, pile concrete shall be cast to the original ground level.

(b)

Where piles are constructed inside rigid permanent lining tubes or permanent casings, pile heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be made. In this case, the tolerance of casting above the cut-off level shall be determined according to Table 4.6. Table 4.6

Casting Tolerance above Cut-off Level for Piles Constructed Inside Rigid Permanent Lining Tubes or Permanent Casings Cut-off distance below original ground, H, (m)

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Casting tolerance above cut-off level (m)

2.2 + H/10

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Repair of damaged pile heads and making-up of piles to the correct level When repairing or extending the head of a pile, the head shall be cut off square in sound concrete, and all loose particles shall be removed by wire brushing, followed by washing with water.

(b)

If the driving of a pile has been accepted but sound concrete of the pile is below the cut-off level, the pile shall be made good to the cut-off level with concrete of a grade not inferior to that of the concrete of the pile.

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Lengthening of cast-in- place piles after driving When it is required to extend a cast-in-place driven pile above ground, the materials to be used and procedures to be adopted shall be subject to the approval of the Engineer.

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Lengthening of permanent pile casings during construction The lengthening of permanent steel pile casings by adding an additional length of the same steel casing during construction shall be carried out in accordance with the relevant clauses of this Section or by other approved methods. The use of casing extension materials and methods other than those specified shall be subject to approval.

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Temporary backfilling above pile casting level (a)

9

After each pile has been cast, any hole remaining shall be protected and shall be carefully backfilled as soon as possible with approved materials.

Cutting off pile heads (a)

When cutting off and trimming piles to the specified cut-off level, the Contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section to the cut-off level.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

Page 28

4.6

STEEL PILES

4.6.1

Scope

1

This Part applies to driven steel piles designed to act as bearing piles.

2

Related Sections and Parts are as follows: This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling

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Section 3, Ground Investigation. Section 5, Concrete References

1

The following standards and other documents are referred to in this Part:

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BS 4, ..........................Structural steel sections

BS 3100, ....................Steel casting for general engineering purposes.

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BS 5135, ....................Process of arc-welding of carbon and carbon manganese steels BS 6265, ....................Resistance steam welding of uncoated and coated low carbon steel

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BS 7613, ....................Hot rolled quenched and tempered weldable structural steel plates

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API 5L,........................Interpretation of non-destructive testing. Submittals

1

Where coatings are specified, the Contractor shall submit for approval full details of the coating procedure and surface preparation according to relevant British or Swedish Standards.

4.6.4

Quality Assurance

1

The Contractor shall provide the Engineer with Works test certificates, analyses, and mill sheets, together with a tube manufacturer's certificate showing details of the pile number, cast number of the steel and a record of all tests and inspections carried out. The Engineer has the right to inspect any stage of the manufacturing processes and shall be given adequate notice by the Contractor of such processes and production tests, provided that, once he has been notified, any delay in his attendance does not cause delay to, or disrupt, the manufacturing process. The Contractor shall provide the Engineer with samples for independent testing when requested.

2

The Contractor shall submit for approval full details of the welding procedures and electrodes, with drawings and schedules as may be necessary. Tests shall be undertaken as may be required by the relevant British Standard or as may be required by the Engineer. Only welders who are qualified in the approved welding procedure in accordance with the tests laid down in the relevant British Standard, or who have a proven record over the previous six months, or who have attained a similar standard, shall be employed on the Works. Proof of welders' proficiency shall be made available to the Engineer on request.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4.6.5

Delivery, Storage and Handling

1

The Contractor shall (a)

Order the piles to suit the construction programme.

(b)

Obtain the Engineer's approval before placing the order.

Page 29

When preliminary piles are specified, the approval for the piles for the main work will not necessarily be given until the results of the driving and tests on preliminary piles have been received and evaluated.

3

Each pile shall be clearly numbered and its length shown near the pile head using white paint. In addition, before being driven, each pile shall be graduated at appropriate intervals along its length and at intervals of 250 mm along the top 3 m.

4

All piles within a stack shall be in groups of the same length and on approved supports. All operations such as handling, transporting and storing of piles shall be carried out in a manner such that damage to piles and their coatings is minimised.

4.6.6

Materials

1

Pile Shoes

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Cast steel shoes shall be of steel to BS 3100, grade Al. Flat plate and welded fabricated steel shoes shall be grade 43A or 50A, conforming to BS 7613 and related standards.

Strengthening of Piles

The strengthening to the toe of a pile in lieu of a shoe or the strengthening of the head of a pile shall be made using material of the same grade as the pile unless otherwise approved.

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Manufacturing Tolerance All piles shall be of the type and cross-sectional dimensions specified. For standard rolled sections the dimensional tolerances and weight shall comply with the relevant standard. The tolerance on length shall be -0 and +75 mm unless otherwise specified. For proprietary sections the dimensional tolerances shall comply with the manufacturer's standards. The rolling or manufacturing tolerances for proprietary sections shall be such that the actual weight of section does not differ from the theoretical weight by more than +4 % or -2½ % unless otherwise agreed. The rolling or manufacturing tolerances for steel tubular piles shall be such that the actual weight of section does not differ from the theoretical weight by more than ±5 %.

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Straightness of Piles (a)

For standard rolled sections the deviation from straightness shall be within the compliance provisions of BS 4, Part 1. When two or more rolled lengths are joined by butt-jointing, the deviation from straightness shall not exceed 1/600 of the overall length of the pile.

(b)

For proprietary sections made up from rolled sections, and for tubular piles, the deviation from straightness on any longitudinal face shall not exceed 1/600 of the length of the pile nor 5 mm in any 3 m length.

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Fabrication of Piles (a)

For tubular piles where the load will be carried by the wall of the pile, and if the pile will be subject to loads that induce reversal of stress during or after construction, the external diameter at any section as measured by using a steel tape on the circumference shall not differ from the theoretical diameter by more than ±1.

(b)

The ends of all tubular piles as manufactured shall be within a tolerance on ovality of ±1 % as measured by a ring gauge for a distance of 100 mm at each end of the pile length.

(c)

The root edges or root faces of lengths of piles that are to be shop butt-welded shall not differ by more than 25 % of the thickness of pile walls not exceeding 12 mm thick or by more than 3 mm for piles where the wall is thicker than 12 mm. When piles of unequal wall thickness are to be butt-welded, the thickness of the thinner material shall be the criterion.

Matching of Pile Lengths

Longitudinal seam welds and spiral seam welds of two lengths of tubular piles being joined shall, whenever possible, be evenly staggered at the butt. However, if in order to obtain a satisfactory match of the ends of piles or to meet specified straightness, the seams cannot be staggered evenly, then they shall be staggered by at least 100 mm.

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Welding

Welding of H-piles and piles that will be subjected to stress reversal, during or after construction, shall be in accordance with BS 5135.

(b)

For a tubular pile where the load will be compressive and non-reversible and will be carried by the wall of the pile or by composite action with a concrete core, the welding shall be to BS 5135 or BS 6265.

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(a)

Coating Piles for Protection against Corrosion Where coatings are specified they shall be provided in accordance with the Particular Specification. In general, coatings will not be called for where piles are fully in contact with undisturbed natural soils or below the standing water table. Cathodic protection may be called for when there is a possibility of stray electrical current from the supported structure flowing to earth through the piles.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

4.6.7

Acceptance Standards For Welds

1

Acceptance Standards for Shop Welds (a)

Longitudinal or spiral welds made in the manufacture of tubular piles are subject to the acceptance standard for interpretation of non-destructive testing specified in latest edition of API 5L. The maximum projecting height of weld reinforcement shall not exceed 3 mm for wall thicknesses not exceeding 13 mm and 5 mm for wall thicknesses greater than 13 mm.

(b)

Longitudinal welds joining the constituent parts of the box or proprietary section shall be in accordance with the manufacturer's specification.

(c)

The maximum projecting height of weld reinforcement for circumferential welds in tubular piles shall be the same as specified above for longitudinal welds in tubular piles.

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Acceptance Standards for Site Butt Welds (a)

Welds shall comply with the requirements of the Weld Quality Acceptance Standards for Site Butt Welds in Steel Bearing Piles published by British Steel Corporation, General Steels Group.

Acceptability and inspection of coatings

1

The finished coating shall be generally of smooth and uniform texture and free from sharp protuberances or pin holes. Excessive sags, dimpling or curtaining will not be acceptable.

2

Any coat damaged by subsequent processes, or which has deteriorated to an extent such that proper adhesion of the coating is in doubt, shall be removed and the surface shall be cleaned to the original standard and recoated with the specified number and thicknesses of coats.

3

The completed coating shall be checked for thickness by an approved magnetic thickness gauge. Areas where the thickness is less than that specified shall receive approved additional coating.

4

Average measured thickness should be equal to or greater than the specified thickness and no single reading should be less than 85 % of the specified thickness. The completed coating shall also be checked for adhesion by the cross-hatching method with lines spaced at ten times the thickness of the coating. Adhesion tests should not be carried out prior to seven days after coating.

5

The tests shall be made on 10 % of the piles. Areas where the adhesion is not approved shall be sand blasted and recoated. The coating shall be approved before pitching and driving of the piles.

4.6.9

Driving of piles

1

Leaders and Trestles

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At all stages during driving and until incorporation in the superstructure, the free length of the pile shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling. In marine works, lengths which remain unsupported after driving shall be adequately restrained until incorporated into the permanent Works. These constraint arrangements shall be such that damage to piles and their coatings is minimised.

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4.6.8

2

Performance of Driving Equipment (a)

The Contractor shall satisfy the Engineer regarding the suitability, efficiency and energy of the driving equipment. Where required in the Contract, dynamic evaluation and analysis shall be provided.

(b)

Where a drop hammer is used, the mass of the hammer shall be at least half that of the pile unless otherwise approved by the Engineer. For other types of hammer the energy delivered to the pile per blow shall be at least equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be used from floating craft in such a manner as to cause instability of the craft.

QCS 2014

Length of Piles (a)

The length of pile to be driven and any additional lengths of pile to be added during driving shall be approved by the Engineer.

Driving Procedure and Redrive Checks The driving of each pile shall be continuous until the specified depth or resistance (set), or both, has been reached. In the event of unavoidable interruption to driving, the pile will be accepted provided it can be driven to the specified depth or resistance (set), or both, without damage.

(b)

A follower shall not be used unless approved, in which case the Engineer will require the set where applicable to be revised in order to take into account reduction in the effectiveness of the hammer blow.

(c)

The Contractor shall inform the Engineer as soon as an unexpected change in driving characteristics is noted. A detailed record of the driving resistance over the full length of the nearest subsequent pile shall be taken, if required by the Engineer.

(d)

At the start of the work in a new area or section a detailed record shall be made over the full driving length of the first pile, and during the last 3 m of the driving of subsequent piles, to establish the driving behaviour. Where required, detailed driving records shall also be made for 5 % of the piles driven, the locations of such piles being specified by the Engineer.

(e)

The Contractor shall give adequate notice and provide all necessary facilities to enable the Engineer to check driving resistance. A set or resistance measurement shall be taken only in the presence of the Engineer unless otherwise approved.

(f)

Redrive checks, if required, shall be carried out in accordance with an approved procedure.

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When driving to a set criterion, the final set of each pile shall be recorded either as the penetration in millimetres per ten blows or as the number of blows required to produce a penetration of 25 mm. When a final set or resistance is being measured, the following requirements shall be met:

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6

(i)

The exposed part of the pile shall be in good condition, without damage or distortion.

(ii)

The dolly and packing, if any, shall be in sound condition.

(iii)

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis.

(iv)

The hammer shall be in good condition, delivering adequate energy per blow and operating correctly.

(v)

The temporary compression of the pile shall be recorded, if required by the Engineer.

Preboring (a)

If preboring is specified the pile shall be pitched after preboring to the designated depth and diameter.

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Jetting (a)

Jetting shall be carried out only when the Contractor's detailed proposals have been approved.

Risen Piles

1

Piles shall be driven in an approved sequence to minimise any detrimental effects of heave and lateral displacement of the ground.

2

When required by the Engineer, levels and measurements shall be taken to determine the movement of the ground or any pile resulting from the driving of adjacent piles.

3

When a pile has risen as a result of adjacent piles being driven, the Engineer may call for redriving or other testing to demonstrate that the performance of the pile under load is unimpaired. If required, the Contractor shall make proposals for correcting detrimentally affected piles and for avoidance or control of heave in subsequent work.

4.6.11

Preparation of pile heads

1

If a steel superstructure is to be welded to piles, the pile cut-off shall be square and to within 5 mm of the elevations shown on the Drawings. If pile heads are to be encased in concrete they shall be cut to that same tolerance and protective coatings shall be removed from the surfaces of the pile heads down to a level 100 mm above the soffit of the concrete.

4.7

MICROPILES (TO BE ADDED LATER)

4.8

REDUCTION OF FRICTION ON PILES

4.8.1

Scope

1

This Part includes preapplied bituminous or other proprietary friction-reducing coating, preapplied low-friction sleeving, formed-in-place low-friction surround, and preinstalled lowfriction sleeving.

2

Related Parts are as follows:

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4.6.10

This Section Part 1, .............. General Requirements for Piling Works Part 2, .............. Concrete Works for Piling Section 3, Ground Investigation. 4.8.2

Submittals

1

Where the particular method of reducing friction is not specified, the Contractor shall submit full details of the method which he proposes.

4.8.3

Friction Reducing Methods

1

General (a)

Where a means of reducing friction on any specified length of pile is required by the Contract, the Contractor shall provide a suitable interface between pile and soil by one of the following, or other approved, methods

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(i)

Preapplied bituminous or other proprietary friction-reducing coating.

(ii)

Preapplied low-friction sleeving.

(iii)

Formed-in-place low-friction surrounds.

(iv)

Preinstalled low-friction sleeving.

Preapplied Bituminous or other Friction-Reducing Coating Materials (a)

Where a proprietary product is specified, the process of cleaning pile surfaces, and the conditions and methods of application shall conform to the manufacturer's current instructions. All materials shall conform to the manufacturer's specification, which shall be given to the Engineer before any coating is applied.

(b)

Where a friction-reducing material has been applied to a preformed pile prior to installation, it shall be protected from damage during handling and transportation. In the event of inadvertent damage to the coating, it shall be repaired on site, prior to the pile being driven, to the same specification as the original coating. Where bituminous materials are involved, precautions shall be taken as necessary in hot weather to prevent excessive flow or displacement of the coating. The coated piles shall be adequately protected against direct sunlight and, if stacked, they shall be separated to prevent their coatings sticking together.

(c)

In the case of applied coatings, the piles shall not be driven when the air temperature is such that the coating will crack, flake or otherwise be damaged prior to entry into the ground. Where bituminous materials are involved, driving shall be carried out while the temperature is at or above 5 °C unless otherwise approved or called for in the manufacturer's instructions.

Formed-In-Place Low-Friction Surround Where a hole is bored in the ground and filled with low-friction material through which a pile is subsequently driven or placed, the method and the properties of the low-friction material both above and below standing groundwater level, together with the dimensions of the prebored hole in relation to the pile, shall be approved by the Engineer.

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Piles may be driven with a preapplied low-friction sleeving subject to the approval of the detailed design and method by the Engineer.

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Preinstalled Low-Friction Sleeving (a)

Where a system is employed involving placing a low-friction sleeve in the ground prior to pile installation, the detailed materials and method of installation of the sleeving shall be approved by the Engineer.

4.8.4

Inspection

1

The Engineer may call for piles to be partially exposed or extracted at the commencement of a contract in order to demonstrate that the method of installation does not impair the effectiveness of the system in the circumstances of use on the particular site. Where damage is found to have occurred, or is likely to occur in the opinion of the Engineer, additional measures or variation of the method may be called for. At the discretion of the Engineer, further inspections shall be carried out to ascertain the effectiveness of the additional measures.

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4.8.5

Driving resistance

1

Allowance shall be made in driving piles to a required resistance or set for any differences between the short-term driving resistance and the long-term static resistance of the coating or surrounding low-friction material which is in use.

4.9

PILE LOAD TESTING

4.9.1

Static Load Testing of Piles

1

Scope This Part deals with the testing of a pile by the controlled application of an axial load. It covers vertical and raking piles tested in compression (i.e. subjected to loads or forces in a direction such as would cause the piles to penetrate further into the ground) and vertical or raking piles tested in tension (i.e., subjected to forces in a direction such as would cause the piles to be extracted from the ground).

References The following standard is referred to in this Part:

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Allowable pile capacity: a load which is not less than the specified working load and which takes into account the pile's ultimate bearing capacity, the materials from which the pile is made, the required factor of safety, settlement, pile spacing, downdrag, the overall bearing capacity of the ground beneath the piles and any other relevant factors. The allowable pile capacity indicates the ability of a pile to meet the specified loading requirements.

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Definitions

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When required, the design and full details of the proposed load application system shall be submitted to the Engineer prior to the commencement of testing. The load application system shall be satisfactory for the required test.

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(b)

Compression pile: a pile which is designed to resist compressive (downward) axial load.

(c)

Constant rate of penetration (CRP) test: a test in which the pile is made to penetrate the soil at a constant controlled speed, while the loads applied at the top of the pile in order to maintain the constant rate of penetration are continuously measured. The purpose of the test is to derive the ultimate bearing capacity of a pile and not its load settlement characteristics.

(d)

Constant rate of uplift (CRU) test: the same in principle as the CRP test, but the pile is subject to tension rather than compression. The purpose of the test is to determine the 'pull-out' capacity of a pile.

(e)

Design verification load (DVL): a test load, in lieu of a specified working load, applied to a single pile at the time of testing to determine that site conditions conform to design assumptions. This load will be peculiar to each preliminary (test) pile and should equal the maximum specified working load for a pile of the same dimensions and material, plus allowances for soil-induced forces and any other particular conditions of the test.

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Kentledge: ballast used in a loading test.

(g)

Maintained load test: a loading test in which each increment of load is held constant either for a defined period of time or until the rate of settlement falls to a specified value.

(h)

Preliminary pile: a test pile installed before the commencement of the main piling works or a specific part of the Works for the purpose of establishing the suitability of the chosen type of pile and for confirming its design, dimensions and bearing capacity.

(i)

Proof load: a load applied to a selected working pile to confirm that it is suitable for the load at the settlement specified. A proof load should not normally exceed the design verification load plus 50 % of the specified working load.

(j)

Raking pile: a batter pile, installed at an inclination to the vertical.

(k)

Reaction system: the arrangement of kentledge, piles, anchors or rafts that provides a resistance against which the pile is tested.

(l)

Specified working load (SWL): the designated load on the head of a pile.

(m)

Tension pile: a pile which is designed to resist a tensile (upward) axial force.

(n)

Test pile: any pile, preliminary or part of the works, to which a test is applied.

(o)

Ultimate bearing capacity: the load at which the resistance of the soil becomes fully mobilised through friction, end bearing or a combination thereof.

(p)

Working pile: one of the piles forming the foundation of a structure.

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Notice of Construction

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The Contractor shall give the Engineer at least 48 hours' notice of the commencement of construction of any preliminary pile which is to be testloaded.

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Method of Construction Each preliminary test pile shall be constructed in a manner similar to that to be used for the construction of the working piles, and by the use of similar equipment and materials. Any variation will be permitted only with prior approval.

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(c)

Boring or Driving Record (i)

(d)

For each preliminary pile to be tested, a detailed record of the conditions experienced during boring and of the progress during driving, shall be made and submitted to the Engineer daily, not later than noon on the next working day. Where the Engineer requires soil samples to be taken or in-situ tests to be made, the Contractor shall include that in the daily report, as well as the test results.

Concrete Test Cubes (i)

In the case of concrete piles, four test cubes shall be made from the concrete 3 used in the manufacturer of each preliminary test pile and from each 50 m of the concrete used in the manufacture of working piles. If a concrete pile is extended or capped for the purpose of testing, an additional four cubes shall be made from the corresponding batch of concrete. The cubes shall be made and tested in accordance with BS 1881.

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations (ii)

(e)

If a test is required on a working pile the Contractor shall cut off or otherwise prepare the pile for testing as required by the Engineer.

Cut-off Level (i)

The cut-off level for a preliminary test pile shall be approved by the Engineer.

.

Supervision The setting-up of pile testing equipment shall be carried out under competent supervision and the equipment shall be checked to ensure that the set-up is satisfactory before the commencement of load application.

(b)

All tests shall be carried out only under the direction of an experienced and competent supervisor experienced with the test equipment and test procedure. All personnel operating the test equipment shall have been trained in its use.

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Safety precautions General

Design, erection and dismantling of the pile test reaction system and the application of load shall be carried out according to the requirements of the various applicable statutory regulations concerned with lifting and handling heavy equipment and shall safeguard operators and others who may from time to time be in the vicinity of a test from all avoidable hazards.

Kentledge

Where kentledge is used, the Contractor shall construct the foundations for the kentledge and any cribwork, beams or other supporting structure in such a manner that there will not be differential settlement, bending or deflexion of an amount that constitutes a hazard to safety or impairs the efficiency of the operation. The kentledge shall be adequately bonded, tied or otherwise held together to prevent it becoming unstable because of deflexion of the supports or for any other reason.

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The pile test shall not be started until the strength of the cubes taken from the pile exceeds twice the average direct stress in any pile section under the maximum required test load, and the strength of the cubes taken from the cap exceeds twice the average stress at any point in the cap under the same load. Variation of procedure will be permitted only if approved by the Engineer.

Preparation of a Working Pile to be Tested (i)

(f)

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(ii)

When kentledge constitutes the principal component of a reaction system, its weight for each test shall be at least 25% greater than the maximum test load for that test. The weight may be determined by scale or the density and volume of the constituent materials. In adding kentledge, care shall be taken to properly position the centre of gravity of the stack.

QCS 2014

(c)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Tension Piles, Reaction Piles and Ground Anchorages (i)

Where tension piles, reaction piles or ground anchorages constitute the principal components of a reaction system, they shall be so designed that they will resist the forces applied to them safely and without excessive deformation which could cause a safety hazard during the work. Such piles (which, unless approved, will not be working piles) or anchorages shall be driven in the specified locations, and all bars, tendons or links shall be aligned to provide a stable reaction in the direction required. Any welding employed to extend or to fix anchorages to a reaction frame shall be carried out so that the full strength of the system is adequate and unimpaired.

Testing Equipment (i)

In all cases the Contractor shall ensure that when the hydraulic jack and loadmeasuring device are mounted on the pile head the whole system will be stable up to the maximum load to be applied.

(ii)

If in the course of carrying out a test any unforeseen occurrence should take place, further loading shall not be applied until a proper engineering assessment of the condition has been made and steps have been taken to rectify any fault. Reading of gauges should, however, be continued where possible and if it is safe to do so.

(iii)

Where an inadequacy in any part of the system might constitute a hazard, means shall be provided to enable the test to he controlled from a position remote from of the kentledge stack or test frame.

(iv)

The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be operated under hydraulic pressure shall be capable of withstanding a pressure of 1.5 times the maximum pressure used in the test without leaking. The maximum test load expressed as a reading on the gauge in use shall be displayed and all operators shall be made aware of this limit.

Pile Head for Compression Test For a pile that is tested in compression, the pile head or cap shall be formed to give a plane surface which is normal to the axis of the pile, sufficiently large to accommodate the loading and settlement measuring equipment and adequately reinforced or protected to prevent damage from the concentrated load applied by the loading equipment.

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(f)

(ii)

Any test pile cap shall be concentric with the test pile; the joint between the cap and the pile shall have a strength equivalent to that of the pile.

(iii)

Sufficient clear space shall be made under any part of the cap projecting beyond the section of the pile so that, at the maximum expected settlement, load is not transmitted to the ground by the cap.

Pile Connection for Tension Test (i)

For a pile that is tested in tension, means shall be provided for transmitting the test load axially without inducing moment in the pile. The connection between the pile and the loading equipment shall be constructed in such a manner as to provide strength equal to 1.5 times the maximum load which is to be applied to the pile during the test.

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Reaction systems

(i)

The reaction for compression tests shall be provided by kentledge, tension piles or specially constructed anchorages. Kentledge shall not be used for tests on raking piles except where the test set-up has been specifically designed to conform to Item 7(g). and has been approved by the Engineer.

(ii)

Where kentledge is to be used, it shall be supported on cribwork and positioned so that the centre of gravity of the load is as close as possible to the axis of the pile. The bearing pressure under supporting cribs shall be such as to ensure stability of the kentledge stack.

Tension Tests (i)

The reaction for tension tests shall be provided by compression piles, rafts or grillages constructed on the ground. In all cases the resultant force of the reaction system shall be coaxial with the test pile.

(ii)

Where inclined piles or reactions are proposed, full details shall be submitted for approval prior to the commencement of testing.

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Working piles shall not be used as reaction piles without approval from the Engineer.

(ii)

Where working piles are used as reaction piles their movement shall be measured and recorded to with an accuracy of 0.5 mm, and recorded.

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Spacing

Where kentledge is used for loading vertical piles in compression, the distance from the edge of the test pile to the nearest part of the crib supporting the kentledge stack in contact with the ground shall be not less than 1.3 m.

(ii)

The centre-to-centre spacing of vertical reaction piles from a test pile shall conform to Paragraph 1 above, but shall be not less than three times the diameter of the test pile or the reaction piles or 2 m, whichever is the greatest, except in the case of piles of 300 mm diameter (or equivalent) or less, where the distance may be reduced to 1.5 m. Where a pile to be tested has an enlarged pile cap, the same criterion shall apply with regard to the pile shaft, with the additional requirement that no surface of a reaction pile shall be closer to the pile cap of the test pile than one half of the pile cap plan dimension.

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(iii)

(e)

Where ground anchorages are used to provide a test reaction for loading in compression, no section of fixed anchor length transferring load to the ground shall be closer to the test pile than three times the diameter of the test pile. Where the pile to be tested has an enlarged pile cap, the same criterion shall apply with regard to the pile shaft, with the additional requirement that no section of the fixed anchor transferring load to the ground shall be closer to the pile cap than a distance equal to one half the pile cap plan dimension.

Adequate Reaction (i)

The reaction frame support system shall be adequate to transmit the maximum test load in a safe manner without excessive movement or influence on the test pile. Calculations shall be provided to the Engineer when required to justify the design of the reaction system.

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(f)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Care of Piles (i)

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The method employed in the installation of the reaction system shall be such as to prevent damage to any test pile or working pile.

Equipment for applying load The equipment used for applying load shall consist of a hydraulic ram or jack. The jack shall be arranged in conjunction with the reaction system to deliver an axial load to the test pile. Proposals to use more than one ram or jack will be subject to approval by the Engineer of the detailed arrangement. The complete system shall be capable of safely transferring the maximum load required for the test. The length of stroke of a ram shall be sufficient to account for deflexion of the reaction system under load plus a deflection of the pile head by up to 15 % of the pile shaft diameter unless otherwise specified or agreed prior to commencement of test loading.

Measurement of load

A load measuring device shall be used and in addition a calibrated pressure gauge included in the hydraulic system. Readings of both the load measuring device and the pressure gauge shall be recorded. In interpreting the test data the values given by the load measuring device shall normally be used; the pressure gauge readings are required as a check for gross error.

(b)

The load measuring device may consist of a load measuring column, pressure cell or other appropriate system. A spherical seating of appropriate size shall he used to avoid eccentric loading. Care shall be taken to avoid any risk of buckling of the load application and measuring system. Load measuring and application devices shall be short in axial length in order to secure stability. The Contractor shall ensure that axial loading is maintained.

(c)

The load measuring device shall be calibrated before and after each series of tests, whenever adjustments are made to the device or at intervals appropriate to the type of equipment. The pressure gauge and hydraulic jack shall be calibrated together. Certificates of calibration shall be supplied to the Engineer.

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Control of loading

The loading equipment shall enable the load to be increased or decreased smoothly or to be held constant at any required value.

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Measuring pile head movement (a)

Maintained Load Test (i)

(b)

In a maintained load test, movement of the pile head shall he measured by one of the methods in Items 11 (d), (e), (f), (g) in the case of vertical piles, or by one of the methods in 11 (d), (f), (g) in the case of the raking piles, as required.

CRP and CRU Tests (i)

In a CRP or a CRU test, the method in Item 11 (d) shall be used. Checklevelling of the reference frame or the pile head shall not be required. The dial gauge shall be graduated in divisions of 0.02 mm or less.

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

(c)

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Reference Beams and Dial Gauges (i)

An independent reference beam or beams shall be set up to enable measurement of the movement of the pile to be made to the required accuracy. The supports for a beam shall be founded in such a manner and at such a distance from the test pile and reaction system that movements of the ground do not cause movement of the reference beam or beams which will affect the accuracy of the test. The supports of the beam or beams shall be at least three test pile diameters or 2 m from the centre of the test pile, whichever distance is the greater.

(ii)

Check observations of any movements of the reference beam or beams shall be made and a check shall be made of the movement of the pile head relative to a remote reference datum at suitable intervals during the progress of the test.

(iii)

The measurement of pile movement shall be made by four dial gauges rigidly mounted on the reference beam or beams, bearing on prepared flat surfaces fixed to the pile cap or head and normal to the pile axis. Alternatively, the gauges may be fixed to the pile and bear on prepared surfaces on the reference beam or beams. The dial gauges shall be placed equidistant from the pile axis and from each other. The dial gauges shall enable readings to be made to an accuracy of at least 0.1 mm and have a stem travel of at least 25 mm. Machined spacer blocks may be used to extend the range of reading. Equivalent electrical displacement-measuring devices may be substituted.

Optical Levelling Method

An optical levelling method by reference to a remote datum may be used.

(ii)

Where a level and staff are used, the level and scale of the staff shall be chosen to enable readings to be made to within an accuracy of 0.5 mm. A scale attached to the pile or pile cap may be used instead of a levelling staff. At least two reliable independent datum points shall be established. Each datum point shall be so situated as to permit a single setting-up position of the level for all readings.

(iii)

No datum point shall be located where it can be affected by the test loading or other operations on the Site.

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(i)

Two parallel reference wires, one on either side of the pile, shall be held under constant tension at right angles to the test pile axis between supports formed as in the method in Item 11 (d). The wires shall be positioned against scales fixed to the test pile head in an axial direction and the movements of the scales relative to the wires shall be determined.

(ii)

Check observations of any movements of the supports of the wires shall be made and a check shall be made on the movement of the pile head at approved time intervals. Readings shall be taken to within an accuracy of 0.5 mm.

Other Methods (i)

The Contractor may submit for approval any other method of measuring the movement of the test pile head.

QCS 2014

Protection of testing equipment (a)

Protection from Weather (i)

(b)

Throughout the test period all equipment for measuring load and shall be protected from exposure to adverse effect of weather.

movement

Prevention of Disturbance (i)

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Construction activity and persons who are not involved in the testing process shall be kept at a sufficient distance from the test to avoid disturbance to the measuring apparatus. Full records shall be kept of any intermittent unavoidable activity that might affect the test set-up.

Notice of test The Contractor shall give the Engineer at least 24 hours' notice of the commencement of the test. No load shall be applied to the test pile before the commencement of the specified test procedure.

Test procedure

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Proof Load Test Procedure (working compression piles)

The maximum load which shall be applied in a proof test shall normally be the sum of the design verification load (DVL) plus 50 % of the specified working load (SWL). The loading and unloading shall be carried out in stages as shown in Table 4.7. Any particular requirements given in the particular contract documentation shall be complied with.

(ii)

Following each application of an increment of load, the load shall be maintained at the specified value for not less than the period shown in Table 4.7 and until the rate of settlement is less than 0.25 mm/h and decreasing. The rate of settlement shall be calculated from the slope of the line obtained by plotting values of settlement versus time and drawing a smooth curve through the points.

(iii)

Each decrement of unloading shall proceed after the expiry of the period shown in Table 4.7.

(iv)

For any period when the load is constant, time and settlement shall be recorded immediately on reaching the load, at not more than 5 min intervals up to 15 min; at approximately 15 min intervals up to 1 h; at 30 min intervals between 1 h and 4 h; and 1 h intervals between 4 h and 12 h after the application of the increment of load.

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(v)

Where the methods of measuring pile head movement given in Item 11 is used, the periods of time for which loads must be held constant to achieve the specified rates of settlement shall be extended as necessary to take into account the lower levels of accuracy available from these methods and to allow correct assessment of the settlement rate.

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Table 4.7 Minimum time of holding load

25% DVL 50% DVL 75% DVL 100% DVL 75% DVL 50% DVL 25% DVL 0 100% DVL 100% DVL + 25% SWL 100% DVL + 50% SWL 100% DVL + 25% SWL 100% DVL 75% DVL 50% DVL 25% DVL 0 100% DVL 100% DVL + 50% SWL 100% DVL + 75% SWL 100% DVL + 100% SWL 100% DVL + 75% SWL 100% DVL + 50% SW 100% DVL + 25% SW 100% DVL 75% DVL 50% DVL 25% DVL 0

1h 1h 1h 1h 10 min 10 min 10 min 1h 6h 1h 6h 10 min 10 min 10 min 10 min 10 min 1h 6h 6h 1h 6h 10 min 10 min 10 min 10 min 10 min 10 min 10 min 1h

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Applicable to tests on Preliminary Pile only

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(i)

The procedure to be adopted for carrying out load tests on preliminary compression piles shall be either the extended proof load test procedure or the constant rate of penetration testing procedure given below. A normal proof load test will constitute the first stage of such a test unless otherwise specified.

(ii)

Extended proof load test procedure. Where test pile is to be loaded up to the sum of design verification load (DVL) plus 100 % of the specified working load, the loading procedure may be carried out as a continuation of the proof load testing procedure given in Item 14 (a).

(iii)

Following the completion of the proof load test, the load shall be restored in two stages (DVL, DVL +50 % SWL), and shall subsequently be increased by stages of 25 % of the specified working load. Following each application of an increment of load, the load shall be maintained at the specified value for the period shown in Table 4.7 and until the rate of settlement is decreasing and is less than 0.25 mm/h.

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(iv)

Where verification of required minimum factor of safety is called for or the pile is to be tested to failure, the loading procedure shall be continued after reaching DVL +100 % SWL stage by increasing the load in increments of 25 % of the specified working load or other specified amount until the maximum specified load of the test is reached. Following each application of increment of load, the load shall be maintained at the specified value for not less than 1 h and until the rate of settlement is decreasing and is less than 0.25 mm/h, or other approved rate appropriate to the stage of loading and its proximity to a failure condition. Permissible settlement at the load corresponding to the required minimum factor of safety called for in the design will not normally be specified.

(v)

The rate of settlement shall be calculated from the slope of the line obtained by plotting values of settlement versus time and drawing a smooth curve through the points. Reduction of load at the end of the test shall be gradual as required by Item 14 (a).and the final rebound of the pile head shall be recorded.

(vi)

Constant rate of penetration (CRP) testing procedure. Where it is required to determine the ultimate load of a preliminary compression pile, and particularly where piles are largely embedded in and bearing on clay soils, the CRP testing procedure will normally be specified.

(vii)

The rate of movement of the pile head shall be maintained constant in so far as is practicable and shall be approximately 0.01 mm/s.

(viii)

Readings of loads, penetration and time shall be made simultaneously at regular intervals; the interval chosen shall be such that a curve of load versus penetration can be plotted without ambiguity.

(ix)

Loading shall be continued until one of the following results is obtained

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The maximum required test load.

2.

A constant or reducing load has been recorded for an interval of penetration of 10 mm.

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The load shall then be reduced in five approximately equal stages to zero load, penetration and load being recorded at each stage.

Testing of Piles Designed to Carry Load in Tension (i)

The testing of piles designed to carry load in tension shall follow the same procedure as specified in 4.9.1

(ii)

In testing by the constant rate of uplift method, overall movements of the pile head will normally be less than those expected in a constant rate of penetration test. The rate of movement of the pile head shall be maintained at approximately 0.005 mm/s in so far as is practicable.

Completion of a test (a)

Removal of Test Equipment

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(i)

On completion of a test and subject to the approval of the Engineer, all measuring equipment and load application devices shall be dismantled and checked. All other test equipment, including kentledge, beams and supporting structures shall be removed from the test pile location. Measuring and other demountable equipment shall be stored in a safe manner so that it is available for further tests, or removed from the Site as approved by the Engineer.

(ii)

Temporary tension piles and ground anchorages shall be cut off below ground level, and off-cut materials removed from the Site. The ground shall be restored to the original contours.

Preliminary Test Pile Cap Unless otherwise specified, the head of each preliminary test pile shall be cut off below ground level, off-cut material shall be removed from the Site and the ground restored to the original contours.

Proof Test Pile Cap

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On completion of a test on a proof pile, the test pile cap shall be prepared as specified and left in a state ready for incorporation into the Permanent Works. Any resulting off-cut materials shall be removed from the Site.

Presentation of results

1

Results to be submitted

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4.9.2

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(i)

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(c)

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(i)

During the progress of a test, all records taken shall be available for inspection by the Engineer.

(b)

Results shall be submitted as

Preliminary report of the test results to the Engineer, unless otherwise directed, within 24 hours of the completion of the test, which shall show. For a test by maintained load: for each stage of loading, the period for which the load was held, the load and the maximum pile movement at the end of the stage.

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1.

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(i)

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(a)

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2.

(ii)

2

For a CRP or CRU test: the maximum load reached and a graph of load against penetration or load against uplift.

The final report of recorded data as prescribed in Item 15 (b).within ten days of the completion of the test.

Schedule of Recorded Data (a)

The Contractor shall provide information about the test pile in accordance with the following schedule where applicable. (i)

General. 1.

site location contract identification

2.

proposed structure

3.

main contractor

4.

piling contractor

5.

engineer client/employer

6.

date and time of test

QCS 2014

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Pile details. 1.

all types of pile

2.

identification (number and location)

3.

specified working load (SWL)

4.

design verification load (DVL)

5.

original ground level at pile location

6.

head level at which test load was applied

7.

type of pile

8.

vertical or raking, compression or tension

9.

shape and size of cross-section of pile, and position of any change in cross-section

10.

shoe or base details

11.

head details

12.

length in ground

13.

tip Elevation

14.

dimensions of any permanent casing

15.

concrete piles

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(ii)

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concrete mix/grade



aggregate type and source



cement type and cement replacement and type where used

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admixtures

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(iii)

16.



slump



cube test results for pile and cap



date of casting of precast pile



reinforcement

steel piles 

steel quality



coating



filling or core materials type and quality, if applicable

Installation details. 1.

2.

all piles 

dates and times of boring, driving and concreting of test pile



difficulties and delays encountered



date and time of casting concrete pile cap

bored piles 

type of equipment used and method of boring



temporary casing - diameter, type and length

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full log of pile borehole



method of placing concrete



Volume of concrete placed



driven preformed and driven cast-in-place piles



Method of support of hammer and pile driven length of pile or temporary casing at final set



Hammer type, and size or weight



Dolly and packing, type and condition



Driving log (depth, hammer drop, blows per 250 mm, interruptions or breaks in driving)



Final set in number of blows to produce penetration of 25 mm



Redrive check, time interval and set in number of blows to produce penetration of 25 mm or other agreed amount at final set and at redrive set, for a drop hammer or for a single acting hammer the length of the drop or stroke, for a diesel hammer the length of the stroke and the blows per minute, for a double acting hammer the operating pressure and the number of blows per minute



condition of pile head or temporary casing after driving



use of a follower



use of preboring



use of jetting



lengthening

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(iv)

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method of placing concrete

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Test procedure.

mass of kentledge

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1.

tension pile, ground anchorage or compression pile details

3.

plan of test arrangement showing position and distances of kentledge supports, rafts, tension or compression piles or ground anchorages, and supports to pile movement reference system

4.

jack capacity

5.

method of load measurement

6.

method(s) of penetration or uplift measurement

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2.

(v)

Test results. 1.

in tabular form

2.

in graphical form: load plotted against pile head movement

3.

ambient temperature records during test.

4.9.3

Low strain Integrity test

1

This test shall be carried out in accordance with ASTM D5882 in a frequency as mentioned in Section 2

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Grosshole Sonic Logging Test

1

This test shall be carried out in accordance with ASTM D4428, D6760 in a frequency as mentioned in Section 2

4.9.5

Calliper Logging Test

1

This test shall be carried out in accordance with ASTM D6167 in a frequency as mentioned in Section 2

4.9.6

Axial Tensile Load Test

1

This test shall be carried out in accordance with ASTM D3689 in a frequency as mentioned in Section 2

4.9.7

Lateral Load Test

1

This test shall be carried out in accordance with ASTM D3966 in a frequency as mentioned in Section 2

4.9.8

Alternative Methods for Testing Piles

1

Scope

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4.9.4

This Part outlines the alternative methods for testing piles. A significant advance in identifying the existence of defects in construction of piles has been the development and adoption of modern integrity testing systems which may be employed to check the quality of construction when required by the Engineer.

(b)

Dynamic pile-testing is normally used to evaluate the pile capacity, soil resistance distribution, and immediate settlement characteristics, hammer transfer energy (efficiency), and pile stresses during driving. The results obtained relate directly to dynamic loading conditions.

(c)

Related Sections and Parts are as follows:

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This Section Section 2

2

3

Quality Assurance (a)

The testing shall be carried out by an approved firm.

(b)

The interpretation of tests shall be carried out by persons competent in the test procedure, and the full test results and findings shall normally be given to the Engineer within 10 d of the completion of each phase of testing. Full details of the ground conditions, pile dimensions and construction method shall be made available to the specialist firm when required in order to facilitate interpretation of the tests.

Integrity-testing of piles (a)

General

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(i)

Integrity-testing of piles is designed to give information about the physical dimensions, continuity and consistency of materials used in piles, and not to give direct information about the performance of piles under the conditions of loading. The methods available are normally applied to preformed concrete piles made in a single length, to steel piles and to cast-in-place concrete piles.

(ii)

This type of testing will not be regarded as a replacement for static load testing, but as a source of supplementary information.

(iii)

There is normally a limit to the length: diameter ratio of pile which can be successfully and fully investigated in this way, depending on the ground conditions.

(iv)

In the event that any anomaly is found in the results of such testing, the Engineer may call for further testing to be carried out in order to investigate the cause, nature and extent of the anomaly and whether the pile is satisfactory for its intended use.

Method of Testing

Where integrity-testing is called for but the method is not specified, the method to be adopted shall be approved by the Engineer and shall be one of the following

3.

The sonic logging method.

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The vibration method.

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Other methods may be adopted subject to the approval of the Engineer and subject to satisfactory evidence of performance.

In the case of cast-in-place concrete piles, integrity tests shall not be carried out until 7 d or more have elapsed after pile-casting, unless otherwise approved by the Engineer.

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Preparation of Pile Heads

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(i)

4

2.

Age of Piles at Time of Testing (i)

(d)

The sonic method.

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(b)

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Where the method of testing requires the positioning of sensing equipment on the pile head, the head shall be clean, free from water, laitance and loose concrete and readily accessible for the purpose of testing.

Dynamic pile-testing (a)

General (i)

Dynamic pile-testing involves monitoring the response of a pile to a heavy impact applied at the pile head. The impact is often provided by the pile-driving hammer and response is normally measured in terms of force and acceleration or displacement close to the pile head.

(ii)

The results directly obtained refer to dynamic loading conditions. Interpretation in terms of static loading requires soil- and pile-dependent adjustments, and corroboration from experience may be required to correlate dynamic testing with normal static load tests as specified in clause 4.9.1 of this Section.

(iii)

Details of the equipment to be used and of the method of analysis of test results shall be provided to the Engineer before the commencement of testing.

QCS 2014

(b)

Section 04: Foundations and Retaining Structures Part 04: Deep Foundations Measuring Instruments (i)

(c)

All instruments affixed to the pile for the purpose of measuring stress and movement, and all equipment for receiving and processing data shall be suitable for the purpose. The equipment required to be attached to the pile shall be appropriately positioned and fixed to the approval of the Engineer.

Hammer (i)

(d)

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The hammer and all other equipment used shall be capable of delivering an impact force sufficient to mobilise the equivalent specified test load without damaging the pile.

Preparation of the Pile Head The preparation of the pile head for the application of the dynamic test load shall involve, where appropriate, trimming the head, cleaning and building up the pile using materials which will at the time of testing safely withstand the impact stresses. The impact surface shall be flat and normal to the axis of the pile.

(e)

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(i)

Time of Testing

Dynamic load tests shall be carried out at appropriate and approved times after pile installation. The time between the completion of installation and testing for a preformed pile shall normally be more than 12 h, and in the case of a cast-inplace concrete piles shall be after the concrete has reached 75 % of its specified 28 day strength so that the pile is not damaged under the impact stresses.

Set Measurements

(g)

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Where required and appropriate, the permanent penetration per blow and temporary compression of the pile and soil system shall be measured independently of the instruments being used to record the dynamic test data.

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(i)

Results

Initial the results shall be provided to the Engineer within 24 hours of the completion of a test. These shall include

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(i)

The maximum force applied to the pile head.

2.

The maximum pile head velocity.

3.

The maximum energy imparted to the pile.

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1.

(ii)

Normally within 10 d of the completion of testing final report shall be given to the Engineer which includes: 1.

Date of pile installation.

2.

Date of test.

3.

Pile identification number and location.

4.

Length of pile below ground surface.

5.

Total pile length, including projection above commencing surface at time of test.

6.

Length of pile from instrumentation position to tip.

7.

Hammer type, drop and other relevant details.

8.

Blow selected for analysis.

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9.

Test load achieved (i.e. total mobilised deduced static load).

10.

Pile head movement at equivalent design verification load.

11.

Pile head movement at equivalent design verification load plus 50 % of specified working load.

12.

Pile head movement at maximum applied test load.

13.

Permanent residual movement of pile head after each blow.

14.

Temporary compression.

DESIGN METHODS AND DESIGN CONSIDERATIONS

4.10.1

Design method

1

The design shall be based on one of the following approaches:

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4.10

The results of static load tests, which have been demonstrated, by means of calculations or otherwise, to be consistent with other relevant experience;

(b)

Empirical or analytical calculation methods whose validity has been demonstrated by static load tests in comparable situations;

(c)

The results of dynamic load tests whose validity has been demonstrated by static load tests in comparable situations;

(d)

The observed performance of a comparable piles foundation, provided that this approach is supported by the results of site investigation and ground testing.

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(a)

Design values for parameters used in the calculations should be in general accordance with design parameters from geotechnical investigations report, but the results of load tests may also be taken into account in selecting parameter values.

3

Static load tests may be carried out on trial piles, installed for test purposes only, before the design is finalized, or on working piles, which form part of the foundation.

4.10.2

Verification of Resistance for Structural and Ground Limit States in Persistent and Transient Situations

1

When considering a limit state of rupture or excessive deformation of a structural element or section of the ground (Structural and Geotechnical), it shall be verified in accordance with (Eurocode1997-1) or equivalent.

4.10.3

Design Considerations

1

The behavior of individual piles and pile groups and the stiffness and strength of the structure connecting the piles shall be considered.

2

In selecting calculation methods and parameter values and in using load test results, the duration and variation in time of the loading shall be considered.

3

Planned future placement or removal of overburden or potential changes in the ground-water regime shall be considered, both in calculations and in the interpretation of load test results.

4

The choice of type of pile, including the quality of the pile material and the method of installation, shall take into account:

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the ground and ground-water conditions on the site, including the presence or possibility of obstructions in the ground;

(b)

the stresses generated in the pile during installation;

(c)

the possibility of preserving and checking the integrity of the pile being installed;

(d)

the effect of the method and sequence of pile installation on piles, which have already been installed and on adjacent structures or services;

(e)

the tolerances within, which the pile can be installed reliably;

(f)

the deleterious effects of chemicals in the ground;

(g)

the possibility of connecting different ground-water regimes;

(h)

the handling and transportation of piles;

(i)

the effects of pile construction on neighboring buildings.

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(a)

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In considering the aspects listed above, the following items should receive attention: the spacing of the piles in pile groups;

(b)

displacement or vibration of adjacent structures due to pile installation;

(c)

the type of hammer or vibrator used;

(d)

the dynamic stresses in the pile during driving;

(e)

for those types of bored pile where a fluid is used inside the borehole, the need to keep the pressure of the fluid at a level to ensure that the borehole will not collapse and that hydraulic failure of the base will not occur;

(f)

cleaning of the base and sometimes the shaft of the borehole, especially under bentonite, to remove remolded materials;

(g)

local instability of a shaft during concreting, which may cause a soil inclusion within the pile;

(h)

ingress of soil or water into the section of a cast-in-situ pile and possible disturbance of wet concrete by the flow of water through it;

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the effect of unsaturated sand layers around a pile extracting water from the concrete;

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(i)

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(a)

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Section 04: Foundations and Retaining Structures Part 04: Deep Foundations

(j)

the retarding influence of chemicals in the soil;

(k)

soil compaction due to the driving of displacement piles;

(l)

soil disturbance due to the boring of a pile shaft.

4.11

AXIALLY LOADED PILES

4.11.1

Limit state design

1

The design shall demonstrate that exceeding the following limit states is sufficiently improbable: (a)

ultimate limit states of compressive or tensile resistance failure of a single pile;

(b)

ultimate limit states of compressive or tensile resistance failure of the pile foundation as a whole;

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(c)

ultimate limit states of collapse or severe damage to a supported structure caused by excessive displacement or differential displacements of the pile foundation;

(d)

serviceability limit states in the supported structure caused by displacement of the piles.

Normally the design should consider the margin of safety with respect to compressive or tensile resistance failure, which is the state in which the pile foundation displaces significantly downwards or upwards with negligible increase or decrease of resistance.

3

For piles in compression it is often difficult to define an ultimate limit state from a load settlement plot showing a continuous curvature. In these cases, settlement of the pile top equal to 10% of the pile base diameter should be adopted as the "failure" criterion.

4

For piles that undergo significant settlements, ultimate limit states may occur in supported structures before the resistance of the piles is fully mobilized. In these cases a cautious estimate of the possible range of the settlements shall be adopted in design.

4.11.2

Compressive Ground Resistance

1

To demonstrate that the pile foundation will support the design load with adequate safety against compressive failure, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations:

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2

as

Fc ≤ Rc

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Where

er

Fc: design axial compression load on a pile or a group of piles

In principle Fc should include the weight of the pile itself and Rc should include the overburden pressure of the soil at the foundation base. However these two items may be disregarded if they cancel approximately. They need not cancel if: (a)

downdrag is significant; the soil is very light,

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(b)

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2

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Rc: design value

(c) 3

the pile extends above the surface of the ground.

For piles in groups, two failure mechanisms shall be taken into account: (a)

compressive resistance failure of the piles individually;

(b)

compressive resistance failure of the piles and the soil contained between them acting as a block.

NOTE: The design resistance shall be taken as the lower value caused by these two

mechanisms. 4

The compressive resistance of the pile group acting as a block may be calculated by treating the block as a single pile of large diameter.

5

The stiffness and strength of the structure connecting the piles in the group shall be considered when deriving the design resistance of the foundation.

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If the piles support a stiff structure, advantage may be taken of the ability of the structure to redistribute load between the piles. A limit state will occur only if a significant numbe r of piles fail together; therefore a failure mode involving only one pile need not be considered.

7

If the piles support a flexible structure, it should be assumed that the compressive resistance of the weakest pile governs the occurrence of a limit state.

8

Special attention should be given to possible failure of edge piles caused by inclined or eccentric loads from the supported structure.

9

If the layer in which the piles bear overlies a layer of weak soil, the effect of the weak layer on the compressive resistance of the foundation shall be considered.

10

The strength of a zone of ground above and below the pile base shall be taken into account when calculating the pile base resistance.

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NOTE: This zone may extend several diameters above and below the pile base. Any weak ground in this zone has a relatively large influence on the base resistance.

Punching failure should be considered if weak ground is present at a depth of less than 4 times the base diameter below the base of the pile.

12

Where the pile base diameter exceeds the shaft diameter, the possible adverse effect shall be considered.

13

For open-ended driven tube or box-section piles with openings of more than 500 mm in any direction, and without special devices inside the pile to induce plugging, the base resistance should be limited to the smaller of:

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11

the shearing resistance between the soil plug and the inside face of the pile;

(b)

the base resistance derived using the cross-sectional area of the base.

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(a)

Ultimate compressive resistance from static load tests

1

The manner in which load tests are carried out shall be in accordance with 4.11.2 and shall be specified in the Geotechnical Design Report.

2

Trial piles to be tested in advance shall be installed in the same manner as the piles that will form the foundation and shall be founded in the same stratum.

3

If the diameter of the trial pile differs from that of the working piles, the possible difference in performance of piles of different diameters should be considered in assessing the compressive resistance to be adopted.

4

In the case of a very large diameter pile, it is often impractical to carry out a load test on a full size trial pile. Load tests on smaller diameter trial piles may be considered provided that:

m

4.11.3

(a)

the ratio of the trial pile diameter/working pile diameter is not less than 0,5;

(b)

the smaller diameter trial pile is fabricated and installed in the same way as the piles used for the foundation;

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the trial pile is instrumented in such a manner that the base and shaft resistance can be derived separately from the measurements.

NOTE: This approach should be used with caution for open-ended driven piles because of the influence of the diameter on the mobilisation of the compressive resistance of a soil plug in the pile. In the case of a pile foundation subjected to downdrag, the pile resistance at failure, or at a displacement that equals the criterion for the verification of the ultimate limit state determined from the load test results, shall be corrected. The correction shall be achieved by subtracting the measured, or the most unfavorable, positive shaft resistance in the compressible stratum and in the strata above, where negative skin friction develops, from the loads measured at the pile head.

6

During the load test of a pile subject to downdrag, positive shaft friction will develop along the total length of the pile. The maximum test load applied to the working pile should be in excess of the sum of the design external load plus twice the downdrag force.

7

When deriving the ultimate characteristic compressive resistance from values measured in one or several pile load tests, an allowance shall be made for the variability of the ground and the variability of the effect of pile installation.

8

The systematic and random components of the variations in the ground shall be recognized in the interpretation of pile load tests.

9

The records of the installation of the test pile(s) shall be checked and any deviation from the normal execution conditions shall be accounted for.

10

The characteristic compressive resistance of the ground may be derived from the characteristic values of the base resistance and of the shaft resistance in accordance with Eurocode1997-1.

4.11.4

Ultimate compressive resistance from ground test results

1

Methods for assessing the compressive resistance of a pile foundation from ground test results shall have been established from pile load tests and from comparable experience.

2

A model factor may be introduced as described as following to ensure that the predicted compressive resistance is sufficiently safe :

3

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5

(a)

the range of uncertainty in the results of the method of analysis;

(b)

any systematic errors known to be associated with the method of analysis

In assessing the validity of a model based on ground test results, the following items should be considered: (a)

soil type, including grading, mineralogy, angularity, density, pre-consolidation, compressibility and permeability;

(b)

method of installation of the pile, including method of boring or driving;

(c)

length, diameter, material and shape of the shaft and of the base of the pile (e.g. enlarged base);

(d)

method of ground testing.

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4.11.5

Ultimate compressive resistance from dynamic impact tests

1

Where a dynamic impact (hammer blow) pile test [measurement of strain and acceleration versus time during the impact event is used to assess the resistance of individual compression piles, the validity of the result shall have been demonstrated by previous evidence of acceptable performance in static load tests on the same pile type of similar length and cross-section and in similar ground conditions.

2

When using a dynamic impact load test, the driving resistance of the pile should be measured directly on the site in question.

.

NOTE A load test of this type can also include a process of signal matching to measured stress wave figures. Signal matching enables an approximate evaluation of shaft and base resistance of the pile as well as a simulation of its load-settlement behaviour. The impact energy shall be high enough to allow for an appropriate interpretation of the pile capacity at a correspondingly high enough strain level.

4

The design value of the compressive resistance of the pile could be calculated and verified according to Eurocode1997-1.

4.11.6

Ultimate compressive resistance by applying pile driving formulae

1

Pile driving formulae shall only be used if the stratification of the ground has been determined.

2

If pile driving formulae are used to assess the ultimate compressive resistance of individual piles in a foundation, the validity of the formulae shall have been demonstrated by previous experimental evidence of acceptable performance in static load tests on the same type of pile, of similar length and cross-section, and in similar ground conditions.

3

For end-bearing piles driven into non-cohesive soil, the design value of the compressive resistance shall be assessed by the same procedure as in 4.11.5.

4

When a pile driving formula is applied to verify the compression resistance of a pile, the pile driving test should have been carried out on at least 5 piles distributed at sufficient spacing in the piling area in order to check a suitable blow count for the final series of blows.

5

The penetration of the pile point for the final series of blows should be recorded for each pile.

4.11.7

Ultimate compressive resistance from wave equation analysis

1

Wave equation analysis shall only be used where stratification of the ground has been determined by borings and field tests.

2

Where wave equation analysis is used to assess the resistance of individual compression piles, the validity of the analysis shall have been demonstrated by previous evidence of acceptable performance in static load tests on the same pile type, of similar length and cross- section, and in similar ground conditions.

3

The design value of the compressive resistance derived from the results of wave equation analysis of a number of representative piles, shall be assessed by the same procedure as in 4.11.3.

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NOTE Wave equation analysis is based on a mathematical model of soil, pile and driving equipment without stress wave measurements on site. The method is usually applied to study hammer performance, dynamic soil parameters and stresses in the pile during driving. It is also, on the basis of the models, possible to determine the required driving resistance (blow count) that is usually related to the expected compressive resistance of the pile. Ground tensile resistance

1

The design of piles in tension shall be consistent with the design rules given in 4.11.2, where applicable. Design rules that are specific for foundations involving piles in tension are presented below.

2

To verify that the foundation will support the design load with adequate safety against a failure in tension, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations in accordance with Eurocode1997-1.

3

For isolated tensile piles or a group of tensile piles, the failure mechanism may be governed by the pull-out resistance of a cone of ground, especially for piles with an enlarged base or rock socket.

4

When considering the uplift of the block of ground containing the piles the shear resistance along the sides of the block may be added to the resisting forces.

5

Normally the block effect will govern the design tensile resistance if the distance between the piles is equal to or less than the square root of the product of the pile diameter and the pile penetration into the main resisting stratum.

6

The group effect, which may reduce the effective vertical stresses in the soil and hence the shaft resistances of individual piles in the group, shall be considered when assessing the tensile resistance of a group of piles.

7

The severe adverse effect of cyclic loading and reversals of load on the tensile resistance shall be considered.

8

Comparable experience based on pile load tests should be applied to appraise this effect.

4.11.9

Ultimate tensile resistance from pile load tests

1

Pile load tests to determine the ultimate tensile resistance of an isolated pile shall be carried out in accordance with 4.9.1 and with regard to 4.11.3.

2

The design tensile resistance could be calculated and verified according to Eurocode1997-1.

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4.11.8

4.11.10 Ultimate tensile resistance from ground test results 1

Methods for assessing the tensile resistance of a pile foundation from ground test results shall have been established from pile load tests and from comparable experience.

2

A model factor may be introduced as following to ensure that the predicted tensile resistance is sufficiently safe. (a)

the range of uncertainty in the results of the method of analysis;

(b)

any systematic errors known to be associated with the method of analys is

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The design value of tensile resistance of a pile could be calculated and verified according to Eurocode1997-1.

4.11.11 Vertical displacements of pile foundations 1

Vertical displacements under serviceability limit state conditions shall be assessed and checked.

2

When calculating the vertical displacements of a pile foundation, the uncertainties involved in the calculation model and in determining the relevant ground properties should be taken into account. Hence it should not be overlooked that in most cases calculations will provide only an approximate estimate of the displacements of the pile foundation.

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NOTE For piles bearing in medium-to-dense soils and for tension piles, the safety requirements for the ultimate limit state design are normally sufficient to prevent a serviceability limit state in the supported structure.

The occurrence of a serviceability limit state in the supported structure due to pile settlements shall be checked, taking into account downdrag, where probable.

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4.11.12 Pile foundations in compression

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NOTE When the pile toe is placed in a medium-dense or firm layer overlying rock or very hard soil, the partial safety factors for ultimate limit state conditions are normally sufficient to satisfy serviceability limit state conditions. Assessment of settlements shall include both the settlement of individual piles and the settlement due to group action.

3

The settlement analysis should include an estimate of the differential settlements that may occur.

4

When no load test results are available for an analysis of the interaction of the piled foundation with the superstructure, the load-settlement performance of individual piles should be assessed on empirically established safe assumptions.

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4.11.13 Pile foundations in tension The assessment of upward displacements shall be done and Particular attention should be paid to the elongation of the pile material.

2

When very severe criteria are set for the serviceability limit state, a separate check of the upward displacements shall be carried out.

4.12

TRANSVERSELY LOADED PILES

4.12.1

Design method

1

The design of piles subjected to transverse loading shall be consistent with the design rules given in 4.10, where applicable. Design rules specifically for foundations involving piles subjected to transverse loading are presented below.

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To demonstrate that a pile will support the design transverse load with adequate safety against failure, the following inequality shall be satisfied for all ultimate limit state load cases and load combinations: Ftr ≤ Rtr Where; Ftr: design value of the transverse load on a pile or a pile foundation Rtr : design resistance of transversally loaded pile One of the following failure mechanisms should be considered: for short piles, rotation or translation as a rigid body;

(b)

for long slender piles, bending failure of the pile, accompanied by local yielding and displacement of the soil near the top of the pile.

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The group effect shall be considered when assessing the resistance of transversely loaded piles.

5

It should be considered that a transverse load applied to a group of piles may result in a combination of compression, tension and transverse forces in the individual piles.

4.12.2

Transverse load resistance from pile load tests

1

Transverse pile load tests shall be carried out in accordance with 4.9.6.

2

Contrary to the load test procedure described in 4.9 tests on transversely loaded piles need not normally be continued to a state of failure. The magnitude and line of action of the test load should simulate the design loading of the pile.

3

An allowance shall be made for the variability of the ground, particularly over the top few meters of the pile, when choosing the number of piles for testing and when deriving the design transverse resistance from load test results.

4

Records of the installation of the test pile(s) should be checked, and any deviation from the normal construction conditions should be accounted for in the interpretation of the pile load test results. For pile groups, the effects of interaction and head fixity should be accounted for when deriving the transverse resistance from the results of load tests on individual test piles.

4.12.3

Transverse load resistance from ground test results and pile strength parameters

1

The transverse resistance of a pile or pile group shall be calculated using a compatible set of structural effects of actions, ground reactions and displacements.

2

The analysis of a transversely loaded pile shall include the possibility of structural failure of the pile in the ground.

3

The calculation of the transverse resistance of a long slender pile may be carried out using the theory of a beam loaded at the top and supported by a deformable medium characterized by a horizontal modulus of subgrade reaction.

4

The degree of freedom of rotation of the piles at the connection with the structure shall be taken into account when assessing the foundation’s transverse resistance.

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4.12.4

Transverse displacement

1

The assessment of the transverse displacement of a pile foundation shall take into account: the stiffness of the ground and its variation with strain level;

(b)

the flexural stiffness of the individual piles;

(c)

the moment fixity of the piles at the connection with the structure;

(d)

the group effect;

(e)

the effect of load reversals or of cyclic loading

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END OF PART

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RETAINING STRUCTURES ---------------------------------------------------------------------------------- 2

5.1

GENERAL---------------------------------------------------------------------------------------------------------- 2

5.2

LIMIT STATES ---------------------------------------------------------------------------------------------------- 2

5.2.2 5.2.3

Ultimate Limit State ---------------------------------------------------------------------------------------------- 2 Serviceability Limit State ---------------------------------------------------------------------------------------- 3

5.3

ACTIONS AND GEOMETRICAL DATA -------------------------------------------------------------------- 3

5.3.1 5.3.2 5.3.3

Actions -------------------------------------------------------------------------------------------------------------- 3 Geometrical data ------------------------------------------------------------------------------------------------- 4 Design Situations ------------------------------------------------------------------------------------------------- 4

5.4

DESIGN AND CONSTRUCTION CONSIDERATIONS ------------------------------------------------- 5

5.5

DETERMINATION OF EARTH PRESSURES ------------------------------------------------------------ 6

5.5.1 5.5.2 5.5.3 5.5.4 5.5.5

General ------------------------------------------------------------------------------------------------------------- 6 At rest values of earth pressure------------------------------------------------------------------------------- 7 Limiting values of earth pressure ----------------------------------------------------------------------------- 7 Intermediate values of earth pressure ----------------------------------------------------------------------- 7 Compaction effects ---------------------------------------------------------------------------------------------- 7

5.6

WATER PRESSURES ------------------------------------------------------------------------------------------ 8

5.7

ULTIMATE LIMIT STATE DESIGN -------------------------------------------------------------------------- 8

5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 5.7.6 5.7.7

General ------------------------------------------------------------------------------------------------------------- 8 Overall stability ---------------------------------------------------------------------------------------------------- 8 Foundation failure of gravity walls ---------------------------------------------------------------------------- 8 Rotational failure of embedded walls ------------------------------------------------------------------------ 8 Vertical failure of embedded walls --------------------------------------------------------------------------- 9 Structural design of retaining structures -------------------------------------------------------------------- 9 Failure by pull-out of anchorages ----------------------------------------------------------------------------- 9

5.8

SERVICEABILITY LIMIT STATE DESIGN ----------------------------------------------------------------- 9

5.8.1 5.8.2

General ------------------------------------------------------------------------------------------------------------- 9 Displacements ---------------------------------------------------------------------------------------------------- 9

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5

RETAINING STRUCTURES

5.1

GENERAL

1

The provisions of this Part 5 apply to retaining structures in general. These are structures used to retain ground comprising soil, rock or backfill and water and this at an angle steeper than the angle they would normally adopt without the presence of those structures. Common retaining structures used within the state of Qatar taking into account the prevailing geologic conditions are: Sheet Piles

(b)

Bored and Cast in Place Concrete Piles

Secant Piles

(c)

Diaphragm Walls

(d)

Composite Shoring Systems

(e)

Concrete Retaining Walls

(ii)

Counter Fort Retaining Wall

(iii)

Gravity Retaining Wall

(iv)

Buttressed Retaining Wall

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Cantilever Retaining Wall

Reinforced Soil Retaining Structures Geogrid and Geotextile Reinforced Earth Systems

(ii)

Galvanized Strips Reinforced Earth System

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Soil and Rock Nailing Systems

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Contiguous Piles

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(a)

This revision of Section 4 – Part 5 is considered preliminary and shall be reviewed and amended as needed in the next revision to elaborate on various subjects not covered herein.

3

This revision of Section 4 – Part 5 is based generally on “EN1997-1:2004+A1:2013” Eurocode 7.

4

Section 4 – Part 5 will cover at this stage the general design aspects knowing that the construction procedures shall be added in future revisions of this Section. Hence, at this stage, the construction related subjects of the retaining structures will follow relevant Parts of the QCS.

5.2

LIMIT STATES

1

During the design of retaining structures the following typical limit states should be considered:

5.2.2

Ultimate Limit State

1

Loss of overall stability: it should be demonstrated that an overall stability failure is unlikely.

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Foundation failure of retaining structures with footings: it should be demonstrated that the foundation pressures (lateral and vertical) do not exceed neither the ground allowable bearing capacity nor the sliding resistance. Uplift pressures under the foundation due to water seepage should also be included in the analysis.

3

Foundation failure of gravity walls, which is the loss of equilibrium of the wall considered as a rigid body.

4

Failure of embedded walls by rotation or horizontal translation or by lack of vertical equilibrium.

5

Failure of a structural element such as a wall, anchorage, wale or strut, including failure of the connection between those elements.

6

Failure of a retaining structure by hydraulic heave, internal erosion or piping, unacceptable leakage of water, or transport of soil particles through or under the wall caused by excessive hydraulic gradients.

5.2.3

Serviceability Limit State

1

Unacceptable movement of the retaining structure, which may affect the appearance or functionality of the structure itself, or other neighbouring structures or utilities influenced by the movement.

2

Unacceptable change in the groundwater regime.

5.3

ACTIONS AND GEOMETRICAL DATA

5.3.1

Actions

1

Generally, the forces exerted on retaining structure with values assumed known at the beginning of the calculation are considered as 'actions', while forces with initially unknown values, to be determined by the interaction of the retaining structure with support elements (ground springs, anchorages, struts, etc.), are considered as 'reactions'. The following actions are to be taken into account: Weight of backfill material

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(b)

Surcharges

(c)

Weight of water

(d)

Wave forces for marine projects

(e)

Seepage forces

(f)

Collision forces

(g)

Temperature effects

(h)

Forces from propping elements (i.e. post-tensioned anchors)

(i)

Siesmic related effects

The above actions should result in the determination of various earth pressures acting on the retaining structure.

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5.3.2

Geometrical data

1

This paragraph covers the uncertainties in the geometrical data namely excavation and water levels. In general, small variations in geometrical data are considered to be covered by the safety factors included in the calculations. However, since the design of retaining structures is sensitive to ground and water levels, special requirements are included in this paragraph, mainly for unforeseen over-dig in front of the wall and groundwater levels change on both sides of the wall.

2

Unforeseen over-dig in front of the wall

Equal to 10% of the wall height above excavation level (up to a maximum of 0.5 m), for cantilever walls;

(b)

Equal to 10% of the distance between the lowest support and the excavation level (up to a maximum of 0.5 m), for supported walls.

Groundwater levels in front of and behind the wall

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The selection of the levels of the phreatic surfaces in front of and behind the wall must consider long-term variations of the groundwater regime and/or the ground permeability, the presence of perched or artesian aquifers and the possibility that drainage behind the wall may cease to function with time. Design Situations

1

The following conditions shall be considered during the design of retaining structures: Anticipated variations in soil properties

(b)

Variations in actions and the ways they are combined

(c)

Excavation, scour or erosion in front of the retaining structure The effect of compaction of the backfill behind the retaining structure

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5.3.3

(e)

The effect of anticipated future structures and surcharge loads/unloads

(f)

Anticipated ground movements

(g)

Inclination of the wall to the vertical

(h)

Variations in groundwater table and the seepage forces in the ground

(i)

Horizontal as well as vertical equilibrium for the entire retaining structure

(j)

The shear strength and weight density of the ground

(k)

The rigidity of the wall and the supporting system

(l)

The wall roughness

(m)

Seismic effect on the various forces

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5.4

DESIGN AND CONSTRUCTION CONSIDERATIONS

1

The design of retaining structures requires consideration of all relevant Ultimate Service States and Service Limit States.

2

For retaining structures without strict serviceability requirements, the geometry is usually determined by Ultimate Limit State design calculations and checked by Service Limit State calculations (if relevant). For the retaining structures with strict serviceability requirements, the Service Limit State requirements often govern the design.

3

The design and construction considerations should cover the following: Demonstrate that vertical equilibrium can be achieved for the assumed pressure distributions and actions on the wall.

(b)

Verification of vertical equilibrium may be achieved by reducing the wall friction parameters.

(c)

Retaining walls should be designed in such a way that there are visible signs of the approach of an ultimate limit state. The design should prevent brittle failure of the structure, e.g. sudden collapse without conspicuous preliminary deformations.

(d)

A critical limit state should be considered to occur if the wall has displaced enough to cause damage to nearby structures or services. Although collapse of the wall may not be imminent, the degree of damage may considerably exceed a serviceability limit state in the supported structure.

(e)

The design methods and partial factor values recommended by “EN19971:2004+A1:2013” are usually sufficient to prevent the occurrence of ultimate limit states in nearby structures, provided that the soils involved are of at least medium density or firm consistency and adequate construction methods and sequences are adopted. Special care should be taken, however, with some highly over-consolidated clay deposits in which large at rest horizontal stresses may induce substantial movements in a wide area around excavations.

(f)

The complexity of the interaction between the ground and the retaining structure sometimes makes it difficult to design a retaining structure in detail before the actual execution starts. In this case, use of the observational method for the design should be considered. The observational method consists of setting criteria enabling monitoring during construction, allowing necessary corrective actions to be taken to rectify the design. Hence, the following requirements shall be set before construction:

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(g)

(i)

Acceptable limits of behaviour

(ii)

The range of potential behaviour shall be analysed showing acceptable probability that the actual behaviour will be within the acceptable limits

(iii)

A plan of monitoring shall be established (including necessary instruments and procedures) enabling the comparison of the actual behaviour to the acceptable limits. The monitoring shall allow early detection of nonconformities, allowing enough time for corrective actions to be taken successfully.

(iv)

A list of contingency actions shall be established which could be used if the actual observed behaviour is outside of the acceptable limits.

The effects of constructing the wall, including: (i)

The provision of temporary support to the sides of excavations;

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(ii)

The changes of in situ stresses and resulting ground movements caused both by the wall excavation and its construction;

(iii)

Disturbance of the ground due to driving or boring operations;

(iv)

Provision of access for construction;

The required degree of water tightness of the finished wall;

(i)

The practicability of constructing the wall to reach a stratum of low permeability, so forming a water cut-off. The resulting equilibrium ground-water flow problem shall be assessed;

(j)

The practicability of forming ground anchorages in adjacent ground;

(k)

The practicability of excavating between any propping of retaining walls;

(l)

The ability of the wall to carry vertical load;

(m)

The ductility of structural components;

(n)

Access for maintenance of the wall and any associated drainage measures;

(o)

The appearance and durability of the wall and any anchorages;

(p)

For sheet piling, the need for a section stiff enough to be driven to the design penetration without loss of interlock;

(q)

The stability of borings or slurry trench panels while they are open;

(r)

For fill, the nature of materials available and the means used to compact them adjacent to the wall.

(s)

Drainage systems

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(ii)

It shall be demonstrated both by comparable experience and by assessment of any water discharge that the drainage system will operate adequately without maintenance.

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(i)

The quantities, pressures and eventual chemical content of any water discharge should be taken into account.

5.5

DETERMINATION OF EARTH PRESSURES

5.5.1

General

1

The Determination of the earth pressures shall take into account the acceptable mode and amount of any movement and strain, which may occur at the limit state under consideration.

2

In the following context the words "earth pressure" should also be used for the total earth pressure from soft and weathered rocks and should include the pressure of ground-water.

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3

Calculations of the magnitudes of earth pressures and directions of forces resulting from them shall take account of the issues highlighted under paragraph “5.3.3”.

4

The amount of mobilized wall friction and adhesion should be considered as a function of: The strength parameters of the ground

(b)

The friction properties of the wall-ground interface

(c)

The direction and amount of movement of the wall relative to the ground

(d)

The ability of the wall to support any vertical forces resulting from wall friction and adhesion

A concrete wall or steel sheet pile wall supporting sand or gravel may be assumed to have a design wall ground interface parameter  d  k. cv ;d . k should not exceed 2/3 for precast

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concrete or steel sheet piling. For concrete cast against soil, a value of k = 1.0 may be assumed. For a steel sheet pile in clay under undrained conditions immediately after driving, no adhesive or frictional resistance should be assumed. Increases in these values may take place over a period of time. In the case of structures retaining rock masses, calculations of the ground pressures shall take into account the effects of discontinuities, with particular attention to their orientation, spacing, aperture, roughness and the mechanical characteristics of any joint filling material.

7

Account shall be taken of any swelling potential of the ground when calculating the pressures on the retaining structure.

5.5.2

At rest values of earth pressure

1

When no movement of the wall relative to the ground takes place, the earth pressure shall be calculated from the at rest state of stress. The determination of the at-rest state shall take into account the stress history of the ground.

5.5.3

Limiting values of earth pressure

1

Limiting values of earth pressures shall be determined taking into account the relative movement of the soil and the wall at failure and the corresponding shape of the failure surface.

5.5.4

Intermediate values of earth pressure

1

Intermediate values of earth pressure occur if the wall movements are insufficient to mobilize the limiting values. The determination of the intermediate values of earth pressure shall take into account the amount of wall movement and its direction relative to the ground.

2

The intermediate values of earth pressures may be calculated using, for example, various empirical rules, spring constant methods or finite element methods.

5.5.5

Compaction effects

1

The determination of earth pressures acting behind the wall shall take into account the additional pressures generated by any placing of backfill and the procedures adopted for its compaction.

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WATER PRESSURES

1

Determination of characteristic and design water pressures shall take account of water levels both above and in the ground.

2

When checking the ultimate and serviceability limit water pressures shall be accounted for in the combinations of actions considering the possible risks of flooding or change in groundwater levels from either sides of the retaining structure.

3

For structures retaining earth of medium or low permeability (silts and clays), water pressures should normally be assumed to act behind the wall. Unless a reliable drainage system is installed, or infiltration is prevented, the values of water pressures should normally correspond to a water table at the surface of the retained material.

4

Where sudden changes in a free water level may occur, both the non-steady condition occurring immediately after the change and the steady condition shall be examined.

5

Where no special drainage or flow prevention measures are taken, the possible effects of water-filled tension or shrinkage cracks shall be considered.

5.7

ULTIMATE LIMIT STATE DESIGN

5.7.1

General

1

The design of retaining structures shall be checked at the ultimate limit state for the design situations appropriate to that state, as specified in 5.3.3, using the design actions or action effects and design resistances.

2

All relevant limit modes shall be considered. These will include, as a minimum, limit modes of the types illustrated in Figures 5.1 to 5.6 for the most commonly used retaining structures.

3

Calculations for ultimate limit states shall establish that equilibrium can be achieved using the design actions or effects of actions and the design strengths or resistances. Compatibility of deformations shall be considered in assessing design strengths or resistances.

5.7.2

Overall stability

1

Principles and calculations should be used as appropriate to demonstrate that an overall stability failure will not occur and that the corresponding deformations are sufficiently small taking into account progressive failure and liquefaction into account as relevant.

5.7.3

Foundation failure of gravity walls

1

The principles of foundation design shall be used as appropriate to demonstrate that a foundation failure is sufficiently remote and that deformations will be acceptable. Both bearing resistance and sliding shall be considered. Failure modes shown in Figure 5.2 should be verified as a minimum.

5.7.4

Rotational failure of embedded walls

1

It shall be demonstrated by equilibrium calculations that embedded walls have sufficient penetration into the ground to prevent rotational failure. As a minimum, limit modes of the types illustrated in Figure 5.3 should be considered.

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5.6

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The design magnitude and direction of shear stress between the soil and the wall shall be consistent with the relative vertical displacement, which would occur in the design situation.

5.7.5

Vertical failure of embedded walls

1

It shall be demonstrated that vertical equilibrium can be achieved using the design soil strengths or resistances and design vertical forces on the wall. As a minimum, the limit mode of the type illustrated in Figure 5.4 should be considered.

2

Where downward movement of the wall is considered, upper design values shall be used in the calculation of pre-stressing forces, such as those from ground anchorages, which have a vertical downward component. The design magnitude and direction of shear stress between the soil and the wall shall be consistent with the check for vertical and rotational equilibrium. If the wall acts as the foundation for a structure, vertical equilibrium shall be checked using the principles of Pile Foundations Design.

5.7.6

Structural design of retaining structures

1

Retaining structures, including their supporting structural elements such as anchorages and props, shall be verified against structural failure in accordance with EN1997-1:2004+A1:2013 “2.4 Geotechnical Design by Calculation” and EN1992, EN1993, EN1995 and EN1996. As a minimum, limit modes of the types illustrated in Figure 5.5 should be considered.

5.7.7

Failure by pull-out of anchorages

1

It shall be demonstrated that equilibrium can be achieved without pull-out failure of ground anchorages. Anchors shall be designed in accordance with Anchorage Design procedures with minimum the limit modes of the types illustrated in Figure 5.6 (a, b) should be considered. For dead-man anchors, the failure mode illustrated in Figure 5.6 (c) should also be considered.

5.8

SERVICEABILITY LIMIT STATE DESIGN

5.8.1

General

1

The design of retaining structures shall be checked at the serviceability limit state using the appropriate design situations as specified in 5.3.3. The assessment of design values of earth pressures should take account of the initial stress, stiffness and strength of the ground and the stiffness of the structural elements.

2

The design values of earth pressures should be derived taking account of the allowable deformation of the structure at its serviceability limit state. These pressures need not necessarily be limiting values.

5.8.2

Displacements

1

Limiting values for the allowable displacements of walls and the ground adjacent to them shall be established for a particular deformation is the value at which a serviceability limit state, such as unacceptable cracking or displacement of adjacent structures or utilities, is deemed to occur. This limiting value shall be agreed during the design, taking into account the tolerance to displacements of supported structures and services.

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2

If the initial cautious estimate of displacement exceeds the limiting values, the design shall be justified by a more detailed investigation including displacement calculations.

3

It shall be considered to what extent variable actions, such as vibrations caused by traffic loads behind the retaining wall, contribute to the wall displacement.

4

Displacement calculations should also be considered in the following cases: (a)

where the wall retains more than 6m of cohesive soil of low plasticity,

(b)

where the wall retains more than 3m of soils of high plasticity;

(c)

where the wall is supported by soft clay within its height or beneath its base.

Displacement calculations shall take into account the stiffness of the ground and structural elements and the sequence of construction.

6

The effect of vibrations on displacements shall be considered with regard to the following:

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Foundations for structures subjected to vibrations or to vibrating loads shall be designed to ensure that vibrations will not cause excessive settlements.

(b)

Precautions should be taken to ensure that resonance will not occur between the frequency of the dynamic load and a critical frequency in the foundation-ground system, and to ensure that liquefaction will not occur in the ground.

(c)

Vibrations caused by earthquakes shall be considered using the guidelines of the designated section of the QCS.

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(a)

Figure 5.1 – Examples of Limit Modes for Overall Stability of Retaining Structures (EN 1997-1:2004+A1:2013)

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Figure 5.2 – Examples of Limit Modes for Foundation Failures of Gravity Walls (EN 1997-1:2004+A1:2013)

Figure 5.3 – Examples of Limit Modes for Rotational Failures of Embedded Walls (EN 1997-1:2004+A1:2013)

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Figure 5.4 – Example of a Limit Mode for Vertical Failure of Embedded Walls (EN 1997-1:2004+A1:2013)

Figure 5.5 – Examples of Limit Modes for Structural Failure of Retaining Structures (EN 1997-1:2004+A1:2013)

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Figure 5.6 – Examples of Limit Modes for Failure by Pull-out of Anchoes (EN 1997-1:2004+A1:2013)

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END OF PART

QCS 2014

Section 05: Concrete Part 01: General

Page 1

GENERAL------------------------------------------------------------------------------------------------------------ 2

1.1 1.1.1 1.1.2 1.1.3 1.1.4

INTRODUCTION --------------------------------------------------------------------------------------------------- 2 Scope ----------------------------------------------------------------------------------------------------------------- 2 References----------------------------------------------------------------------------------------------------------- 2 Definitions ------------------------------------------------------------------------------------------------------------ 3 Approved Products ------------------------------------------------------------------------------------------------ 4

1.2 1.2.1 1.2.2 1.2.3 1.2.4

IMPLEMENTATION ----------------------------------------------------------------------------------------------- 4 Approved Installers ------------------------------------------------------------------------------------------------ 4 Field Quality Control ----------------------------------------------------------------------------------------------- 4 Rejected materials ------------------------------------------------------------------------------------------------- 5 Records --------------------------------------------------------------------------------------------------------------- 5

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Section 05: Concrete Part 01: General

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GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section includes the requirements for concrete work for pipelines, roadworks, runways, structures, water retaining structures, foundations and bases for structures and equipment.

2

This Part includes relevant standards, definitions, abbreviations, and requirements for testing facilities, rejected materials, and record keeping.

3

Related Sections are as follows:

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Aggregates Cementitious Materials Water Admixtures Property Requirements Concrete Plants Transportation and Placing of Concrete Formwork Curing Reinforcement Construction Joints Inspection and Testing of Hardened Concrete Protective Coatings to Concrete Hot Weather Concrete Miscellaneous Precast Concrete Prestressed Concrete Water Retaining Structures

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This Section: Part 2, Part 3, Part 4, Part 5, Part 6, Part 7, Part 8, Part 9, Part 10, Part 11, Part 12, Part 13, Part 14, Part 15, Part 16, Part 17, Part 18, Part 19,

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Section 1, Section 2, Section 4, Section 6, Section 8, Section 9,

General Quality Assurance and Quality Control Foundations and Retaining Structures Roadworks Drainage Works Mechanical and Electrical Equipment

1.1.2

References

1

The following standards are referred to in this Part: ASTM C31 ..................Standard Practice for Making and Curing Concrete Test Specimens in the Field ASTM C39 ..................Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens ASTM C143 ................Standard Test Method for Slump of Hydraulic-Cement C Concrete ASTM C1064 ..............Standard Test Method for Temperature of Freshly Mixed HydraulicCement Concrete

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Section 05: Concrete Part 01: General

Page 3

BS 6100, ....................Glossary of Building and civil engineering terms BS EN 932-1 ..............Tests for general properties of aggregates. Methods for sampling BS EN 932-2 ..............Tests for general properties of aggregates. Methods for reducing laboratory samples BS EN 12350-1 ..........Method of sampling fresh concrete in site BS EN 12350-2 ..........Testing fresh concrete. Slump-test BS EN 12390-1 ..........Shape, dimensions and other requirements for specimens and moulds BS EN 12390-2 .......... Making and curing specimens for strength tests GSO ISO 1920-1 ........Testing of concrete —Part 1: Sampling of fresh concrete GSO ISO 1920-2 ........Testing of concrete – Part 2: Properties of fresh concrete GSO ISO 1920-3 ........Testing of concrete – Part 3: Making and curing test specimens Definitions

1

Definitions used in this Section.

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1.1.3

The following are terms and abbreviations used:

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degree Celsius calorie centimetre day Characteristic compressive strength of concrete determined by testing cylinders Compressive strength of concrete determined by testing cylinders Characteristic compressive strength of concrete determined by testing cubes Compressive strength of concrete determined by testing cubes Mean compressive strength of concrete Mean compressive strength of concrete at the age of (j) days ground granulated blast furnace slag guaranteed ultimate tensile strength hour kilogram kilojoule kilonewton litre metre square metre cubic metre milligram minute millimetre square millimetre months mega Pascal kilo Pascal moderate sulphate resisting Portland cement ordinary Portland cement pulverised fuel ash polyvinylchloride second silica fume sulphate resisting Portland cement

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C cal cm d fck,cyl fc,cyl fck,cube fc,cube fcm fcm,j GGBS GUTS h kg kJ kN l m 2 m 3 m mg min mm 2 mm months MPa kPa MSRPC OPC PFA PVC s SF SRPC

QCS 2014

ton ppm

1000 kg part per million

micron

10

µm

10 meter

Page 4

-6 -6

Reference to a technical society, institution, association or governmental authority is made in accordance with the following abbreviations.

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American Association of State Highway and Transportation Officials American Concrete Institute American Society for Testing and Materials American Welding Society British Standard British Standard Code of Practice British Standards Institution Cement and Concrete Association Construction Industry Research and Information Association Concrete Reinforcing Steel Institute Concrete Society Deutsches Institut fur Normung e.V. Euro Norm Federal Highway Authority GCC Standardization Organization Institution of Civil Engineers International Organization for Standardization Prestressed Concrete Institute Qatar Construction Specifications Qatar Standards United Kingdom Department for Transport

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AASHTO ACI ASTM AWS BS BSCP BSI C & CA CIRIA CRSI CS DIN EN FHWA GSO ICE ISO PCI QCS QS UK DfT Products

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Section 05: Concrete Part 01: General

Approved Products

1

The contract specific documentation may identify approved products and approved or prequalified manufacturers and suppliers of products used in concrete work.

1.2

IMPLEMENTATION

1.2.1

Approved Installers

1

The contract specific documentation may identify approved or prequalified providers of concrete construction services.

1.2.2

Field Quality Control

1

The Contractor shall carry out the test procedures required by this Section and any other tests and test procedures as directed by the Engineer from time to time. The test procedures shall be carried out using the facilities of an approved independent testing laboratory.

2

Supply, storage, sampling and testing of all materials shall be the responsibility of the Contractor, unless the Contract specifies otherwise.

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1.1.4

QCS 2014

Section 05: Concrete Part 01: General

Page 5

The Engineer may also require the Contractor to take samples of materials and deliver them to the Central Materials Laboratory for additional tests to be carried out by the Employer. Sampling procedures shall be in accordance with BS EN 932 or relevant ASTM Standards, and sample sizes shall conform to the requirements shown in Table 1.1.

4

The minimum equipment required for testing on Site is given in Table 1.2. This equipment shall be maintained on Site at all times during concreting operations together with the necessary scoops, buckets, sample containers, and other items required for sampling. The cube curing tank shall be located in an air-conditioned area as stated in part 06.

1.2.3

Rejected materials

1

Any material rejected by the Engineer, in particular cement which has deteriorated or aggregates which have segregated or become contaminated, shall be immediately removed from the Site.

1.2.4

Records

1

The Contractor shall maintain on the Site full records of all work carried out accurately related to the location of the work on site, which shall include:

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formwork props were fully removed all cubes and other tests

(c)

daily maximum and minimum temperatures.

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(b)

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One copy of all test results shall be sent to the Engineer immediately upon completion of the tests

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Table 1.1 Sampling Procedure and Minimum Sample Sizes for Central Materials Laboratory

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Cement

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Material

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the time and date when all concrete was poured, formwork removed and when

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(a)

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Aggregate

Reinforcement Water

Test

Min. Sample

Full range of tests

Composite sample of 7 kg taken from at least 12 bags

Full range of tests

200 kg

Sieve analysis Chemical analysis Soundness test Water absorption Particle density Flakiness index Fines content LA Abrasion value

50 kg

Tensile test

500 mm

Bend test

300 mm

Full range of tests

5 litres

QCS 2014

Section 05: Concrete Part 01: General

Page 6

Table 1.2 Minimum Testing Equipment for Each Site* Test

Equipment to be Provided

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ASTM C1064

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Cube curing BS EN 12390-2 or GSO ISO 1920-3 or ASTM C39

Hessian or sacking, impervious sheet Maximum/minimum thermometer Waterproof marking crayon/paint or equivalent Curing tank (in air conditioned room) Supply of packing materials for sending cubes to commercial laboratory Concrete thermometer

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Cube making BS EN 12390-1 and BS EN 12350-1:2000 or GSO ISO 1920-1 and GSO ISO 1920-3 or ASTM C31 and C39

Slump cone with base plate Compacting rod, circular cross-section and round ends Remixing container, 300 mm ruler, moist cloth Scoop and shovel Timer 100 or 150 mm cubical or cylindrical 1 moulds Compacting rod or bar Set of tools for assembling and stripping moulds Remixing container Trowel, Scoop, Shovel and Mallet Mould release agent in closed container with brush

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Slump test BS EN 12350-2 or GSO ISO 1920-2 or ASTM C143

Minimum Number Required 1 1 1 1 1

6 1 1 1 lot 1 1 1 Lot 1

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1 - The use of 100 mm cube and cylinder moulds are permitted when the nominal maximum aggregate size is not greater than 20mm

END OF PART

QCS 2014

Section 05: Concrete Part 10: Curing

Page 1

CURING .................................................................................................................. 2

10.1 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 2 Storage 2

10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8 10.2.9 10.2.10 10.2.11 10.2.12

CURING .................................................................................................................. 2 General 2 Water for Curing 3 General Requirements 3 Curing of Formed Surfaces 4 Curing of Unformed Surfaces 4 Moisture Curing 4 Moisture Retaining Cover Curing 4 Liquid Membrane Curing 5 Steam Curing 5 Pavements and other slab on ground 5 Buildings, bridges, and other structures 5 Mass concrete 6

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QCS 2014

Section 05: Concrete Part 10: Curing

Page 2

10

CURING

10.1

GENERAL

10.1.1

Scope

1

This part covers the requirements for the curing of concrete.

2

Related Sections and Parts are as follows:

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References AASHTO M 148.74, ...Liquid Membrane Curing

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ACI 308 ..................... Guide to Concrete Curing

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10.1.2

.

This Section Part 1, ............ General Part 4, ............ Water Part 6, ............ Property Requirements Part 15, ........... Hot Weather Concreting Part 16, ........... Miscellaneous.

ASTM C 309, .............. Specification for Liquid Membrane-forming Compounds for Curing Concrete

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BS 7542,..................... Method of test for curing compounds for concrete. Quality management systems -- Requirements

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ISO 9001: 2008 Submittals

1

The Contractor shall submit to the Engineer the proposed method of curing for approval.

10.1.4

Quality Assurance

1

The Contractor shall submit to the Engineer for approval the details of proposed curing media, if any. Details shall include chemical tests for the product in accordance with BS 7542 and details of quality assurance procedures, including ISO 9001 certificates if held.

10.1.5

Storage

1

Chemical curing compounds shall be stored in accordance with manufacturer's recommendations.

10.2

CURING

10.2.1

General

1

The Contractor shall ensure that curing is provided for 24 hours per day including holidays and that all related necessary plant and labour resources are also available.

2

Special attention shall be given to the curing of vertical and overhanging surfaces to ensure satisfactory curing.

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10.1.3

QCS 2014

Section 05: Concrete Part 10: Curing

Page 3

The Contractor shall adopt curing measures that preclude the possibility of thermal shock to the concrete during curing. This may be achieved by ensuring that the temperature of the water used for curing does not differ from that of the concrete by more than 15 C.

4

Curing shall continue for at least 7 days and until it attains an in-place compressive strength of the concrete of at least 70% of the specified compressive or flexural strength, whichever period is longer. Curing shall not stop unless otherwise approved by the Engineer.

5

When low W/cm is used, the concrete shall be preferably cured by water.

10.2.2

Water for Curing

1

Water used for any curing purposes shall conform to the requirements of Part 4 of this Section.

10.2.3

General Requirements

1

Freshly placed concrete shall be protected from sun, wind, rain, exposure and excessive drying out.

2

All concrete shall be cured for a period of time required to obtain the full specified strength, but not less than seven consecutive days. The method of curing shall be by water for the first seven days and by water or membrane until the concrete has reached the full specified strength.

3

For mixtures with a low to zero bleeding rate, or in the case of aggressively evaporative environments, or both, the curing shall start at early anytime between placement and final finishing of the concrete. The curing shall be by reducing the moisture loss from surface using fogging systems and the use of evaporation reducers such as monomolecular water curing compound.

4

Exposed surfaces shall be protected from air blown contamination until 28 d after the concrete is placed.

5

The method of curing shall ensure that sufficient moisture is present to complete the hydration of the cement, and shall be to the approval of the Engineer. The method of curing shall not:

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(a)

disfigure permanently exposed surfaces

(b)

affect bonding of subsequent coatings

(c)

increase the temperature of the concrete.

6

During the curing period, exposed concrete surface shall be protected from the direct rays of the sun.

7

When liquid membrane is used to cure the concrete, it shall not be applied if bleeding water is present on the surface of the concrete.

8

The applied film of the liquid membrane shall be continuous and protected from rain and any damages for at least 14 days.

QCS 2014

Section 05: Concrete Part 10: Curing

Page 4

Curing of Formed Surfaces

1

Formed surfaces, including the underside of beams, girders, supported slabs and the like, by moist curing with the forms in place for the full curing period, or until the forms are removed.

2

When the forms are stripped, curing shall continue by any approved method.

3

When liquid membrane curing is used, it shall be applied immediately after de-shuttering. In such cases the concrete surface shall be prepared prior to the application of the membrane as recommended by the manufacturer.

4

Water curing is not required when liquid membrane is used.

10.2.5

Curing of Unformed Surfaces

1

Unformed surfaces shall be protected as soon as possible after the concrete has been placed by polythene sheeting. When sufficiently hard, hessian or other absorbent material shall be placed on the concrete surface and shall be kept wet for the required period. The hessian shall be overlaid with a sheet of 1000 gauge polythene to assist in the retention of water. Alternatively a curing method approved by the Engineer may be used.

2

Once the concrete is sufficiently hard, the top exposed surface of walls, columns and beams shall be water cured and covered with wet hessian for the required curing period.

10.2.6

Moisture Curing

1

Moisture curing shall be performed by :

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10.2.4

covering the surface of the concrete with water and keeping it continuously wet

(b)

continuous use of fine fog water sprays

(c)

covering the surface with a saturated absorptive cover and keeping it continuously wet.

(d)

Burlap, cotton mats, and other absorbent materials can be used to hold water on horizontal or vertical surfaces.

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Wet straw or hay can be used for wet-curing small areas, but there is the danger that wind might displace it unless it is held down with screen wire, burlap, or other means

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(e)

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(a)

2

Where method (a) is employed, the bunds used shall not be made from fill from excavations or any other areas where there is the possibility of chloride contamination.

10.2.7

Moisture Retaining Cover Curing

1

The concrete surface shall be covered with a suitable absorptive covering, such as wet hessian.

2

The absorptive covering shall be overlaid with a 1000 gauge polythene sheet.

3

The cover shall be in the widest practical widths and shall have 100 mm side and end laps.

4

Any penetrations or tear in the covering shall be shall be repaired with the same material and waterproof tape.

QCS 2014

Section 05: Concrete Part 10: Curing

Page 5

Liquid Membrane Curing

1

Liquid membrane curing shall be in accordance with the requirements of BS 7542, ASTM C 309 or C1315 when tested at the rate of coverage use on the job.

2

ASTM C 156 shall be used as a test method to evaluate water-retention capability of liquid membrane forming compounds. ASTM C 1151 provides an alternative laboratory test for determining the efficiency of liquid membrane-forming compounds.

3

Membrane forming curing compounds shall be applied in accordance with the manufacturer's recommendations immediately after any water sheen which may develop after finishing has disappeared from the surface and within 2 h of stripping formwork on formed surfaces.

4

Membrane forming curing compounds shall not be used on surfaces against which additional concrete or other material is to be bonded unless:

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10.2.8

it is proven that the curing compound will not prevent bond, or

(b)

positive measures are taken to remove it completely from those areas which are to receive bonded applications

(c)

on fair faced concrete surfaces.

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(a)

Steam Curing

1

An enclosure shall be formed around the concrete using tarpaulin or other suitable means.

2

Application of steam shall not be commenced until at least 2 h after final placement of concrete.

3

Steam shall be applied at a temperature between 65 C and 80 C.

4

Excessive rates of heating and cooling shall be prevented during steam curing and temperatures in the enclosure shall not be allowed to increase or decrease by more than 22 C per hour.

5

The maximum steam temperature shall be maintained in the enclosure until concrete has reached its specified strength.

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10.2.9

10.2.10 Pavements and other slab on ground 1

Curing shall ensure that no plastic shrinkage crack will occur, this can be done by protective measures such as sun shields, wind breaks, evaporation reducers, or fog spraying should be initiated immediately to reduce evaporation.

2

Mats used for curing can either be left in place and kept saturated for completion of the curing, or can be subsequently replaced by a liquid membrane-forming curing compound, plastic sheeting, reinforced paper, straw, or water

10.2.11 Buildings, bridges, and other structures 1

Additional curing shall be provided after the removal of forms

QCS 2014

Section 05: Concrete Part 10: Curing

Page 6

2

After the concrete has hardened and while the forms are still in place on vertical and other formed surfaces, form ties may be loosened when damage to the concrete will not occur and water applied to run down on the inside of the form to keep the concrete wet.

3

Care shall be taken to prevent thermal shock and cracks when using water that is significantly cooler than the concrete surface. Curing water should not be more than about o 11 C cooler than the concrete.

4

Immediately following form removal, the surfaces shall be kept continuously wet by a water spray or water-saturated fabric or until the membrane-forming curing compound is applied. Curing

10.2.12 Mass concrete Mass concrete is often cured with water for the additional cooling benefit in warm weather; however, this can be counterproductive when the temperature gradient between the warmer interior and the cooler surface generates stress in the concrete.

2

Horizontal or sloping unformed surfaces of mass concrete can be maintained continuously wet by water spraying, wet sand, or water saturated fabrics.

3

For vertical and other formed surfaces, after the concrete has hardened and the forms are still in place, the form ties may be loosened and water supplied to run down the inside of the form to keep the concrete wet

4

Care shall be taken to prevent thermal shock and cracks when using water that is significantly cooler than the concrete surface. Curing water should not be more than about o 11 C cooler than the concrete.

5

Curing shall start as soon as the concrete has hardened sufficiently to prevent surface damage.

6

For unreinforced massive sections not containing ground granulated blast-furnace slag or pozzolan, curing shall be continued for not less than 2 weeks. Where ground granulated blast-furnace slag or pozzolan is included in the concrete, the minimum time for curing shall be not less than 3 weeks.

7

For reinforced mass concrete, curing shall be continuous for a minimum of 7 days or until 70% of the specified compressive strength is obtained, if strength is the key concrete performance criterion. For construction joints, curing shall be continued until resumption of concrete placement or until the required curing period is completed.

8

Curing shall not stop until favourable differential temperature is attained and at the approval of the Engineer.

9

For mass concrete, thermocouples shall be used to monitor the temperature differential of the concrete.

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END OF PART

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 1

REINFORCEMENT ................................................................................................. 2

11.1 11.1.1 11.1.2 11.1.3 11.1.4 11.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 3 Quality Assurance 3 Delivery Storage and Handling 3

11.2 11.2.1 11.2.2 11.2.3

REINFORCING MATERIALS .................................................................................. 4 Reinforcing Bars 4 Welded Steel Wire Fabric 4 Tie Wire 5

11.3 11.3.2 11.3.3

INSPECTION, SAMPLING AND TESTING.............................................................. 5 Sampling 5 Testing 6

11.4

CUTTING AND BENDING OF REINFORCEMENT ................................................. 6

11.5 11.5.1 11.5.2 11.5.3 11.5.4 11.5.5 11.5.6 11.5.7 11.5.8 11.5.9 11.5.10 11.5.11

FIXING OF REINFORCEMENT ............................................................................... 6 General 6 Welding 7 Mechanical Splices 8 Bundling and Splicing of Bundled Bars 8 Examination 8 Electrolytic Action 8 Cover 8 Reinforcement 8 Forms and Linings 9 Tanking 9 Adjustment and Cleaning 9

11.6 11.6.2 11.6.3 11.6.4

PROTECTIVE COATINGS TO REINFORCEMENT ................................................ 9 Epoxy Coated Reinforcing Bars 9 Handling of Epoxy Coated Reinforcement 11 Testing of Epoxy Coated Reinforcement 11

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QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 2

11

REINFORCEMENT

11.1

GENERAL

11.1.1

Scope

1

This Part includes tension, compression, and temperature reinforcing steel, including welded wire fabric, and epoxy coated reinforcing. The work includes furnishing, fabrication, and placement of reinforcement for cast-in-place concrete, including bars, welded wire fabric, ties, and supports.

2

Related Sections and Parts are as follows: This Section

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References

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ASTM A416/A416M....Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete

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ASTM 615/615M ........Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

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ASTM A706, ...............Specification for Low-allow Steel Deformed Bars for Concrete Reinforcement

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ASTM A881/A881M ...Standard Specification for Steel Wire, Deformed, Stress-Relieved or Low-Relaxation for Prestressed Concrete Railroad Ties Filled

Epoxy-Coated

Seven-Wire

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ASTM A882/A882M- ..Standard Specification for Prestressing Steel Strand

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ASTM A955/A955M-14 Standard Specification for Deformed and Plain Stainless-Steel Bars for Concrete Reinforcement

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ASTM A1035/ A1035M Deformed and Plain, Low-carbon, -Chromium, -Steel Bars for Concrete Reinforcement:

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Part 16 ............. Miscellaneous Part 17 ............. Structural Precast Concrete

BS 4449 : 2005...........Specification for Carbon steel bars for the reinforcement of concrete BS 4482: 2005,...........Specification for Cold reduced steel wire for the reinforcement of concrete BS 4483: 2005............Steel fabric for the reinforcement of concrete BS 5896,.....................Specification for high tensile steel wire and strand for the prestressing of concrete. BS 8666,.....................Specification for scheduling, dimensioning, bending and cutting of steel reinforcement for concrete EN 1011, ....................Welding. Recommendation for welding of metallic materials EN 1992-1-1 Eurocode 2: Design of concrete structures. General rules and rules for buildings ISO 14654, .................Epoxy- coated steel for the reinforcement of concrete ISO 14656, .................Epoxy powder and sealing material for the coating of steel for the reinforcement of concrete

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 3

ISO 3766 ...................Construction drawings -- Simplified representation of concrete reinforcement ISO 9000, ..................Quality management systems. Fundamentals and vocabulary QS ISO 6935-1:2007, .Steel for the reinforcement of concrete -Part 1: Plain bars QS ISO 6935-2:2007 ..Steel for the reinforcement of concrete Part 2: Ribbed bars QS ISO 6935-3:2007 ..Steel for the reinforcement of concrete Part 3: Welded fabric Submittals

1

Product data including the manufacturer’s specification and installation instructions for proprietary materials and reinforcement accessories shall be provided.

2

The Contractor shall submit the manufacturer’s records of chemical and physical properties of each batch of billet steel bars and a certificate that the respective material furnished meets the requirements for the steel reinforcement specified. The manufacturer’s records shall include certificates of mill as well as analysis, tensile and bend tests of the reinforcement.

3

Three copies of the steel test report shall be furnished with each consignment of steel reinforcement. The steel shall be tagged and cross-referenced with mill certificates.

11.1.4

Quality Assurance

1

The Contractor shall submit to the Engineer for source approval details of the proposed source of supply of the reinforcement. Details shall include chemical and physical tests for the past six months production and any independent test results for this period. Details of quality assurance procedures, including ISO 9000 certificate if held, shall also be given.

2

The Contractor shall furnish the Engineer with a certificate of compliance for each shipment of epoxy coated bars. The certificate of compliance shall state that representative samples of the epoxy coated bars have been tested and that the test results comply with the requirements herein specified. Test results shall be retained by the Contractor for seven years. A complete set of test results shall also be handed to the client at the completion of reinforcement works, and shall be made available to the Engineer upon request.

11.1.5

Delivery Storage and Handling

1

On delivery, bars in each lot shall be legibly tagged by the manufacturer. The tag shall show the manufacturer’s test number and lot number and other applicable data that will identify the material with the certificate issued for that lot of steel. The fabricator shall furnish three copies of a certification which shows the batch number or numbers from which each size of bar in the shipment was fabricated.

2

Storage of reinforcement shall be on suitable structures a minimum of 450 mm above the ground surface to prevent damage and accumulation of dirt, rust and other deleterious matter. Storage facilities shall be such as to permit easy access for inspection and identification. Reinforcement bundles shall be clearly tagged with bar schedule and bar mark reference.

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11.1.3

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 4

3

The reinforcement shall not be roughly handled, dropped from a height, or subjected to shock loading or mechanical damage. Steel reinforcing bars shall be kept clean and shall be free from pitting, loose rust, mill scale, oil, grease, earth, paint, or any other material which may impair the bond between the concrete and the reinforcement. The reinforcement shall be covered to ensure protection from wind blown dust, condensation and other deleterious materials.

11.2

REINFORCING MATERIALS

11.2.1

Reinforcing Bars

1

Reinforcement shall be from an acceptable source. All steel reinforcement bars shall comply with the requirements of: QS ISO 6935 with minimum grade of B500 MPa or

(ii)

BS 4449 with minimum grades of B500 MPa ; or..

(iii)

ASTM A615 / A615M with minimum grade of 75 [520MPa]; or

(iv)

Deformed and Plain, Low-carbon-Chromium-Steel Reinforcement: ASTM A1035/ A1035M

(v)

ASTM A1022/A1022M-14a Standard Specification for Deformed and Plain Stainless Steel Wire and Welded Wire for Concrete Reinforcement

(vi)

ASTM A955/A955M-14 Standard Specification for Deformed and Plain Stainless-Steel Bars for Concrete Reinforcement

(vii)

Other types of reinforcement, as approved by Qatar Standards

Bars

for

Concrete

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(i)

As per project design, other steel grades of less than B500MPa may be used only for stirrups and secondary reinforcement of diameter of 10mm or less.

3

If the steel has excessive surface rust, dust or other deleterious material then the steel shall be sand blasted. Sand for blasting shall not contain materials deleterious to the durability of the reinforcement or concrete. Dune sand shall not be used for the sandblasting of reinforcement.

4

For extreme exposure class X5; protection measures such as epoxy coated bars; Lowcarbon-chromium-steel bars; or Stainless Steel may be considered.

11.2.2

Welded Steel Wire Fabric

1

Steel fabric reinforcement shall comply with the requirements of QS ISO 6935-3 or BS 4483 and shall be delivered to Site in flat mats.

2

Welded intersections shall not be spaced more than:

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(a)

300 mm for plain round bars

(b)

400 mm apart for deformed high yield bars in direction of calculated stress except when used as stirrups.

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 5

Tie Wire

1

Tie wire shall conform to the requirements of BS 4482.

2

1.6 mm black annealed mild steel shall be used for tie wire.

3

No wires smaller than size D-4 shall be used.

11.3

INSPECTION, SAMPLING AND TESTING

1

Inspection of reinforcing steel and the installation thereof will be conducted by the Engineer.

2

The Contractor shall give 24 hour notice to the Engineer before closing forms or placing concrete.

3

The Engineer may instruct the Contractor to break out and remove completely all sections of the work already constructed under any of the following circumstances:

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11.2.3

reinforcing steel sample under test fails to meet the specification requirements at any time

(b)

the Engineer considers that samples which were presented to him for test were not truly representative

(c)

a previously rejected reinforcing steel has been used in the Works.

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(a)

Sampling

1

Representative samples of all reinforcing steel proposed for use in the Works must be submitted by the Contractor, before work is commenced, to the Engineer for his written approval.

2

Manufacturer's certificates stating clearly for each sample: (a)

place of manufacture expected date and size of deliveries to site

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11.3.2

(c)

all relevant details of composition, manufacture, strengths and other quality of the steel.

3

The Engineer reserves the right to sample and inspect reinforcement steel upon its arrival at the work site.

4

Frequency of sampling and the method of quality control shall be in accordance with steel bars manufactured standard QS ISO 6935 or BS 4449 .

5

Where epoxy coated steel is used, a sample of the coating material shall be supplied with each batch in an airtight container and identified by the batch number.

6

Allow 14 days for Engineer’s review of samples.

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 6

Testing

1

Tests shall be carried out when directed by the Engineer.

2

Tests shall be carried out in accordance with QS ISO 6935 or BS 4449.

3

The following information shall be provided with each delivery of reinforcement: elastic limit

(b)

ultimate strength

(c)

stress/strain curve

(d)

cross-sectional area

(e)

deformation/bond characteristics of deformed bars.

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11.3.3

The Contractor shall allow for dimensions and weight measurements, tensile, bend and/ or rebend tests at own cost, for each size of bar to be used in the concrete construction.

5

Test results for each bar size shall be submitted to the Engineer three weeks before concrete work commences on Site.

6

Full testing shall be required if the source of supply of reinforcement changes, in which case the cost of such extra testing will be borne by the Contractor.

7

When any test results do not conform to the relevant standard the reinforcement steel shall be removed from the Site and all costs resulting therefrom shall be borne by the Contractor.

11.4

CUTTING AND BENDING OF REINFORCEMENT

1

Cutting and bending of reinforcement shall be in accordance with ISO 3766 or BS 8666 and shall be done without the application of heat. Bends shall have a substantially constant curvature. For epoxy coated steel the provisions of Clause 11.6.1 of this Part shall apply

2

Steel bars manufactured according to the approved ASTM standards shall be bent according to the same standard.

3

Reinforcement shall not be straightened or rebent without the approval of the Engineer. If permission is given to bend projecting reinforcement care shall be taken not to damage the concrete and to ensure that the radius is not less than the minimum specified in ISO 3766 or BS 8666.

11.5

FIXING OF REINFORCEMENT

11.5.1

General

1

All reinforcement shall be securely and accurately fixed in positions shown on the Drawings to ensure that the reinforcement steel framework as a whole shall retain its shape. The framework shall be supported to retain its correct position in the forms during the process of placing and consolidating the concrete.

2

The ends of all tying wires shall be turned into the main body of the concrete and not allowed to project towards the surface.

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Section 05: Concrete Part 11: Reinforcement

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3

No part of the reinforcement shall be used to support access ways, working platform or for the conducting of an electric current.

4

The Contractor’s specific attention is drawn to the following general requirements: (a)

lapped joints shall be as indicated on the Drawings and/or in accordance with the requirements of EN 1992-1-1 or BS 8666

(b)

hooks shall be semicircular with a straight length of at least: (i)

four bar diameters for mild steel

(ii)

six bar diameters for high yield steel.

Welding

1

Welding shall not be used unless authorised by the Engineer and recommended by the reinforcement manufacturer.

2

Where welding is approved it shall be executed under controlled conditions in a factory or workshop.

3

Welding shall not take place on site without the approval of the Engineer and unless suitable safeguards and techniques are employed and the types of steel employed have the required welding properties.

4

Welding if approved, may be used for:

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11.5.2

fixing crossing or lapping reinforcement in position

(b)

fixing bars to other steel members

(c)

structural welds involving transfer of loads between reinforcement or between bars and other steel members.

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The length of run deposited in a single pass shall not exceed five times the bar diameter. If a longer welded length is required, the weld shall be divided into sections with the space between runs made not less than five times the bar diameter.

6

Butt welds shall be formed by flash butt welding or metal-arc welding. Other methods may be approved, subject to their satisfactory performance in trial joints.

7

Metal-arc welding or electrical resistance welding may be used for fixing suitable steels or for lapped joints.

8

Flash butt welding shall be executed with the correct combination of flashing, heating, upsetting and annealing, using only machines which automatically control this cycle of operations.

9

Metal-arc welding shall comply with EN 1011 and the recommendations of the reinforcement manufacturer.

10

Welded joints shall not be made at bends in the reinforcement. Joints in parallel bars of principle reinforcement shall be staggered, unless otherwise approved. The distance between staggered joints shall be not less than the end anchorage length joints.

11

Weldable reinforcement where shown on the Drawings shall conform to ASTM A706.

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Section 05: Concrete Part 11: Reinforcement

Page 8

Mechanical Splices

1

Mechanical splices shall comply with EN 1992-1-1 or BS 8666, and shall be used as and where indicated on the Drawings.

2

Details of mechanical splices shall be submitted to the Engineer for approval.

11.5.4

Bundling and Splicing of Bundled Bars

1

Bundling and splicing of bundled bars shall be in accordance with EN 1992-1-1 or BS 8666.

2

Splicing, except where indicated on the Drawings or approved shop drawings, will not be permitted without the approval of the Engineer.

11.5.5

Examination

1

The Contractor shall notify the Engineer at least 24 hours before commencing the fixing of reinforcement in order to facilitate the inspection of formwork.

2

The Contractor shall ensure that areas to receive reinforcement are cleaned before fixing.

11.5.6

Electrolytic Action

1

Reinforcement shall not be fixed or placed in contact with non-ferrous metals.

11.5.7

Cover

1

Correct concrete cover to reinforcement shall be maintained with the aid of approved spacer pieces.

2

The cover shall not be less than given in Section 5 Part 6.

3

Spacers, chairs and other supports shall be provided as necessary to maintain the reinforcement in its correct position.

4

In a member where the nominal cover is dimensioned to the links, spacers between the links and formwork shall be the same dimension as the nominal cover.

5

Spacer bars shall be of the same diameter as longitudinal bars, but not less than 25 mm in diameter, and shall be fixed between two layers at 1.5 m centres except where bundled bars are detailed.

6

Spacers, chairs and other supports shall be made of concrete, plastic or other material to the approval of the Engineer. Where supports are made of concrete they shall have at least the same cube strength as the concrete in the host member.

11.5.8

Reinforcement

1

Placing of all reinforcement steel bars will be checked by the Engineer and in no case is concrete to be placed around any reinforcement steel that has not been approved by the Engineer. Insertion of bars into or the removal of bars from concrete already placed will not be permitted.

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11.5.3

QCS 2014

Section 05: Concrete Part 11: Reinforcement

Page 9

2

Reinforcement steel temporarily left projecting from the concrete at the joints shall not be bent without the prior approval of the Engineer.

11.5.9

Forms and Linings

1

Damage to forms and linings shall be avoided.

11.5.10 Tanking 1

Reinforcement shall not be fixed until completion of placing tanking (membrane) protection.

11.5.11 Adjustment and Cleaning

.

Check position of reinforcement before and during placing concrete: pay particular attention to the position of top reinforcement in cantilever sections

(b)

ensure that reinforcement is clean and free from corrosive pitting, loose rust, loose mill scale, oil and other substances which may adversely affect reinforcement, concrete, or the bond between the two.

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1

Protect projecting reinforcement from the weather where rust staining of exposed concrete surfaces may occur.

3

At the time of concreting, all reinforcement steel shall have been thoroughly cleaned and freed from all mud, oil or any other coatings that might destroy or reduce the bond:

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clean all set or partially set concrete which may have been deposited thereon during the placing of a previous lift of concrete

(b)

all uncoated rust bars shall be again sand blasted and pressure washed.

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Immediately before concrete placing the reinforcing steel shall be washed thoroughly with high pressure potable water jets to remove any deposited salts.

11.6

PROTECTIVE COATINGS TO REINFORCEMENT

1

All the forgoing clauses of this part apply equally to epoxy coated reinforcing bars.

11.6.2

Epoxy Coated Reinforcing Bars

1

Reinforcing steel which are to be coated shall be free of slivers, scabs, excessive pitting, rust, grease, oil and other surface defects detrimental to proper coating.

2

The surface shall be prepared in accordance with ISO 14654.

3

Coating shall be applied to the cleaned surface as soon as possible after cleaning and before any visible oxidation to the surface occurs.

4

Reinforcing steel shall not have surface defects that would be detrimental to coating.

5

Coating material shall be epoxy resin powders as specified in ISO 14654 and ISO 14656 for coating of reinforcing bars and as follows:

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(a)

epoxy resin powders which do not meet the above requirements must be tested by an approved independent testing laboratory and accepted by the Engineer before use

QCS 2014

6

Section 05: Concrete Part 11: Reinforcement

Page 10

(b)

only fusion bonded epoxy-coated reinforcing steel will be accepted

(c)

no other means of epoxy coating will be approved.

Patching material shall be: (a)

furnished by the epoxy coating manufacturer

(b)

compatible with the coating

(c)

inert in concrete

(d)

suitable for repairs to the coated reinforcing bars to be made by the coating applicator and the Contractor at the project site.

Fabrication shall be performed before coating except as hereinafter specified for bent bars and straight bars less than 7.6 m long.

8

Bent reinforcing steel bars shall be coated after bending, unless the fabricator can show that satisfactory results can be obtained by coating before bending.

9

Any visible cracks in the coating on the outside of the bend or damage to coating resulting in debonding of the coating after bending shall be rejected.

10

Bars less than 7.6 m long may be sheared or sawn to length after coating, provided:

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end damage to coating does not extend more than 12 mm back

(b)

cut end is patched before any visible oxidation appears.

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(a)

Flame cutting will not be permitted.

12

Epoxy coating shall be checked visually after cure for continuity of coating and shall be free from holes, contamination, cracks and damaged areas.

13

There shall not be more than two holidays (pinholes not visually discernible) in any 300 mm of the epoxy coated bar.

14

A holiday detector shall be used in accordance with the manufacturer's instruction to check the epoxy coating for holidays. A 67.5 V detector such as the Tinker and Rasor Model M-1 or its approved equivalent shall be used.

15

Patching of holidays is not required if there are less than three holidays per 300 mm length. Bars having three or more holidays per 300 mm shall be cleaned and recoated or replaced as directed by the Engineer.

16

Epoxy coating film shall be cured and/or post cured to a fully cured condition. A representative proportion of each production lot shall be checked by the epoxy coating applicator, using the method most effective for measuring cure to ensure that the entire production lot of epoxy coating is supplied in the fully cured condition.

17

Contractor shall repair all coating damaged by fixtures used to handle or support the bars in the coating process as follows:

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11

(a)

patching shall be done as soon as possible and before visible oxidation occurs

(b)

excessive patching from other causes will not be permitted

QCS 2014

(c)

Section 05: Concrete Part 11: Reinforcement

Page 11

satisfactory correction shall consist of proper adjustment of process, and rerunning the bars through the plant.

The Engineer reserves the right for access to the epoxy coating applicator’s plant to witness epoxy coating processes for project work and to obtain specimens from test bars for any testing desired.

19

All chairs, tie wires and other devices used in connecting, supporting, securing or fastening epoxy coated reinforcement steel shall be made of or coated with a dielectric material.

20

Before the reinforcement is lowered into place and before placement of the concrete, the coated bars shall be inspected by the Engineer for damage to the epoxy coating.

21

Sheared ends of bars and other areas requiring limited repair due to scars and minor defects shall be repaired, using the specified patching or repair materials.

11.6.3

Handling of Epoxy Coated Reinforcement

1

Reinforcement steel bars shall be handled and stored in a manner to prevent damage to bars or, where used, the epoxy coating.

2

Bars, or where used epoxy coating, damaged in handling or other operations shall be satisfactorily repaired at no additional cost to the Employer.

3

Where epoxy coated bars are used all handling systems shall have plastic mandrel and padded contact areas wherever possible.

4

Where epoxy coated bars are used all bundling bands shall be padded.

5

All bundles shall be lifted with a strongback, multiple supports or a platform bridge so as to prevent bar to bar abrasion from sags in the bar bundle.

6

Bars or bundles shall not be dropped or dragged.

7

During vibration care shall be taken to ensure that the epoxy-coated reinforcement is not damaged by the pokers.

11.6.4

Testing of Epoxy Coated Reinforcement

1

Adhesion and flexibility of the epoxy coating shall be evaluated on test bars coated with each production lot.

2

At least 1 % of the length or 6 m, whichever is less, of each size of bar to be coated shall be furnished as test bars.

3

Test bars may be in one length or multiple lengths as required to have one test bar of each size with each production lot.

4

The production epoxy coated test bars shall be evaluated by bending 120  (after rebound) around a mandrel of a diameter corresponding to size of bar indicated in Table 11.1.

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Section 05: Concrete Part 11: Reinforcement

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Table 11.1 Mandrel Diameter for Bar Diameter for Evaluation Test of Epoxy Coated Test Bars Diameter of Mandrel (mm)

10 12 13 14 16 18 20 22 24 25 26 28 30 32 34 36

79 95 103 111 127 143 159 175 191 198 206 222 238 254 270 286

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Bar Diameter (mm)

Bend shall be made at a uniform rate and may take up to one minute to complete.

6

Bend test shall be conducted at a room temperature of between 20 °C and 30 °C after the specimen has been exposed to room temperature for a sufficient time to ensure that it has reached thermal equilibrium.

7

No cracking of the epoxy coating shall be visible to the naked eye on the outside radius of the bent bar.

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END OF PART

QCS 2014

Section 05: Concrete Part 12: Joints

Page 1

JOINTS.................................................................................................................... 2

12.1 12.1.1 12.1.2 12.1.3 12.1.4 12.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Definitions 3

12.2 12.2.1 12.2.2

CONSTRUCTION JOINTS ...................................................................................... 4 General 4 Construction Joints in Water Retaining Structures 4

12.3 12.3.1 12.3.2 12.3.3

MOVEMENT JOINTS .............................................................................................. 5 General 5 Joint Filler 6 Joint Sealants 6

12.4 12.4.1

SLIP BEARINGS ..................................................................................................... 7 General 7

12.5 12.5.1 12.5.2 12.5.3 12.5.4

WATERSTOPS ....................................................................................................... 7 General 7 Waterstops 7 Butyl Rubber Waterstops 8 Water Swelling Gaskets 8

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Section 05: Concrete Part 12: Joints

Page 2

12

JOINTS

12.1

GENERAL

12.1.1

Scope

1

This part deals with movement and construction joints, slip bearings, waterstops and associated sealants and filler materials.

2

Related Sections and Parts are as follows:

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12.1.2

.

This Section Part 1 ............... General Part 10, ............ Curing Part 15, ............ Hot Weather Concreting Part 16, ............ Miscellaneous References

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ASTM D1751 ..............Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Non-extruding and Resilient Bituminous Types) ASTM D2240 ..............Standard Test Method for Rubber Property—Durometer Hardness

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ASTM D3575 ..............Standard Test Methods for Flexible Cellular Materials Made From Olefin Polymers

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BS 903........................Physical testing of rubber BS 2571......................General purpose flexible PVC compounds for moulding and extrusion

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BS 2782,.....................Methods of testing plastics BS 6093,.....................Design of joints and joining in building construction

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BS 7164,.....................Chemical tests for raw and vulcanized rubber

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BS EN 1992-3 ............Eurocode 2. Design of concrete structures. Liquid retaining and containing structures

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BS EN ISO 7214 ........Cellular plastics. Polyethylene. Methods of test CRD-C572 ..................Corps of Engineers Specifications for Polyvinylchloride Waterstop ISO 9001 ....................Quality management systems. Requirements

12.1.3

Submittals

1

The Contractor shall submit for approval by the Engineer as soon as practicable after acceptance of his Tender and not less than three weeks before commencement of concreting, drawings showing his proposals for the position of construction joints having due regard to any that may be shown on the Contract Drawings.

QCS 2014

Section 05: Concrete Part 12: Joints

Page 3

For slide bearings the Contractor shall provide at least three samples of the proposed material, together with the manufacturer's technical specifications and recommendations in respect of application and performance.

3

For slip joints the Contractor shall provide at least three samples of materials proposed, together with manufacturer's technical specifications and recommendations in respect of application and performance.

4

For waterstops the Contractor shall provide at least three samples of proposed types, including prefabricated joints and junctions, if applicable. If joints are to be made up on site, provide worked samples, including samples for each make of waterstop, where samples from different manufacturers are provided.

5

The Contractor must supply a certificate of compliance for the joint sealant, stating that it meets the requirements of the specification. The Contractor shall also supply the Manufacturer’s technical and installation data for the proposed material. The Contractor shall provide details of previous installations of the product, with the client name, structure name, type of joint and value of contract.

6

The Contractor shall prepare shop drawings that show the layout of the waterstops, specials and joints.

12.1.4

Quality Assurance

1

The joint sealant, including primers and debonding materials shall be compatible with each other and shall be supplied from a manufacturer operating the ISO 9001 or 9002 Quality Assurance Scheme.

12.1.5

Definitions

1

Construction Joint: The surface where two successive placements of concrete meet, across which it is desirable to develop and maintain bond between the two concrete placements, and through which any reinforcement which may be present is not interrupted.

2

Contraction Joint: Formed, sawed, or tooled groove in a concrete structure to create a weakened plane and regulate the location of cracking resulting from the dimensional change of different parts of the structure. (See also Isolation Joint.)

3

Expansion Joint: A separation between adjoining parts of a concrete structure which is provided to allow small relative movements such as those caused by thermal changes to occur independently.

4

Isolation Joint: A separation between adjoining parts of a concrete structure provided to isolate and element and thus allow independent movement.

5

Joints Fillers: Materials that are used to fill space within movement joints during construction. They may provide support to a sealant applied subsequently.

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QCS 2014

Section 05: Concrete Part 12: Joints

Page 4

CONSTRUCTION JOINTS

12.2.1

General

1

Where construction joints are required in slabs or beams (designed by Direct Design Method DDM) they shall be located within the middle third of their spans, and at one-third to onequarter of span in slabs and beams subject to a maximum spacing of approximately 9 metres. Where slabs are supported by beams then the beams and slabs shall be constructed in one operation.

2

In all cases vertical stop boards of a form to be approved by the Engineer shall be provided by at the end of each section of work which is to be concreted in one operation and the concrete shall be thoroughly compacted against these stop boards.

3

Where slabs, beams and walls incorporate construction joints, panels shall generally be constructed consecutively. Where this is not possible a gap not exceeding one metre shall be formed between adjacent panels. This gap shall not be concreted until a minimum interval of 7 d has expired since the casting of the most recent panel.

4

The size of bays for reinforced floors, walls and roofs shall be as shown on the drawings but in no event shall they exceed 7.5 m in either direction and 6 m when unreinforced or with nominal reinforcement.

5

Horizontal construction joints in walls will only be permitted when the wall is continuous with the floor slab. Walls shall be keyed on cast kickers 150 mm high or on the tops of walls meeting the soffits of suspended members.

6

Construction joints in monolithic structures shall be aligned with each other whenever practicable.

7

Before placing new concrete against concrete which has already set the latter shall be treated to expose the aggregate over the full section and leave a sound irregular surface. This shall be done while the concrete is still fresh by means of water spray and light brushing or other means approved by the Engineer.

8

Immediately before the new concrete is placed all foreign matter shall be cleaned away and the surface moistened.

9

If during the course of the Contract it should become apparent that the Contractor’s methods of forming construction joints are not proving effective the Engineer may order the Contractor to execute at the Contractor’s expense such preventative measures as the Engineer may consider necessary to ensure the watertightness of the construction joints in further work.

12.2.2

Construction Joints in Water Retaining Structures

1

The floor may be designed as fully restrained against shrinkage and thermal contraction and should be cast directly onto the blinding concrete.

2

In large structures, the floor shall be designed as a series of continuous strips with transverse induced contraction joints provided to ensure that cracking occurs in predetermined positions. Longitudinal joints between the strips should form contraction joints.

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12.2

QCS 2014

Section 05: Concrete Part 12: Joints

Page 5

Waterstops shall be incorporated into construction joints, crack induced joints, contraction joints and expansion joints in water retaining structures. The Contractor shall ensure that all such joints are watertight and any joints which may leak or weep shall be rectified by the Contractor to the Engineer’s satisfaction.

4

The spacing of construction joints, crack induced joints, contraction joints and expansion joints in water retaining structures shall be shown on the design drawings.

5

Where the positions or type of joints are not indicated on the drawings, the spacing of construction joints or crack induced joints in water retaining structures shall not exceed 5 m.

6

Where the positions or type of joints are not indicated on the drawings in the ground floor slab, construction joints, crack induced joints, contraction joints and expansion joints shall be incorporated into the works as appropriate. for slabs on grade, construction joints or crack induced joints should be provided at areas where differences in subgrade and slab support may cause cracks. The slab shall be cast in strips not more than 15 metres wide across the width of the building. Within each strip for both directions, crack induced joints shall be provided at areas where cracks are expected and not more than 5.0 metre spacing, and construction or contraction joints shall be provided at not more than 15.0m spacing.

7

Construction or contraction joints shall be provided between adjacent strips.

8

Waterstops of a type acceptable to the Engineer shall be embedded in the concrete. The waterstop should be made of a high quality material, which must retain its resilience through the service life of the structure for the double function of movement and sealing. The surface of waterstops should be carefully rounded to ensure tightness of the joint even under heavy water pressure. To ensure a good tightness with or without movement of the joints, the waterstop should be provided with anchor parts. The cross-section of the waterstops should be determined in accordance with the presumed maximum water pressure and joint movements. The complete works of fixed and welded connections must be carried out strictly in accordance with the manufacturer’s instructions.

9

Engineer’s acceptance shall be obtained by the Contractor, prior to start of work, on the casting sequence and the layout of joints.

12.3

MOVEMENT JOINTS

12.3.1

General

1

Movement joints for expansion and contraction shall be constructed in accordance with the details and to the dimension shown on the Drawings or where otherwise ordered by the Engineer and shall be formed of the elements specified.

2

Movement Joints in Water Retaining Structures shall be in accordance with the details and to the dimension shown on the Drawings and EN 1992-3.

3

The Contractor shall pay particular attention to the effects of climatic extremes on any material which he may desire to use on any movement joint and shall submit for approval by the Engineer his proposals for the proper storage, handling and use of the said materials having due regard for any recommendations made by the manufacturer in this connection.

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Section 05: Concrete Part 12: Joints

Page 6

Joint Filler

1

Joint fillers shall conform to the requirements of BS 6093 or ASTM D1751 or equivalent if they are bituminous type or to the requirements of ASTM D3575 or BS EN ISO 7214 or equivalent if they are polymer foam type.

2

The joint filler shall be fixed to the required dimensions of the joint cross-section and shall provide a firm base for the joint sealer.

3

When required between two concrete surfaces as a resilient movement joint, the filler shall be an approved granulated cork bound with insoluble synthetic resin.

4

When required between blockwork and concrete as a low density movement joint filler or for building details it shall be an approved bitumen impregnated fibreboard or preformed closed cell polyethylene.

12.3.3

Joint Sealants

1

All joints to be sealed shall be formed and the groove grit blasted to remove all traces of deleterious materials such as form oil or curing compounds and also to remove any surface laitance from the sides of the joint. The joint shall be dry prior the application of priming. Where the use of grit blasting is not possible the Contractor may propose alternative methods subject to the approval of the Engineer.

2

The back of the joint shall receive a debonding tape or polyethylene foam backer cord in order to provide the correct depth to width ratio and prevent three sided adhesion.

3

The areas adjacent to the joint shall be protected using masking tape.

4

The sides of the joint shall be primed with the relevant primer as recommended by the sealant manufacturer and the sealant material applied in accordance with the manufacturers instructions.

5

The sealant material shall be a non-biodegradable multicomponent pitch polyurethane elastomeric joint sealant, carefully selected as appropriate for the specific climatic and environmental exposure conditions expected. Alternative types of sealant will be considered, including epoxy-polyurethane, rubber bitumen and acrylic, subject to the requirements of the specification and the approval of the Engineer.

6

Where the joint sealant is to be in contact with a protective coating the Contractor shall satisfy the Engineer that the sealant and protective coating are compatible

7

Sealants shall exhibit the following properties:

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12.3.2

(a)

Movement accommodation factor

25 %

(b)

Shore ‘A’ hardness

(c)

Solids content

(d)

Service temperature range

(e)

Chemical resistance to Sewage, Sabkha, Mineral acids and Alkalis

(f)

Width to depth ratio

20 - 25

100 %

2:1

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0 C to 90 C

QCS 2014

Section 05: Concrete Part 12: Joints

Page 7

Where shown on the Drawings sealants shall also be suitable for use with potable water.

9

All surface preparation, priming, mixing and application shall be carried out in strict accordance with the manufacturer’s instructions.

10

The sealant shall have a proven track record of no less than ten years under similar local conditions.

12.4

SLIP BEARINGS

12.4.1

General

1

Slip bearings shall be preformed low friction bearing strips to form a thin sliding joint.

2

They shall be extruded from specially formulated polyethylene to form a durable lamina resistant to sewage, mineral acids and alkalis, solvents and weathering.

3

Slip bearings shall be applied in two layers with the bottom layer bonded to the substrate with a high quality solvent borne adhesive based on polychloroprene rubber. The substrate shall be clean and free from deleterious materials such as form oil or curing compounds and surface laitance. The surface shall be level and even along the full length of the joint

4

The applied loads for slip bearings shall not exceed 0.7 MPa.

5

Operating temperatures shall be up to 80 C

6

The coefficient of friction shall not exceed 0.15

12.5

WATERSTOPS

12.5.1

General

1

Waterstops and associated materials shall be by a manufacturer with a minimum of ten years experience in the field of engineering waterproof products.

2

PVC waterstops shall be suitable for storage, handling, installation and service within a range of 15 C to 65 C.

12.5.2

Waterstops

1

The waterstop shall be a high performance system forming a continuous network as shown on the Drawings.

2

Site jointing is to be limited to butt joints and shall be performed strictly in accordance with the manufacturer’s instructions.

3

Centrally placed waterstops shall employ centre bulbs/shutter stop with ribs on the web sections.

4

Externally placed waterstops shall have ribs on either side of the centre of the waterstop. The water bar used at the location of expansion joints shall have a bulb in the centre to accommodate the movements.

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Section 05: Concrete Part 12: Joints

Page 8

5

Waterstops shall have a minimum thickness of 3 mm.

6

The minimum test performance data for PVC waterstops shall be as follows: Tensile strength Elongation at break Hardness

>12 MPa 300 % Shore ‘A’ 80 to 90

The materials shall be tested in accordance with BS 2571 or BS 2782 or CRD–C572 or ASTM D2240.

12.5.3

Butyl Rubber Waterstops

1

Butyl rubber waterstops shall have the properties stated in Table 12.1 when tested in accordance with BS 903.

Property

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BS 903

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Table 12.1 Properties Requirements of Butyl Rubber Waterstops

.

7

Requirements 3

Density

Part A26

Handness

Part A2

Tensile Strength

Part A2

Elongation at break point

Not less than 450 %

Part A/6

Water Absosption (48 hours immersion)

Not exceeding 5 %

1100 kg/m (± 5 %) 60-70 IRHD Not less than 17.5 N/mm

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Part A1

Butyl rubber waterstops shall be suitable for storage, handling, installation and service within a temperature of 0 °C to 40 °C

12.5.4

Water Swelling Gaskets

1

Where active sealing is required for critical areas, waterstops shall be hydrophilic polymer modified chloroprene rubber strips. The rubber strips shall conform to the following properties as applicable: Water pressure resistance

:

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(b)

Expansion in contact with water :

(c)

:

Reversible

:

- 30 to + 70 °C

(d)

2

5 Bar (50 m)

Application Temperatures

2 x original SRE

The selected rubber strips shall be available for three exposures: (a)

Fresh Water

(b)

Seawater

(c)

Chemicals (if the condition demands or upon the Engineer’s request)

The supplier shall furnish references upon request of the Engineer. END OF PART

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 1

INSPECTION AND TESTING OF HARDENED CONCRETE .................................. 2

13.1 13.1.1 13.1.2 13.1.3 13.1.4 13.1.5 13.1.6

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Non-Compliance of Work 3 General Fieldwork Requirements 4

13.2 13.2.1 13.2.2 13.2.3 13.2.4

CONCRETE CORES ............................................................................................... 4 General 4 Drilling Cores 5 Testing for Strength 6 Assessment of Strength 7

13.3

REINFORCEMENT COVER MEASUREMENTS ..................................................... 7

13.4 13.4.1 13.4.2 13.4.3 13.4.4

ULTRASONIC PULSE MEASUREMENTS .............................................................. 8 General 8 Selection of Test Locations 8 Execution of Tests 8 Estimated In-Situ Cube Strength 9

13.5

RADIOGRAPHY OF CONCRETE ........................................................................... 9

13.6 13.6.1 13.6.2 13.6.3 13.6.4

SURFACE HARDNESS ........................................................................................... 9 General 9 Method of Test 9 Equipment 10 Reporting 10

13.7 13.7.1 13.7.2

CHEMICAL CONTENT .......................................................................................... 10 Sampling 10 Laboratory Testing 11

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QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 2

13

INSPECTION AND TESTING OF HARDENED CONCRETE

13.1

GENERAL

13.1.1

Scope

1

This Part of the specification covers the inspection, sampling and testing of hardened concrete.

2

Related Section and Parts are as follows:

.

This Section Part 6 ............... Property Requirements References

1

The following standards are referred to in this part of the specification:

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ACI 214.4R .................Guide for Obtaining Cores and Interpreting Compressive Strength Results

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ACI 318 ERTA ............Building Code Requirements for Structural Concrete (ACI 318-08) and Commentary

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ASTM C42 ..................Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete

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ASTM C823 ................Standard Practice for Examination and Sampling of Hardened Concrete in Constructions

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BS 1881-124 ..............Testing concrete. Methods for analysis of hardened concrete

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BS 1881-204, .............Testing concrete. Recommendations on the use of electromagnetic covermeters BS EN 12350..............Testing fresh concrete

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BS EN 12504-1 ..........Testing concrete in structures cored specimens taking, examining and testing in compression BS EN 12504-2 ..........Non-destructive testing. Determination of rebound number

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BS EN 12504-3:2005 Testing concrete in structures. Determination of pull-out force BS EN 12504-4 ..........Determination of ultrasonic pulse velocity BS EN 13791..............Assessment of in-situ compressive strength in structures and precast concrete components GSO ISO 1920-6 ........ Testing of concrete – part 6: sampling, preparing and testing of concrete core . 13.1.3

Submittals

1

The Contractor shall submit to the Engineer his quality assurance procedures for the particular parts of the testing work that will be carried out.

2

The Contractor shall submit for the Engineer’s approval the curriculum vitae (CV) of the supervisor proposed for the work.

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 3

The Contractor shall through testing agency prepare a factual report that identifies the test methods used and the test results. The report shall also identify any unusual results or pertinent information relating to the testing. The report shall be presented in hard and electronic copies.

4

For each of the test results the Contractor shall identify the precision or repeatability of the particular sampling and testing method. This shall be as given from experience of the particular test by the laboratory or as expected from information in the particular test standard.

5

In-place tests will be valid only if the tests have been conducted using properly calibrated equipment in accordance with recognized standard procedures and acceptable correlation between test results and concrete compressive strength has been established and is submitted.

6

Non-destructive tests shall not be used as the sole basis for accepting or rejecting concrete, but they may be used to “evaluate” concrete when the standard-cured strengths fail to meet the specified strength criteria

13.1.4

Quality Assurance

1

All field and laboratory testing of concrete shall be carried out by an independent laboratory approved by the Engineer.

2

The evaluation of concrete in structure is needed when an existing structure is to be modified or redesigned; to assess structural adequacy when doubt arises about the compressive strength in the structure due to defective workmanship, deterioration of concrete due to fire or other causes;when an assessment of the in-situ concrete strength is needed during construction; to assess structural adequacy in the case of non-conformity of the compressive strength obtained from standard test specimens; assessment of conformity of the in-situ concrete compressive strength when specified in a specification or product standard.

13.1.5

Non-Compliance of Work

1

If the 28 d works test cubes as defined in clause 6.6 of this Section fail to meet the minimum criteria, the Engineer shall direct the Contractor to carry out in-place methods to estimate the concrete strength by non-destructive testing, in-situ drilling of concrete cores or load testing.

2

The parts or elements of the structure made from the defective batch or batches of concrete as represented by the works test cubes shall be identified by the Engineer and based on this information the Engineer shall instruct the Contractor on the required number and position of concrete cores.

3

The Engineer shall review the concrete core test results in conjunction with BS EN 13791 or ACI 318 whichever is applicable to the structural design.

4

Based on this assessment the Engineer shall decide the acceptability of the concrete in the structural element and may either:

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(a)

accept the concrete

(b)

instruct that certain remedial works are carried out

(c)

instruct that the element is replaced.

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 4

General Fieldwork Requirements

1

The Contractor shall make all arrangements to provide safe stable access to testing locations.

2

When gaining access to testing locations and whilst testing the Contractor shall take care not to damage the structure or leave it in an untidy or unclean state.

3

The Contractor shall take precautions to ensure that cooling water from concrete coring/other operations is discharged such as not to cause a mess or damage the interior or exterior parts of the structure.

4

The Contractor shall be responsible for arranging the water supply required for testing.

5

The Contractor shall arrange for a suitable power supplies. Where testing is being carried out on an occupied structure a power supply from the building services may not available and the Contractor shall make arrangements for power supply and extension leads of adequate length.

6

The Contractor shall appoint a qualified field supervisor to co-ordinate and manage the field work. The supervisor shall have not less than five years experience of such work.

7

Before starting the work, the Engineer with the Contractor’s supervisor will mark the positions where field testing is to be carried out. A unique referencing system to identify each sample or testing location will be adopted, and this will either be referenced on sketch plans or drawings or by a detailed description used throughout the report to identify test locations.

8

If testing is being carried out on an occupied structure the Contractor shall co-ordinate with the owner or operator of the structure to arrange the detailed programme for the works and gain access to the various parts of the structure.

9

As soon as laboratory test results are available these shall be submitted by hand or faxed to the Engineer in draft form. The testing laboratory, or technical bureau assigned by the testing agency, assigned by the contractor shall provide a technical report providing visual information and analysing the tests conducted.

10

All core holes, dust sample holes and exploratory investigation areas shall be reinstated with a proprietary non shrink cementitious repair mortar. The preparation of the hole or area before reinstatement shall be carried out as per the recommendation of the repair mortar supplier.

11

Before filling any core holes, dust sample holes or exploratory investigation areas, the Contractor shall allow the Engineer time to inspect these areas and obtain written confirmation from the Engineer before filling.

13.2

CONCRETE CORES

13.2.1

General

1

The drilling and testing of cores shall be carried out in accordance with BS EN 13791 & BS EN 12504-1, or GSO ISO 1920-6 or ASTM C42 and ACI 214.4 whichever is applicable to the structural design.

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13.1.6

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 5

All of the supplementary information listed by the relevant standards shall be included in the test report with photographs of the cores.

3

An assessment of in-situ compressive strength for a particular test region shall be based on at least 3 cores. Consideration shall be given to any structural implications resulting from taking cores. The diameter of concrete core shall be at least 100 mm for strength evaluation unless clear spacing of reinforcement is less than 100 mm and approved by Engineer.

4

The preferred minimum core diameter is three times the nominal maximum size of the coarse aggregate, but it shall be at least two times the nominal maximum size of the coarse aggregate

5

The Engineer will advise the required number and locations of cores. If the results of the initial coring are inconclusive, the Engineer may instruct that further cores be taken at certain locations.

6

Unless otherwise directed by the Engineer, the Contractor shall ensure that coring does not cut through any reinforcing steel. The required diameter and depth of concrete cores shall be as stated in table 13.1

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Table 13.1

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Minimum Depth of Sampling of Concrete for Testing Purposes (ASTM C823) Thickness of Section, m

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Types of Construction

0.3 or less 0.3 or greater

entire depth 0.3

0.15 or less

entire depth

0.15 – 0.6

one half the thickness or 0.15 whichever is greater

0.6 or greater

0.6

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Slabs, pavements, walls, linings, foundations, structural elements accessible from one side only 2 Suspended slabs , walls, conduits, foundations, structural elements exposed to the atmosphere at two or more sides; concrete products Massive sections

Minimum Depth to Be Sampled, m

1 The requirements of table 13.2.1 may not provide the quantities or dimensions of samples that are required for all tests, in that case, the necessary additional quantity of concrete in pieces of appropriate minimum size should be taken at each sampling location. 2 When suspended slabs are cored, it is desirable to leave the lower 25 mm uncored, so as not to lose the core by its falling from the barrel and to make it easier to patch the core hole. 13.2.2

Drilling Cores

1

Before beginning coring operations the Contractor shall use a proprietary cover meter to identify the position of steel reinforcing bars at the testing location.

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 6

The Engineer may instruct that the core is taken through the concrete without hitting any reinforcement or the Engineer may instruct that the core is taken in a position where it is expected reinforcement will be cut in order to provide a sample of the reinforcement to check its condition. The locations of all drilling points shall be chosen so that the core contains no steel parallel to its length.

3

Before capping, the core shall have a length of at least 95 % of its diameter. Once prepared for test the core shall have a length at least equal to the diameter and not more than 1.2 times its diameter.

4

Cores of both 100 mm and 150 mm nominal diameters may be tested provided that the aggregate size does not exceed 20 mm and 40 mm respectively. Where possible 150 mm cores should be taken to reduce the variability due to drilling and increase the reliability of the testing, unless reinforcement is congested and the use of 100 mm cores will reduce the possibility that the core will contain steel or it is necessary to restrict the sampling to a length of less than 150 mm.

5

Where the size of the section precludes the use of 100 mm or 150 mm cores, smaller cores may be used with the permission of the Engineer.

6

During drilling operations, a log of observations that may affect the interpretation of core samples shall be prepared.

7

If instructed by the Engineer, immediately after the core has been cut and removed and the structure a carbonation test will be carried out by using a 1 or 2 % solution of phenolphthalein poured over the cut surface. A photograph shall be taken of the cut core with the phenolphthalein solution applied to provide a record of the test.

8

If during the drilling of the core, the core collapses due to weak honeycombed or defective concrete, the Contractor shall stop the drilling operation and carry out testing at an adjacent location as advised by the Engineer. If when testing at the second location, the core again breaks due to honeycombed or defective concrete the freshly cut core shall be retained for reference and a note made of the condition.

13.2.3

Testing for Strength

1

The compressive strength of field concrete cores shall be assessed in accordance with BS EN 13791.

2

The details of the concrete core in accordance with BS EN 13791 shall be recorded and two photographs on either side of the core taken.

3

Where there is reinforcement in the core, the size and the type of bar shall be noted along with its cover to the concrete surface, the condition of reinforcing bars shall be noted with a detailed description of any corrosion of the reinforcement.

4

Before carrying out the compressive strength testing of the cores, the Contractor shall inform the Engineer to allow him to witness the testing if required.

5

Crushed core samples shall be retained by the laboratory and only disposed of after written approval by the Engineer.

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Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 7

Assessment of Strength

1

The estimated in-situ strength of the concrete shall be calculated from the core result using BS EN 13791, ACI 214.4 or ACI 318 whichever is applicable by the structural design.

13.3

REINFORCEMENT COVER MEASUREMENTS

1

The measurement of cover to reinforcing steel and other metallic items in concrete shall be carried out in accordance with BS 1881 Part 204 using an electromagnetic device that estimates the position depth and size of the reinforcement.

2

The locations for checking cover and the spacing between measurements shall be advised by the Engineer based on the objective of the investigation. The Contractor shall carry out calibrations of the electric magnetic device for a particular bar size to allow the bar diameter to be measured.

3

While testing, the orientation of steel bars shall be checked.

4

The electromagnetic device shall incorporate scale or digital display range and shall be calibrated in accordance with BS 1881 Part 204. When calibrated in this manner the indicated cover to steel reinforcement shall be accurate to within 5 % or 2 mm which ever is the greater over the working range given by the manufacturer.

5

The cover meter shall be used in accordance with the manufacturers instructions and checks on the zero carried out as specified.

6

The search head shall be traversed systematically across the concrete, and, where reinforcement is located, rotated until the maximum disturbance with electromagnetic field is indicated by the meter.

7

The cover to the reinforcement shall be noted along with the axis of the reinforcement. The cover shall also be recorded on the concrete surface with chalk or a suitable non-permanent marking pen.

8

Care should be taken to avoid interference from other metallic sources or magnetic material.

9

The cover meter checks shall be carried out by an operator with five years experience.

10

The test report on cover shall include the following information:

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13.2.4

(a)

date

(b)

time and place of test

(c)

description of the structure or component under investigation

(d)

location of test areas

(e)

make and type of cover meter used

(f)

date of last laboratory calibration of cover meter

(g)

details of site calibration of cover meter, indicated values of cover

(h)

estimated accuracy of quantitative measurements

(i)

configuration of steel reinforcement

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 8

ULTRASONIC PULSE MEASUREMENTS

13.4.1

General

1

The ultrasonic velocity test equipment shall be capable of measuring the transit time of a pulse vibration through concrete. The length of the pulse part between the transducer equipment shall be measured, and the pulse velocity calculated.

2

Ultrasonic pulse velocity testing shall be carried out in accordance with the provisions of BS EN 12504-4.

3

Velocities shall be measured at a number of locations around a structure and a velocity contour of the structure established. A minimum of 40 velocities shall be measured for each structural element.

13.4.2

Selection of Test Locations

1

Wherever possible direct transmission arrangements shall be used. The transducers shall be mounted on a specially formed moulded surface.

2

The minimum path length shall be 100 mm for concrete in which the nominal maximum size of aggregate is 20 mm or less and 150 mm for concrete in which the nominal maximum size of aggregate is between 20 mm and 40 mm. but the path length shall not be longer than required to detect small regions of bad concrete.

3

Where concrete contains steel the pulse velocity shall be adjusted in accordance with the requirement of BS EN 12504-4.

4

Locations that contain reinforcement directly along or close to the pulse paths shall be avoided.

5

Where repositioning is not possible the semi-direct transmission measurement, where transducers are placed on adjacent faces of the concrete, may be used.

13.4.3

Execution of Tests

1

Positions chosen for the test locations shall be clearly and accurately marked on the surface of the concrete.

2

The surface of the concrete shall be shall be cleaned and free from grit and dust. Path lengths shall be determined to an accuracy of 1 % and a suitable couplant (such as grease) applied to each of the test points.

3

Pulse transit times shall be measured by a skilled operator, with a minimum of five years experience in the use of the equipment.

4

Pulse velocity measurement equipment shall be in accordance with the requirements of BS EN 12504-4.

5

Test results shall be examined and any unusual readings repeated carefully for verification or amendment.

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13.4

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 9

Estimated In-Situ Cube Strength

1

A correlation shall be established between the cube crushing strength of the particular mix used in the structure and the pulse velocity.

2

Where it is not possible to obtain cubes with the same mix design as the original structure a combination of coring and ultrasonic pulse velocity testing may be carried out at the direction of the Engineer, where the cores are used to provide the correlation information required for the interpretation of the ultrasonic pulse velocity tests.

13.5

RADIOGRAPHY OF CONCRETE

1

Gamma rays and high energy X-rays, which illustrate by radiographs the concrete defects: The testing shall be carried out in accordance with the requirements of BS 1881-205 or equivalent.

13.6

SURFACE HARDNESS

13.6.1

General

1

Testing of concrete surfaces for hardness using rebound hammers shall be carried out in accordance with BS EN 12504-2.

2

The rebound hammer shall only be used for estimation of concrete strength where a specific correlation is carried out of the concrete from the structure being tested; this shall be from works test cubes or cores taken from the structure.

3

The correlation between concrete strength and the rebound number shall be carried out in accordance with BS EN 12504-2. The precision of the correlation curve between the mean rebound number and strength shall be stated and this shall be used when reporting any strength interpretations from surface hardness readings. The use of general manufacturers’ correlation or calibration curve for strength shall not be used.

4

It should be noted that the rebound hammer number only provides information on a surface layer of approximately 30 mm in depth of the concrete and that this should be quoted in the test report.

5

The rebound hammer maybe used to establish the uniformity of the finish products or similar elements in a structure at a constant age, temperature, maturity and moisture condition.

13.6.2

Method of Test

1

A minimum of 12 readings shall be taken to establish a single surface hardness at a particular location.

2

The reading shall be on a regular grid between 20 mm to 50 mm spacing over an area not exceeding 300 mm by 300 mm.

3

The mean of each set of readings shall be calculated including abnormally high and abnormally low results unless there is good reason to doubt the validity of a particular reading.

4

The coefficient of variation and the standard deviation of the readings shall be reported.

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13.4.4

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Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 10

Equipment

1

The rebound hammer shall be a proprietary type that has been used successfully and serviced for a minimum of five years.

2

The hammer shall comprise of a mass propelled by a spring that strikes a plunger in contact with the surface.

3

The manufacturers’ literature shall identify the impact energy and contact area of the plunger for the hammer.

13.6.4

Reporting

1

The test report shall affirm that the hardness was determined in accordance with BS EN 12504-2 and shall provide the following information:

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13.6.3

date time and place of test

(b)

description of structure and location of test

(c)

details of concrete

(d)

type of cement

(e)

cement content

(f)

type of aggregate

(g)

type of curing

(h)

age of concrete

(i)

type of compaction of concrete

(j)

forming of surface

(k)

moisture condition of the surface

(l)

carbonation state of surface

(m)

any suspected movement of the concrete under test

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direction of test

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(a)

(o)

any other factors that are considered significant in influencing the hardness readings.

2

The details of the rebound hammer correlation with strength including the mean, range, standard deviation and coefficient and variation of each reading shall also be included.

13.7

CHEMICAL CONTENT

13.7.1

Sampling

1

The Engineer shall instruct the depth increments over which the dust samples are to be taken, the types of chemical testing to be carried out and the quantity of sample required.

2

The depth of sample shall not be less than the concrete cover to the reinforcement and at least 50 mm from the surface of concrete. In presence of reinforcement, the chemical content shall be tested at least at two levels before and after the depth of reinforcement from the surface of concrete.

QCS 2014

Section 05: Concrete Part 13: Inspection and Testing of Hardened Concrete

Page 11

To provide uniform samples of cement matrix and aggregate, three separate holes shall be drilled at one location. The diameter of the holes shall be between 12 and 20 mm.

4

Care shall be taken to discard the material from any render or finish unless this is specifically required under the investigation.

5

Care shall be taken to ensure that dust increments are accurately measured by marking the drill bit.

6

The dust samples increments shall be carefully transferred to plastic bags and sealed to avoid contamination. Each sealed bag shall be uniquely identified by the sample identification and depth increment.

13.7.2

Laboratory Testing

1

Residual split samples of dust from the field investigation shall be retained until the Engineer has reviewed the chloride test results. The Engineer may instruct that repeat tests are carried out on certain samples.

2

Chloride testing of concrete dust samples shall be by an acid soluble method in accordance with BS 1881 Part 124. The results shall be reported to two decimal places.

3

Sulphate testing of concrete dust samples shall be in accordance with BS 1881 Part 124, using an acid soluble method.

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END OF PART

QCS 2014

Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 1

PROTECTIVE TREATMENTS FOR CONCRETE ................................................... 2

14.1 14.1.1 14.1.2 14.1.3 14.1.4 14.1.5 14.1.6 14.1.7 14.1.8 14.1.9

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 Preinstallation and Co-ordination 4 Delivery, Storage and Handling 4 Protection 4 General Requirements for all Treatments 5 Final Inspection 5

14.2 14.2.1 14.2.2 14.2.3 14.2.4

EPOXY COATING ................................................................................................... 5 General 5 Surface Preparation 5 Materials 6 Application 6

14.3 14.3.1 14.3.2 14.3.3 14.3.4

WATERPROOF MEMBRANE ................................................................................. 6 General 6 Materials 7 Waterproof Membrane 7 Application 7

14.4 14.4.1 14.4.2 14.4.3 14.4.4

PENETRATIVE PRIMER ......................................................................................... 8 General 8 Material 8 Surface Preparation 8 Application 8

14.5 14.5.1 14.5.2 14.5.3 14.5.4

PROTECTIVE COATING ........................................................................................ 9 General 9 Surface Preparation 9 Material 10 Application 10

14.6 14.6.1 14.6.2 14.6.3 14.6.4 14.6.5 14.6.6 14.6.7 14.6.8 14.6.9 14.6.10 14.6.11

PLASTIC SHEET LINER FOR CONCRETE STRUCTURES ................................. 11 General 11 Shop Drawings and Submittals 11 Liner Material Requirements 11 Plastic Sheet Liner Strip Properties 12 Basic Sheet Dimensions 12 Liner Details 12 Installation 13 Testing Requirements 13 Special Requirements 14 Joints in Lining for In-Situ Concrete Structures 15 Testing and repairing damaged surfaces 15

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 2

14

PROTECTIVE TREATMENTS FOR CONCRETE

14.1

GENERAL

14.1.1

Scope

1

This Part covers the materials and application requirements for coatings for concrete surfaces including epoxy coatings, waterproof membranes, penetrative primers, protective coatings, and coatings and treatments for specialist applications where there is a harsh environment.

2

Related Section and Parts are as follows:

References

1

The following standards are referred to in this Part:

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This Section Part 1, ............. General

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ASTM D412 ................Test Methods for Vulcanized Rubbers and Thermoplastic Elastomers Tension ASTM D543 ................Test Method for Resistance of Plastics to Chemical Reagents

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ASTM D570 ................Test Method for Water Absorption of Plastics ASTM D638 ................Test Method for Tensile Properties of Plastics (Metric)

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ASTM D746 ................Test Method for Brittleness Temperature of Plastics and Elastomers by Impact

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ASTM D882 ................Test Methods for Tensile Properties of Thin Plastic Sheeting

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ASTM D1000 ..............Test Method for Pressure Sensitive Adhesive Coated Tapes Used for Electrical and Electronic Applications

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ASTM D1004 ..............Test Method for Initial Tear Resistance of Plastic Film and Sheeting

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ASTM D4541 ..............Test Method for Pull Off Strength of Coatings Using Portable Adhesion Testers ASTM E 96 .................Test Methods for Water Vapor Transmission of Materials

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ASTM E154 ................Test Methods for Water Vapor Retarders Used in Contact with Earth Under Concrete Slabs, on Walls, or as Ground Cover BS 1881......................Testing Concrete BS EN 12350..............Testing fresh concrete CIRIA Technical Note 130, Protection of Reinforced Concrete by Surface Treatments. ISO 9000 ....................Quality management and quality assurance standards ISO 9001 ....................Quality systems - Model for quality assurance in design, development, production, installation and servicing 14.1.3

Submittals

1

The Contractor shall submit manufacturers' specifications, installation instructions and other data to show compliance with the requirements of this part of the specification and the Contract Documents.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 3

The Contractor shall submit samples of all materials to be used in the works before delivery of material to Site. Samples of membrane waterproofing shall be 300 mm square. Samples of liquid components shall be a minimum of one litre.

3

The Contractor shall submit comprehensive test results for the protective coating system as per the tests in the specification which shall clearly indicate whether the values are mean values measured in current production or minimum values which the property does not fall below.

4

The Contractor shall clearly state the chemical composition of the material and the process by which protection is given to the concrete.

5

In addition to the test methods identified in this clause of this specification, the Engineer may require the Contractor to carry out further tests to different standards.

6

If the Contractor wishes to propose a material which has been tested to alternative standards, the Contractor shall submit correlation tests showing the comparable values of the two test methods. These test results shall be comprehensive giving full details of the sample conditioning, preparation, method of test, criteria for assessment etc.

7

The Contractor shall submit comprehensive information of previous applications of the material in similar conditions and environments. This information shall include: project name, type/grade of material used, quantity of material used, name of client, name of consultant, name of Contractor. If requested by the Engineer, the Contractor shall supply the contact details of the client, consultant or Contractor where the material was previously installed.

8

The Contractor shall submit a guaranty for the protective coating system and the workmanship. The guaranty shall be worded to reflect the required performance of the material and shall be approved by the Engineer. The guaranty shall be worded to include the phrase ‘the Contractor shall, at the convenience of the Employer, effect all repairs and replacements necessary to remedy defects all to the complete satisfaction of the Engineer’. Unless stated otherwise in the contract specific documentation, the performance guaranty shall be for a period of ten years except for the penetrative primer which shall be for a period of five years.

9

The use of alternatives may be considered by the Engineer. If the Contractor wishes to propose such systems, a technical submission shall be made which shall include a comprehensive justification giving an explanation of why the proposed system is equivalent or superior to the one designated.

14.1.4

Quality Assurance

1

The protective coating system shall be supplied by a manufacturer who is certified to the ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of the ISO 9000 series certificate that clearly states the scope of the certification.

2

The protective coating system shall be supplied by a manufacturer who provides technical assistance on the suitability for the application and installation for the material. For the initial use of the material on Site, the Contractor shall arrange for the technical representative of the manufacturer to be present to demonstrate the correct use of the material.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

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The protective coating system shall be applied by a contractor or subcontractor who is certified to the ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of the ISO 9000 certificate that clearly states the scope of the certification. the Engineer may permit the use of an applicator who is not certified to ISO 9000 if the applicator works to a quality system that is approved by the Engineer.

4

The works shall be executed by an approved specialist subcontractor having a minimum of 5 years successful experience in the installation of the specified material. Only tradesmen experienced with the installation of the materials specified shall be used.

14.1.5

Preinstallation and Co-ordination

1

After approval of all materials and before installation, a prework conference with the Engineer shall be held at the Site. The meeting shall be attended by representatives of the Engineer, Contractor, subcontractor, and manufacturer.

2

The parties shall:

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review drawings, specifications and approved materials

(b)

correct conflicts, if any, between approvals and specification requirements

(c)

examine Site conditions, including inspection of substrate, material labels and methods of storing materials

(d)

review installation procedures and scheduling

(e)

review protection methods for finished work from other trades.

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(a)

Before applying the coating system to the permanent works the Contractor shall carry out a small trial of the coating system for the review and approval of the Engineer.

14.1.6

Delivery, Storage and Handling

1

Materials shall be delivered in their original, tightly sealed containers or unopened packages, all clearly labelled with the manufacturer's name, brand name, and number and batch number of the material where appropriate. Materials and equipment shall be stored as directed in a neat and safe manner.

2

Storage areas shall comply with the manufacturers requirements with regard to shade, ventilation and temperature limits and shall be located away from all sources of excess heat, sparks or open flame. Containers of liquid material shall not be left open at any time in the storage area.

3

Materials not conforming to these requirements will be rejected by the Engineer and shall be removed from the Site and replaced with approved materials.

4

The Contractor shall deliver materials to Site in ample time to avoid delay in job progress and at such times as to permit proper co-ordination of the various parts.

14.1.7

Protection

1

The Contractor shall protect the protection system installation from damage during the construction period so that it will be without any indication of abuse, defects or damage at the time of completion.

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The Contractor shall protect the building/structure from damage resulting from spillage, dripping and dropping of materials.

3

The Contractor shall prevent any materials from running into and clogging drains.

4

Materials and plant shall not be stored on any newly constructed floor without the permission of the Engineer.

5

Impervious membranes shall be laid as protection to all concrete surfaces in contact with the soil and shall consist of tanking or similar accepted material, based on soil investigation report.

6

All foundations shall be provided with protection such as epoxy coatings or similar other accepted equivalents so that concrete is not exposed to harmful effects of soil, chlorides etc.

14.1.8

General Requirements for all Treatments

1

Protective treatments shall be applied where designated in the contract specific documentation.

2

All protective coating systems to be used shall be applied strictly in accordance with the manufacturers recommendations.

3

The Contractor shall take all necessary precautions against fire and other hazards during delivery, storage and installation of flammable materials specified herein and comply any regulations imposed by the Civil Defence Department of the Ministry of the Interior in respect of the storage and use of hazardous materials required under this section.

4

The Engineer shall specify the required final colour of the coating and the Contractor shall submit samples showing the colour before ordering the materials.

14.1.9

Final Inspection

1

Upon completion of the installation, an inspection shall be made by a representative of the material manufacturer in order to ascertain that the system has been properly installed.

14.2

EPOXY COATING

14.2.1

General

1

The coating shall be a decorative flexible high solids, epoxy polyurethane coating applied in two coats to a dry film thickness of 200 m minimum.

14.2.2

Surface Preparation

1

The surface of the concrete shall be free from oil, grease, loose particles, decayed matter, moss or algae growth and general curing compounds. All surface contamination and surface laitance shall be removed by high pressure water jetting or sweep blasting.

2

Blow holes and areas of substantial pitting shall then be filled with a solvent free thixotropic epoxy resin fairing coat. The mixing and application of this coat shall be in accordance with the product manufacturer’s recommendations.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 6

Where surface cracking is apparent these cracks shall be chased, by an approved mechanical means, to the depth of the crack. A thixotropic epoxy resin shall be applied using a trowel, scraper or filling knife ensuring that full compaction is achieved into the chased section and providing a flush finish with the concrete surface. A minimum period of 24 h shall be allowed before applying any subsequent protective coating systems.

14.2.3

Materials

1

External above ground coating materials shall provide protection against chlorides and carbonation, and be UV and abrasion resistant.

2

The above ground coating shall be applied over the below ground coating and shall continue for a minimum of 150 mm above the ground level.

3

The epoxy coating shall be UV stable.

4

The finished coating shall be pinhole free and have a total minimum dry film thickness of 200 m.

5

The materials used in the coating system shall comply with the following requirements:

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> 85 % -20 C to 70 C 4 MPa 6 MPa greater than 3.5 MPa 90 MPa (neat resin) 6-8 % (neat resin) Nil 50 mg 97 MPa @ 7 days -6 46.8 x 10 mm/mm/degree C

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Solids content Service temperature Tensile strength (DIN 53504) Resistance against crack (DIN 53515) Adhesion to concrete (ASTM D-4541) Compressive strength (ASTM D-695) Tensile elongation (ASTM D-638) Water absorption (MIL D-24613) Abrasion resistance (ASTM C-501) Compressive strength (ASTM C-579) Thermal coefficient of expansion (ASTM C-531) Application

1

Where required by the Engineer, trial areas not exposed in the finished work shall first be treated using the selected materials.

2

The exposed concrete surfaces as defined in the documents or as agreed with the Engineer shall be treated with the material.

3

The coating shall be applied by spray, roller or brush to achieve a finish acceptable to the Engineer.

4

In all operations of storage, mixing and application, the Contractor is to comply with the health and safety recommendations of the manufacturer and governing authorities.

14.3

WATERPROOF MEMBRANE

14.3.1

General

1

This Subpart covers the use of waterproof membrane for general protection to buried concrete.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 7

Where indicated on the Drawings or directed by the Engineer, concrete in contact with the ground shall be protected by a preformed flexible self-adhesive bituminous type membrane.

3

The laying, lapping and sealing of the membrane shall be in accordance with the manufacturer’s instructions.

14.3.2

Materials

1

The material shall be an externally applied waterproof membrane shall be an impervious, cold applied flexible laminated sheet, consisting of multilayer high density cross-laminated polyethylene film with a backing of self-adhesive rubber bitumen compound, protected with silicone coated release paper.

2

Primer for Sheet Membrane: As recommended by the manufacture of the sheet membrane.

3

Protection Board: Provide a minimum 6 mm thick asphalt protection board manufactured from selected aggregates, bound in modified bitumen encased between two layers of strengthened asphalt paper. The bituminous material shall be a minimum of 1.0 mm thick and the membrane shall be capable of bridging crack widths in the substrate up to 0.6 mm wide.

14.3.3

Waterproof Membrane

1

The material shall be suitable for use in the Gulf region the compound shall be specially formulated for hot climates and shall have proven experience in the Middle East.

2

The waterproofing material shall conform to the standards detailed in Table 14.1

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Table 14.1 Waterproof Membrane Property Requirements

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Property

Standard ASTM D638

Tear resistance

ASTM D1004

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Elongation Film

Value Longituduial 210 % Transverse 160 % Longitudinal 340 MPa Transverse 310 MPa

Adhesion to primed concrete

ASTM D1000

1.8 MPa

Elongation compound

ASTM D1000

1.8 MPa

Puncture resistance

ASTM E154

220 N over 65 mm

Water resistance

ASTM D570

After 24 h. 0.14 % After 35 d 0.95 %

Environmental resistance Moisture vapour transmission rate

ASTM D543 ASTM E96

Minimum thickness

2

0.3g/M 24 h 1.0 mm.

14.3.4

Application

1

Waterproofing membranes placed on vertical concrete faces shall be protected by preformed asphalt board.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 8

Boards shall be bonded onto position with high quality solvent borne contact adhesive based on polychloroprene rubber.

3

The Contractor shall co-ordinate the installation of waterproofing membrane with floor drains, equipment bases and other adjacent work and mask adjacent work to prevent soil marks.

4

Areas where waterproofing is applied shall be protected from all traffic and where necessary backfilling. All damage to finished portions of the waterproofing membrane shall be either repaired or replaced, or both, in a manner acceptable to the Engineer.

14.4

PENETRATIVE PRIMER

14.4.1

General

1

The system shall be a penetrating hydrophobic treatment that protects concrete from both water and chloride intrusion, while permitting water vapour transmission.

2

The treatment shall significantly reduce the absorption of water and water borne salts but allow the transmission of water vapour from the substrate.

3

The treatment shall not produce any discoloration of the substrate and shall have excellent resistance to weathering.

14.4.2

Material

1

The material shall be a low viscosity silane-siloxane system which penetrates deeply into a porous substrate and reacts to produce a bonded hydrophobic lining to the pores.

2

The material shall be resistant to petrol, oil, and atmospheric contaminants such as car exhaust fumes and industrial exhausts.

14.4.3

Surface Preparation

1

The surface shall be dry, free from oil and grease, loose particles, decayed matter, algae growth and curing compounds.

2

If the concrete surface is newly cast and has a very smooth finish, the surface shall be roughened by sand or grit blasting, water blasting or some mechanical means. The Engineer shall decide if this means of preparation is required.

3

Moss or algae growth on the surface shall be removed using a proprietary fungicidal wash in accordance with the manufacturer’s recommendations.

4

Concrete finishing required shall be completed before the application of the treatment.

5

Cracks of width greater than 0.2 mm shall be filled in accordance with the manufacturer’s recommendations.

14.4.4

Application

1

Unless directed otherwise by the Engineer the treatment shall be applied a minimum period of 24 h after the wet curing period, and shall be surface dry.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 9

The Contractor shall carry out tests to verify the depth of penetration of the material. These tests shall be carried out on specimens of the actual mix design and shall use coloured dyes to trace the penetration of the material.

3

Where fine cracking has occurred in the concrete (at a width not greater than 0.3 mm for reinforced concrete and 0.2 mm for water retaining structures) an additional four 'stripe coats' of the treatment shall be applied before the main treatment.

4

The application of the material on surfaces shall be by a low pressure spray direct from the can. Under no circumstances should thinning of the material be carried out.

5

The rate of application shall ensure that the surface is completely saturated. The impregnated coating shall be applied to two or more flood coats each flood coat shall be a 2 minimum of 0.4 l/m .

6

The material shall be applied strictly in accordance with the manufacturers instructions and as follows:

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the material shall be applied by a fine nozzle spray

(b)

application will not be permitted when the ambient air temperature is above 35 C or in windy conditions

(c)

the surface shall be cleaned by a stiff brush or compressed air to remove all loose deposits

(d)

concrete to be treated shall be surface dry for a minimum period of 24 h before impregnation

(e)

membranes, joint sealers and cast in concrete ancillaries shall be masked off before treatment

(f)

application shall be made by saturation flooding

(g)

the interval between application shall be at least 6 h

(h)

treated areas shall be protected from sea water and rain for 6 h after treatment.

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(a)

PROTECTIVE COATING

14.5.1

General

1

The coating system shall be used for the protection of new or existing reinforced concrete structures against carbonation or chloride induced corrosion.

2

The system shall comprise of a penetrating, reactive primer and an acrylic polymer top coat system to minimise ingress of acidic gases, chlorides and water.

14.5.2

Surface Preparation

1

Before application, all surfaces must be dry and free from oil, grease, loose particles, decayed matter, moss or algae growth and general curing compounds.

2

All such contamination and laitence must be removed by the use of grit blasting, high pressure water jetting or equivalent mechanical means.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 10

Before proceeding to apply the protective coatings, all surfaces which are not to be coated but which may be affected by the application of the coating shall be fully masked and, in particular, flora and fauna shall be protected.

4

Blow holes and areas of pitting shall be made good with a one part modified cementitious material and allowed to cure in accordance with the manufacturer's recommendations. In particular, the application shall be in accordance with the manufacturer's recommendations, with respect to the maximum application thickness.

14.5.3

Material

1

The materials are required to provide in-depth protection against carbonation and chloride penetration whilst permitting water vapour transmission from the concrete.

2

The primer shall be a low viscosity silane-siloxane system which penetrates deeply into a porous substrate and reacts to produce a bonded hydrophobic lining to the pores.

3

The material employed for the coating shall comply with the following requirements:

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400 µm 200 µm R Value at 325 microns > 161 metres.

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Wet film thickness Dry film thickness Carbon Dioxide diffusion resistance (Taywood Engineering Laboratories) Water vapour transmission (Taywood Engineering Laboratories) Reduction in chloride ion penetration (BS 1881 : Part 124) Tear Resistance (ASTM D624) Crack bridging (BRE Method) Chloride Ion Diffusion (Taywood Engineering Labororatories)

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Shall be more than 13 g/m .d 94 % minimum at 28 d 7.3 kN/mm 5.1 mm

2

-10

3.63 x 10

2

cm /sec.

Where test methods are not specified, the procedure for establishing compliance with the above criteria shall be agreed with the Engineer.

5

The Contractor is required to adhere strictly to the manufacturer's recommendations regarding the use, storage, application and safety rules in respect of the approved materials.

14.5.4

Application

1

Where required by the Engineer, trial areas not exposed in the finished work shall first be treated using the selected materials. These trial areas shall be noted on the Drawings and shall be carried out using the type of materials, mixing procedures and applications that will be used on the contract and shall be approved by the Engineer before the Contractor commences with the general work.

2

The exposed concrete surfaces as defined in the documents or as agreed with the Engineer shall be conditioned by the application of a penetrating hydrophobic treatment. The primer shall be allowed to dry in accordance with the manufacturer's requirements.

3

The Contractor shall then apply two coats of pigmented topcoat in accordance with the manufacturer's instructions. The finished coating shall be pinhole free and have a total minimum dry film thickness of 150 m. The colour and finish is to be as agreed with the Engineer.

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The coating shall be applied by spray, roller or brush to achieve a finish acceptable to the Engineer.

5

In all operations of storage, mixing and application the Contractor shall comply with the health and safety recommendations of the manufacturer and governing authorities.

14.6

PLASTIC SHEET LINER FOR CONCRETE STRUCTURES

14.6.1

General

1

This Subpart covers the supply and installation of sheet liners in reinforced concrete structures.

2

The liner must be continuous and free of pinholes both across the joints and in the liner itself.

3

All work for and in connection with the installation of the lining in concrete pipe and structure, and the field sealing and welding of joints, will be done in strict conformity with all applicable specifications, instructions, and recommendations of the lining manufacturer.

14.6.2

Shop Drawings and Submittals

1

The Contractor shall submit to the Engineer for approval the following:

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liner schedule

(b)

material certifications

(c)

test results

(d)

material samples

(e)

the manufacturer of the lining will submit an affidavit attesting to the successful use of its material as a lining for sewer pipes and structures for a minimum period of five years in service conditions recognised as corrosive or otherwise detrimental to concrete.

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(a)

Liner Material Requirements

1

The sheet liner shall be manufactured from, high molecular weight PVC or PE resin and other components necessary to make a material of permanent flexibility suitable for a liner in concrete pipes and structures in sewerage service. The weld strips and the joint strips shall be made from like material. For PVC and PE sheet liners, the actual resin used in manufacture must constitute not less than 99 % of the resin used in the formulation.

2

Copolymer resins will not be permitted.

3

All plastic sheets including locking extensions, all joints and welding strips shall be free of cracks, asperities and other defects that may affect the protective properties of the material.

4

The properties of PVC and PE sheet are shown in Table 14.2

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Page 12

Table 14.2 Properties of PVC and PE Sheet Liners Property

Test Method

PVC Elongation at break Tensile Strength Low Temp. Brittleness PE Elongation at break Tensile Strength Low Temp. Brittleness

Requirement

ASTM D638/882 ASTM D638/412 ASTM D746

300 % 15 MPa 0°C

ASTM D638/882 ASTM D638/412 ASTM D746

Exceeds 600 % 10-20 MPa -75 °C

Plastic Sheet Liner Strip Properties

1

Except at shop welds, all plastic sheet liners and strips shall have the properties shown in Table 14.3 when tested at 25 °C.

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Table 14.3 Properties of Plastic Sheet Liner Strips

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Property

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Shore Durometer

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Weight change

15 MPa 200 % 1 s 50 - 60 5 (with respect to 10 s 35 - 50 5) 1.5 %

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Tensile strength Elongation at break

Requirement

Basic Sheet Dimensions

1

The minimum thickness of the material shall be as shown in Table 14.4

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14.6.5

Table 14.4 Plastic Sheet Liner Minimum Dimensions

Material Thickness

Sheet with locking extensions Sheet, plain Joint strip Weld strip

Structures 4.0 mm 2.3 mm 1.9 mm 2.4 mm

14.6.6

Liner Details

1

Locking extensions (T-shaped) shall be of the same materials as that of the liner and shall be integrally extruded with the sheet.

2

Locking extensions shall be approximately 65 mm apart and shall be at least 10 mm high.

3

Sheets not used for shop fabrication into larger sheets shall be shop tested for pinholes using an electrical spark tester set at 9000 V per 1.0 mm thickness of lining minimum. Holes shall be repaired and retested.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 13

14.6.7

Installation

1

Installation of the lining, including preheating of sheets in cold weather and the welding of all joints, shall be performed in accordance with the recommendations of the manufacturer.

2

The lining to be held snugly in place against inner forms by means of steel banding straps or other means recommended by the manufacturer.

3

Concrete that is to be poured against the lining shall be vibrated, spaded, or compacted in a careful manner to protect the lining and produce a dense, homogenous concrete, securely anchoring the locking extensions into the concrete.

4

In removing forms care shall be taken to protect the lining from damage. In particular:

(b)

when forms are removed, any nails that remain in the lining to be pulled, without tearing the lining, and the resulting holes clearly marked.

(c)

form tie holes to be marked before ties are broken off and all areas of serious abrasion or damage shall be marked.

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All nail and tie holes and all cut, torn, and seriously abraded areas in the lining shall be patched as follows: patches made entirely with welding strip to be fused to the liner over the entire patch area

(b)

larger patches may consist of smooth liner sheet applied over the damaged area with adhesive

(c)

all edges must be covered with welding strip fused to the patch and the sound lining adjoining the damaged area.

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(a)

Hot joint compounds, such as coal tar, shall not be poured or applied to the lining.

7

The Contractor shall take all necessary measures to prevent damage to the installed lining from equipment and materials used in or taken through the work.

14.6.8

Testing Requirements

1

Samples taken from sheets, joints or weld strips shall be tested to determine material properties. Determination of tensile strength and elongation shall be in accordance with ASTM D 412 using Die B. Determination of indentation hardness shall be in accordance with ASTM D 2240 using a Type D Durometer, except that a single thickness of material and indentation hardness shall be made on 25 mm by 75 mm specimens. Thickness of specimens shall be the thickness of the sheet or strip.

2

The measurement of initial physical properties for tensile strength, weight, elongation and indentation hardness shall be determined before chemical resistance tests.

3

Chemical resistance tests shall be carried out to determine the physical properties of the specimens after exposure to chemical solutions. Test specimens shall be conditioned to constant weight at 43 °C before and after submersion in the solutions detailed in Table 14.5 for a period of 112 d at 25  3 °C.

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 14

Volumetric percentages of concentrated reagents of CP grade: At 28 day intervals, specimens shall be removed from each chemical solution and tested. If any specimen fails to meet the 112 day exposure, the material will be subject to rejection.

5

Pull test for locking extensions: Liner locking extensions embedded in concrete shall withstand a test pull of at least 18 kN/m, applied perpendicularly to the concrete surface for a period of 1 min, without rupture of the locking extensions or withdrawal from embedment. This test shall be made at a temperature between 21 °C to 27 °C inclusive.

6

Shop-welded joints: Shop-welded joints, used to fuse individual sections of liner together, shall be a least equal to the minimum requirements of the liner for thickness, corrosion resistance and impermeability. Welds shall show no cracks or separations and shall be tested for tensile strength. Tensile strength measured across the welded joint in accordance with ASTM D 412 using Die B shall be at least 15 MPa. Test temperature shall be 25  3 C and the measured minimum width and thickness of the reduced section shall be used.

7

Spark test: All liner shall be shop tested for holes with a spark tester set to provide from 15 000 to 20 000 V. Sheets having holes shall be satisfactorily repaired in the shop before shipment from the manufacturer’s plant.

8

The Contractor shall provide the Engineer with certified copies of test reports before the shipment of the product to the Site.

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Table 14.5 Chemical Resistance Tests

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Chemical Solutions Sodium Hydroxide Nitric Acid

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5% 1% 1%

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Ferric Chloride

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Ammonium Hydroxide

20 %

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Sulphuric Acid

Concentration

0.1 %

Detergent (Linear alkyl benzyl sulphonate or LAS)

0.1 % BOD not less than 700 mg/l

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Phosphoric Acid 14.6.9

Special Requirements

1

Liner sheets to be closely fitted and properly secured to the inner forms.

2

50 %

(a)

sheets that are to be cut to fit curved and warped surfaces shall use a minimum number of separate pieces

(b)

a 50 mm wide water resistant tape or welding strip shall be welded on the back of butt joints to prevent wet concrete from flowing around the edges.

Unless otherwise shown on the Drawings, the lining will be returned at least 75 mm at the surfaces of contact between the concrete structure and items not of concrete and (a)

the same procedure will be followed at joints where the type of protective lining is changed or the new work is built to join existing unlined concrete

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Section 05: Concrete Part 14: Protective Treatments for Concrete

Page 15

(b)

at each return, the returned liner will be sealed to the item in contact with the plastic lined concrete with an adhesive system

(c)

if the liner cannot be sealed with this adhesive because of the joint at the return being too wide or rough or because of safety regulations, the joint space shall be densely caulked with lead wool or other approved caulking material to a depth of 50 mm and finish with a minimum of 25 mm of an approved corrosion resistant material.

14.6.10 Joints in Lining for In-Situ Concrete Structures Field joints and Lining at joints shall be free of all mortar and other foreign material and shall be clean and dry before joints are made.

2

All welding is to be in strict conformance with the specifications of the lining manufacturer.

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all welds shall be physically tested by a non-destructive probing method

(b)

all patches over holes, or repairs to the liner wherever damage has occurred.

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Each transverse welding strip which extends to a lower edge of the liner will be tested by an approved testing agency at the cost of the Contractor. the welding strips will extend 50 mm below the liner to provide a tab.

(b)

a 5 kg pull will be applied to each tab. The force will be applied normal to the face of the structure by means of a spring balance

(c)

liner adjoining the welding strip will be held against the concrete during application of the force

(d)

the 5 kg pull will be maintained if a weld failure develops until no further separation occurs.

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All surfaces covered with lining, including welds, will be tested with an approved electrical holiday detector with the instrument set at 9000 V per 1.0 mm of lining minimum:

defective welds will be retested after repairs have been made tabs shall be trimmed away neatly by the installer of the liner after the welding strip has passed inspection.

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14.6.11 Testing and repairing damaged surfaces

(g)

inspection will be made within two days after joints has been completed in order to prevent tearing the projecting weld strip and consequent damage to the liner from equipment and materials used in or taken through the work.

END OF PART

QCS 2014

Section 05: Concrete Part 15: Hot Weather Concreting

Page 1

HOT WEATHER CONCRETING ............................................................................. 2

15.1 15.1.1 15.1.2 15.1.3 15.1.4 15.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definition of Hot Weather 2 System Description 3 Submittals 3

15.2

PLACING TEMPERATURE ..................................................................................... 3

15.3

PLANNING CONCRETING ..................................................................................... 4

15.4

MIX DESIGN ........................................................................................................... 4

15.5 15.5.1 15.5.2 15.5.3 15.5.4 15.5.5 15.5.6

TEMPERATURE CONTROL ................................................................................... 4 General 4 Aggregates 4 Water 5 Cement 5 Addition of Ice 5 Liquid Nitrogen 6

15.6

BATCHING AND MIXING ........................................................................................ 6

15.7

TRANSPORTATION ............................................................................................... 6

15.8

PLACING AND FINISHING ..................................................................................... 6

15.9

CURING AND PROTECTION.................................................................................. 7

15.10

INSPECTION AND TESTING .................................................................................. 7

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Section 05: Concrete Part 15: Hot Weather Concreting

Page 2

HOT WEATHER CONCRETING

15.1

GENERAL

15.1.1

Scope

1

This Part covers the precautions to be taken for hot weather concreting for all structural concrete except blinding concrete, where a minimum compressive strength is specified.

2

Related Sections and Parts are as follows:

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This Section Part 6, .............. Property Requirements Part 7, .............. Concrete Plants Part 8 .............. Transportation and Placing of Concrete Part 10 ............. Curing

.

15

References

ta

ACI 305R-91...............American Concrete Institute , Hot Weather Concreting

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ASTM C1064 ..............Measuring the Temperature of Concrete

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BS EN 1992-1-1 .........Eurocode 2, Design of concrete structures. General rules and rules for buildings

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BS EN 480..................Admixtures for concrete, mortar and grout. Test methods

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BS EN 934..................Admixtures for concrete, mortar and grout Definition of Hot Weather

1

The requirements of the following clauses of the specification are applicable during the hot weather period in Qatar.

2

The hot weather period shall be defined as starting when the maximum ambient air shade temperature on the Site exceeds 35 C for three consecutive days. The end of the hot weather period shall be defined as the period when the maximum air shade temperature is below 35 C on three consecutive days.

3

The Contractor shall establish a thermometer on Site that records the ambient air shade temperature. The thermometer shall be established at a position to provide representative air temperature for the Site conditions. If requested by the Engineer the Contractor shall arrange for the calibration of the Site thermometer.

4

Hot Weather” shall mean any combination of the following conditions that tends to impair the quality of freshly mixed or hardened concrete by accelerating the rate of moisture loss and rate of cement hydration, or otherwise causing detrimental results such as:

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15.1.3

(a)

High ambient temperature (when the shade temperature is above 40 deg C on a rising thermometer, 43 deg C on a falling thermometer),

(b)

High concrete temperature,

(c)

Low relative humidity,

(d)

High wind speed

QCS 2014

Section 05: Concrete Part 15: Hot Weather Concreting

(e)

the rate of evaporation exceeds 0.75 kg/m /h

Page 3

2

15.1.4

System Description

1

The Contractor shall undertake hot weather concreting procedures that are effective in controlling the following potential problems associated with concreting in hot weather: increased water demand of the mix

(b)

increased rate of slump loss

(c)

increased rate of setting

(d)

increased tendency for plastic shrinkage cracking

(e)

decreased long-term strength

(f)

increase tendency for drying shrinkage and cracking

(g)

increased tendency for differential thermal effects with consequent cracking

(h)

decreased durability from cracking where there is increased permeability.

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Submittals

1

The Contractor shall prepare weekly in advance his proposed concreting programme showing the quantities to be placed and the anticipated placing hours.

2

At least one month before the start of the hot weather period the Contractor shall submit his specific proposals for the control of the concrete temperature for the constituent materials; cement, water aggregates.

3

Where required the Contractor shall submit to the Engineer his proposals for the use of liquid nitrogen for cooling which shall include details of previous project application and the intended methods to be used and quantities of liquid nitrogen.

15.2

PLACING TEMPERATURE

1

This Subpart of the specification applies at all times of the year and at all times of the day.

2

Maximum fresh concrete temperature (at placement) shall not exceed 32°C unless construction testing to verify a proposed concrete mixture will function satisfactorily at a concrete temperature greater than 32°C. No concrete shall be placed if the concrete temperature is above 35°C

3

Concrete shall not be placed if the shade temperature exceeds 40ºC.

4

The temperature of each truck of concrete shall be measured using either a glass, dial type or electronic thermometer, just before the placing of the concrete and the temperature recorded on the delivery ticket. The maximum temperature at placing shall apply to the entire load of concrete in the truck or conveyer.

5

The Contractor shall allow for the increase in concrete temperature in the period from dispatch from the plant while in transportation or whilst awaiting placement on Site and take adequate measures to ensure the maximum temperature is not exceeded.

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Section 05: Concrete Part 15: Hot Weather Concreting

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PLANNING CONCRETING

1

During the hot weather period as defined in Clause 15.1.3 of this Part, the Contractor shall plan concreting operations such that no concreting takes place between the hours of 10:00 hours and 17:00 hours.

2

The Contractor shall arrange concrete pours such that the programme of works can be achieved without concreting during the period from 10:00 hours to 17:00 hours.

3

The Contractor shall nominate one member of his staff to be the co-ordinator for the supply of concrete. The co-ordinator’s responsibilities shall include ensuring the batched rate matches that of delivery and placement and the preparations needed before commencing a concrete pour.

15.4

MIX DESIGN

1

In the hot weather period, the Contractor shall review all concrete mix designs to ensure that the design slump or workability specified is achieved without increase in the mix water content. The Contractor shall make modifications to the mix design to allow for increased slump loss during transportation in hot weather.

2

This shall be achieved by adjusting the proportion of admixture, plasticiser or super plasticiser. The permitted range of admixture shall be clearly stated on the concrete mix design with nominal values for cold weather and hot weather use.

3

Under no circumstances will the addition of extra water that increases the water cement ratio be permitted during hotter weather.

4

All concrete materials and proportions used in periods of hot weather shall be those that have a satisfactory record of use in such conditions.

15.5

TEMPERATURE CONTROL

15.5.1

General

1

The Contractor’s specific proposals for the control of the concrete temperature shall include extent and type of shading of aggregates, method of chilling mix water and procedures for batching and mixing, transportation, placing and finishing, curing and protection.

2

These shall include calculations in accordance with ACI 305R, clause 3.1 “estimating concrete temperature”. The Contractor shall calculate the temperature of freshly produced concrete based on the input temperatures of the constituent materials and the weights from particular mix designs. The calculations shall make allowance for the rise in temperature between mixing and placing due to the transportation and waiting period. The calculations shall successfully demonstrate that the temperature can be maintained below 32 C at the point of placing.

15.5.2

Aggregates

1

All practical means shall be employed to keep the aggregates as cool as possible.

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15.3

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Section 05: Concrete Part 15: Hot Weather Concreting

Page 5

Stockpiles of aggregates shall be shaded from direct sunlight. Shades shall extend beyond the edge of aggregate storage areas and stockpile layouts shall be such that direct sunlight is not incident on the aggregates. Shades shall be constructed to allow access for mechanical shovels or means of conveyance. Shades and stockpiles shall be constructed so as to permit the free flow of air over the aggregates. Embedded cooling pipes may also be used to cool the aggregate.

3

Sprinkling of coarse aggregates to reduce temperature by evaporation or direct cooling shall not be permitted.

15.5.3

Water

1

Mix Water shall be cooled by storing in underground tanks or insulated tanks above ground.

2

The water shall be chilled by the use of proprietary chillers or the addition of ice to the water tank. Measures shall be taken to ensure that ice pieces are not inadvertently deposited directly into the mixer.

3

Water shall not be chilled below a temperature of 5 C.

4

Tanks, pipes or trucks used for the storage or transportation of water shall be insulated and painted white.

5

The mechanical refrigeration equipment and insulated water storage shall be adequate for the anticipated hourly and daily production rates of concrete during the hot weather period.

6

Mixing water may also be chilled by injection of liquid nitrogen into an insulated holding tank, such procedures shall be to the approval of the Engineer.

7

Ice shall be completely melted in mixing water prior to adding water to the mixer.

15.5.4

Cement

1

The use of freshly ground cement at very high temperatures is not permitted.

2

The cement shall be kept below the temperature which there is a tendency of false set.

3

Under no conditions shall the temperature of the cement exceed 75 C when it enters the mixture.

4

The Contractor shall make arrangements for storage on Site to allow cooling of freshly ground and delivered cement.

15.5.5

Addition of Ice

1

Crushed shaved or chipped ice can be used as part of the mixing water for reducing the concrete temperature.

2

The maximum nominal size of ice particles shall be 10 mm and all the ice must be melted before the completion of mixing of the concrete in the pan.

3

To ensure proper concrete mixing the maximum proportion by substitution shall be 75 % of the batch water requirement.

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Page 6

Crushed ice shall be stored at a temperature that will prevent lumps from forming by refreezing of particles.

5

The batching plant shall incorporate a mechanical system for correctly proportioning and weighing the ice to be added to the mixture.

6

The quantity of ice shall be deducted from the total batch water.

7

The Contractor shall ensure there are adequate quantities of ice in suitable refrigerated storage on the Site at the plant to meet the anticipated daily and hourly production rates of concrete during the hot weather period.

15.5.6

Liquid Nitrogen

1

Freshly mixed concrete maybe cooled by the injection of liquid nitrogen.

2

Care shall be taken to ensure that the concrete directly adjacent the injection nozzle is not frozen.

3

The use of liquid nitrogen for cooling concrete shall include a nitrogen supply vessel and injection facility for the batching plant or one or more injection stations for truck mixers.

4

The system may be set up at the Site for injection just before placing.

5

Proper safety precautions as advised by the supplier of the liquid nitrogen shall be used.

15.6

BATCHING AND MIXING

1

The drums of concrete mixer trucks shall be painted white to minimise solar heat gain.

2

Where a truck mixer has been left standing in the sun, the empty drum shall be sprayed with water and the drum flushed out with cold water before batching. Care shall be taken to ensure all water is removed from the drum before batching.

3

The temperature of the concrete shall be checked after discharge from the mixer and written on the delivery ticket. Temperature check shall be carried out at the plant on the concrete 3 floor for every 50 m produced or every hour which ever is the minimum.

4

A water-reducing, set-retarding chemical admixture conforming to the requirements of BS EN 480 Parts 1, 2 and 4 may be used in varying proportions under different air temperature conditions.

15.7

TRANSPORTATION

1

The transportation, placing, compaction and finishing of concrete shall be at the fastest possible rate. Delivery of concrete to the Site shall be properly scheduled to match the rate of placement and compaction.

15.8

PLACING AND FINISHING

1

If the temperature of the first truck of concrete of a particular pour is above the specification maximum temperature limit then placing shall not commence.

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Section 05: Concrete Part 15: Hot Weather Concreting

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If a pour is in progress and the temperature of a particular truck exceeds the maximum permitted temperature the placing may be allowed to continue at the discretion of the Engineer in order to avoid the possible development of a cold joint.

3

However, no further concreting pours shall take place until the Contractor has submitted revised calculations, in accordance with ACI 305R clause 3.1 to demonstrate that the maximum temperature will not be exceeded in the future. Before beginning new pours the temperature of the concrete constituent materials shall be monitored to verify that they meet the assumptions of the calculations.

15.9

CURING AND PROTECTION

1

Curing and protection shall conform to the requirements of Part 10 of this Section.

2

Evaporation shall be minimised, particularly during the first few hours subsequent to placing concrete, by suitable means such as applying moisture by fog spraying or any other means acceptable to the Engineer.

15.10

INSPECTION AND TESTING

1

All thermometers used for the measurement of concrete temperature shall be calibrated weekly against a glass mercury thermometer. Calibration shall be carried out over the temperature range of 10 C to 100 C using a water bath with ice or heating.

2

The method used to determine acceptance of temperature controlled concrete should be in accordance with ASTM C1064.

3

All concrete test specimens for strength or other purposes shall be carefully protected and cured.

4

Specimens shall be protected from accidental damage by plant personnel or equipment on Site.

5

Specimens shall be kept moist by the addition of water or covering by suitable curing materials.

6

The exact time of preparation of the specimen on Site shall be noted and the time when it is transferred to the laboratory. These times shall be written on the test report.

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END OF PART

QCS 2014

Section 05: Concrete Part 16: Miscellaneous

Page 1

MISCELLANEOUS .................................................................................................. 2

16.1 16.1.1 16.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

16.2 16.2.1 16.2.2 16.2.3 16.2.4 16.2.5 16.2.6 16.2.7 16.2.8

PAVEMENT QUALITY CONCRETE ........................................................................ 3 Scope 3 Mix Designs 3 Cement 4 Water 4 Aggregates 5 Admixtures 5 Air content 5 Density 5

16.3 16.3.1 16.3.2 16.3.3

CEMENTITIOUS GROUT ........................................................................................ 6 General 6 Material 6 Workmanship 6

16.4 16.4.1 16.4.2

SCREEDS ............................................................................................................... 7 Scope 7 General 7

16.5

CELLULAR CONCRETE ......................................................................................... 9

16.6 16.6.1 16.6.2 16.6.3

REPAIR OF CONCRETE ........................................................................................ 9 General 9 Honeycombing or Spalling 9 Crack injection 11

16.7

POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE ......................................................... 13 General 13 Resin 13 Minimum strength 14

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16.7.1 16.7.2 16.7.3

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Section 05: Concrete Part 16: Miscellaneous

Page 2

16

MISCELLANEOUS

16.1

GENERAL

16.1.1

Scope

1

This Part deals with miscellaneous items related to concrete works including pavement quality concrete, no fines concrete, lightweight concrete, cementitious grout, screeds, repair of concrete and guniting.

2

Related Sections and Parts are as follows:

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Part 2, .............. Aggregate Part 3, .............. Cementitious Material Part 4, .............. Water Part 5, .............. Admixture Part 6, .............. Property Requirements Part 7, .............. Concrete Plants Part 8, .............. Transportation and Placing of Concrete Part 9, .............. Formwork Part 10, ............ Curing Part 15, ............ Hot Weather Concreting.

.

This Section

References

1

The following standards are referred to in this Part:

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16.1.2

ACI 506, .....................Guide to Shotcrete

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ASTM C989 –10, ........Standard Specification for Slag Cement for Use in Concrete and Mortars

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BS 146,.......................Portland-blast furnace cement

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BS 812,.......................Testing aggregates BS 1881,.....................Testing concrete

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BS 2782,.....................Methods of testing plastics BS 3892,.....................Pulverised fuel ash BS 4551,.....................Methods of testing mortars, screeds and plasters BS 5075,.....................Concrete admixtures BS 6319,.....................Testing of resin and polymer / cement compositions for use in construction BS 6610,.....................Specification for pozzolanic pulverised-fuel ash cement. BS 8203,.....................Code of practice for installation of resilient floor coverings. BS 8500,.....................Concrete BS EN 197-1, .............Cement. Composition, specifications and conformity criteria for common cements BS EN 480,.................Admixtures for concrete, mortar and grout. Test methods (parts: 1, 2, 4, 5, 6, 8, 10, 11, and 12) BS EN 934,.................Admixtures for concrete, mortar and grout (parts: 2, 6) BS EN 998,.................Specification for mortar for masonry

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Section 05: Concrete Part 16: Miscellaneous

Page 3

BS EN 1744-1, ...........Tests for chemical properties of aggregates. Chemical analysis BS EN 12350,.............Testing fresh concrete BS EN 12390-5, .........Flexural strength of test specimens BS EN 12620,............. Aggregates for concrete EN 197-4:2004 ...........Cement. Composition, specifications and conformity criteria for low early strength blastfurnace cements EN 197-4, ...................Cement. Composition, specifications and conformity criteria for low early strength blastfurnace cements EN 12350, ..................Testing fresh concrete EN 1744-1, .................Tests for chemical properties of aggregates. Chemical analysis

.

GSO EN 206-1, ..........Concrete Specification, performance, production and conformity

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SHW 1000 ..................Specification for Highway Works – UK ROAD PAVEMENTS – CONCRETE MATERIALS

PAVEMENT QUALITY CONCRETE

16.2.1

Scope

1

This Subpart covers the mix design for concrete used for aircraft aprons and roadworks as surface slabs, continuously reinforced concrete roadbase, and wet lean mix except cement bound granular material used as a roadbase or sub-base or as a backfill material for excavations.

16.2.2

Mix Designs

1

Concrete in rigid or composite pavements shall be one of the grades given in Table 16.1 below, in accordance, with the pavement design shown on the Drawings or as directed by the Engineer.

2

All concrete for use in pavements shall be designed mixes or equivalent standard mixes in accordance with the relevant clauses of BS 8500 and GSO EN 206-1, except where otherwise specified.

3

Prescribed mixes may be used for rapid construction with the approval of the Engineer.

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16.2

Table 16.1 Pavement Grades Pavement Layer

BS 8500 and GSO EN 2061Designed Mix

Surface Slabs Unreinforced Concrete

C40

Jointed Reinforced Concrete ( JRC )

C40

Continuously Reinforced Concrete Pavement ( CRCP )

C40

Continuously Reinforced Concrete Roadbase ( CRCR )

C40

Ground Anchorage Beam

C40

BS 8500 and GSO EN 206-1 Standard Mix

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Section 05: Concrete Part 16: Miscellaneous

Page 4

BS 8500 and GSO EN 2061Designed Mix

BS 8500 and GSO EN 206-1 Standard Mix

Wet Lean Mix Concrete 4

C20

ST4

Wet Lean Mix Concrete 3

C15

ST3

Wet Lean Mix Concrete 2

C10

ST2

Wet Lean Mix Concrete 1

C7.5

ST1

Pavement Layer

Cement

1

The general term 'cement' in this Part means the materials shown below.

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16.2.3

Complying with

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EN 197-1

Specification for pozzolanic pulverised-fuel ash cement (grades C20 or below)

BS 6610

BS 146 or EN 197-4

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Cement. Composition, specifications and conformity criteria for common cements Portland blast furnace cement

The use of a combination of Portland cement and ground granulated blast furnace slag is permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate the minimum combined cementitious material content required for the mix.

3

The use of a combination of Portland cement and pulverised fuel ash (PFA) is permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate the minimum combined cementitious material content required for the mix. PFA shall be in accordance with BS 3892.

4

The use of microsilica in the mix designs will be permitted if approved by the Engineer.

5

The Engineer will stipulate the minimum combined cementitious material content required for the mix where PFA or GGBFS are used.

6

The maximum proportion of ground granulated blastfurnace slag with Portland cement shall be as per Table 6.6 of Part 5.6.

7

In combination with Portland cement, the proportion of PFA by mass to the total cement shall be as per Table 6.6 of Part 5.6.

8

The limit of chloride content of the concrete shall be as stated in Table 6.5 of Part 5.6.

9

The minimum cement content for concrete pavements shall be preapproved by Qatar Standards.

16.2.4

Water

1

Water for use in the making and curing of concrete shall conform to the requirements of Part 4 of this Section.

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Section 05: Concrete Part 16: Miscellaneous

Page 5

The water content shall be the minimum required to provide the agreed workability for full compaction of the concrete to the required density, as determined by trial mixes or other means approved by the Engineer..

16.2.5

Aggregates

1

The requirements of Part 2 of this specification will govern, except as modified below.

2

Aggregates for all pavement concrete shall be complying with BS EN 12620

3

Alternatively coarse aggregate of recycled and secondary aggregate materials may be used to replace up to 50% by mass of coarse aggregate

4

The nominal size of coarse aggregate shall not exceed 40 mm. When the spacing between longitudinal reinforcement is less than 90 mm, the nominal size of coarse aggregate shall not exceed 20 mm.

5

If requested by the Engineer, the Contractor shall carry out tests on the proposed aggregate combination to check for the possibility of alkali silica reaction. Such tests shall be carried out in accordance with the procedure laid down in Part 2 of this Section.

16.2.6

Admixtures

1

Plasticisers or water reducing admixtures shall comply with BS 5075, BS EN 480 and BS EN 934. Admixtures containing calcium chloride shall not be used.

2

Other chloride-free admixtures may be used with the approval of the Engineer.

16.2.7

Air content

1

The total quantity of air in air-entrained concrete as a percentage of the volume of the mix shall be 5  1.5 % for mixes of nominal aggregate size 20 and be 4  1.5 % for mixes of nominal aggregate size 40.

2

The air content shall be determined at the point of delivery by a pressure type air meter in accordance with BS EN 12350-7, at the rate of one determination per 300 m2 of slab or at least six times per day whichever is the greater, in conjunction with tests for workability and strength. For areas less than 300 m2, the rate shall be at least one determination to each 20 m length of slab or less constructed at one time or at least three times per day. If the air content is outside the specified limits, a further determination shall be made immediately on the next available load of concrete before discharging. If the air content is still outside the limit, the Contractor shall immediately adjust the air content of the concrete to improve its uniformity, before further concrete is used in the Works.

3

The air-entraining agent shall be added at the mixer, by an apparatus capable of dispensing the correct dose within the tolerance for admixtures given in EN 206-1, and so as to ensure uniform distribution of the agent throughout the batch during mixing.

16.2.8

Density

1

The density of concrete Grades greater than C30 shall be such that without air-entrainment the total air voids are not more than 3 %. With air entrainment, the total air voids shall be not more than 8 %, for 20 mm aggregate or 7 % for 40 mm aggregate.

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Section 05: Concrete Part 16: Miscellaneous

Page 6

The density of concrete Grades B15 and B20, mix ST4 or below shall be at least 95 %, of the theoretical maximum dry density.

16.3

CEMENTITIOUS GROUT

16.3.1

General

1

This Subpart covers a general purpose non-shrink cementitious grout. The grout shall be used to where it is necessary to eliminate shrinkage when filling the void between a base plate and a substrate such as in the grouting of stanchion bases, anchorage fixings, including masts, anchor bolts and fence posts.

2

The grout shall be supplied by a reputable construction chemical company as a single pack prepackaged cement based product which is chloride free.

3

For a particular application, the Contractor shall submit a method statement detailing how the formwork will be placed and the points where the grout will be poured.

4

Before beginning work on large repetitive works, the Contractor shall arrange for a site trial of the materials and methods with the suppliers representative being present to train the Contractor’s personnel in the correct use of the material.

16.3.2

Material

1

The grout shall be suitable for filling gaps of thickness up to 100 mm and shall be free flowing and non shrink.

2

Positive volumetric expansion shall take place while the grout is plastic by means of gaseous expansion to avoid shrinkage and cracking.

3

The compressive strength of the grout when tested in accordance with BS EN 12390-3 shall be a minimum of 25 MPa at 24 h, 40 MPa at 7 d and 50 MPa at 28 d.

4

The grout shall exhibit a high early strength gain yet not be subject to cracking or other detrimental effects.

5

At ambient temperatures above 35 C, cool water shall be used for mixing the grout before placing.

16.3.3

Workmanship

1

The storage handling and pouring of the grout shall be in strict accordance with the manufacturer’s instructions.

2

The substrate surface shall be free from oil grease or loose or partially bonded material.

3

If the concrete surface is defective or has laitance it shall be cut back to a sound base.

4

Bolt holes and fixing pockets shall be blown clean of dirt or debris.

5

The substrate shall be soaked with fresh potable water before grouting, although immediately before grouting, free water shall be removed and blown out of bolt holes or pockets.

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Grout shall not be placed in a gap of less than 25 mm for base plates larger than 1 m wide. For larger base plates or flow areas the manufacturers instructions shall be followed.

7

Base plates and metallic items shall be clean and free from oil, grease, or scale.

8

Vent holes shall be provided to allow the release of air from isolated spots.

9

Formwork shall be made leak proof by the use of form rubber strip or mastic sealant between the constructive formwork and joints. Formwork shall extend above the required pour height and if necessary shall be extended to allow a hydrostatic head to aid placement.

10

The grout shall be mixed mechanically with a slow speed drill fitted with a high-shear mixer.

11

The quantity of water to be added to the preweighed bags shall be enough to give the desirable consistency as trowelable or flowable.

12

Mixing shall take place for a minimum of 5 min.

13

The grout shall be placed within the time limit specified by the manufacturer depending on the actual application temperature.

14

Grout shall be poured from one side and it shall be verified that the grout has flowed under all of the base plate with no voids. Pouring from several sides shall not be permitted.

15

Exposed areas of grout shall be thoroughly cured in accordance with Part 10 of this Section.

16.4

SCREEDS

16.4.1

Scope

1

This Subpart covers screeds that provide by means of a layer of mortar a level surface in flooring applications and to provide falls on flat concrete roofs.

16.4.2

General

1

Screeds shall be suitable for application onto a concrete substrate.

2

The screeds shall be suitable for receiving surface finishes which may arrange from thin flexible sheeting to ceramic tiling. The screed is not intended to be the final wearing surface.

3

Screed mortars shall generally comprise sand and cement modified by additives or substituted by other materials such as polymers in order to provide specific performance requirements.

4

For screeds of thickness greater than 40 mm it is permissible to incorporate a proportion of 10 mm aggregate.

5

Aggregates used for screeds shall not contain deleterious materials such as coal or iron particles which may affect the finish the surface of the screed.

6

Admixtures for mortar screeds shall assist workability or alter rates of setting and hardening and shall comply with the appropriate part of BS EN 480 and BS EN 934.

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Section 05: Concrete Part 16: Miscellaneous

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7

Polymer based additives may be used to improve adhesion and strength of thin or featured screeds, these shall be based on polyvinyl acetate (PVA) styrene bituene rubber (SPR) or acrylic polymers.

8

Ready to use sand cement screeds shall comply with the material requirements BS EN 998.

9

Screeds with a rapid drying time to enable earlier floor finishes to be applied shall be used strictly in accordance with the manufacturers’ instructions.

10

The interface of the screed in the concrete substrate shall be specified as one of the following options by the Engineer: Monolithic with the concrete base: The screed shall be applied within 3 hours of placing the concrete base.

(b)

Bonded to the concrete base: Screed shall be laid onto a concrete base which is hardened and is subsequently been prepared to receive the screed, the minimum thickness of the screed shall be 25 mm and the maximum thickness 40 mm.

(c)

As an unbonded screed: The screed shall be laid on a separating layer.

(d)

As a floating screed: The screed shall be laid on an insulating material.

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The cement and sand screed mix shall have the minimum amount of water added to give sufficient workability and allow the material to be thoroughly compacted.

12

Pan type mixes shall be used to ensure efficient mixing of materials, the cement to aggregate ratio shall be between 1 to 3 and 1 to 4.5 by weight. The mixing of the sand cement, water and admixtures shall ensure a thorough homogeneous mixture with no balling up of the cement.

13

Screeds shall be laid either between carefully levelled and trued batons or between strips of screed laid and compacted to a finished level.

14

For bonded screed where a high degree of bond is required the surface laitance of the concrete base shall be mechanically removed to expose the coarse aggregate. A thin layer of neat cement grout shall be applied to the prewetted or dampened concrete and the screed applied and compacted while the grout is wet.

15

Screeds shall be fully compacted by heavy hand or mechanical tamping. The screed at joints around the perimeter shall be particularly well compacted to avoid breaking out and curling.

16

Screeds thicker than 50 mm shall be laid in two approximately equal layers; screed shall be kept protected by waterproof sheeting for at least 7 days after laying.

17

Sheet and non ceramic tiling finishes shall only be applied after the screed has cured and necessary strength achieved.

18

If requested by the Engineer the Contractor shall carry out a soundness and impact test in accordance with BS 8203.

19

Screeds shall be laid in bays of a size to minimise thermal moisture contraction. Contraction or movement joints shall be provided as appropriate, where shown on the drawings or as directed by the Engineer. Bays shall be laid alternatively.

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Section 05: Concrete Part 16: Miscellaneous

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Bay sizes shall be approximately 15 m2 for 100 mm thick screed and 12 m2 for 75 mm thick screed.

16.5

CELLULAR CONCRETE

1

Cellular Concrete (CC) is conventional concrete, where natural aggregate (gravel) is exchanged for an insulation medium, namely air, embedded in an organic and biodegradable foam. It behaves, like conventional concrete, in particular concerning curing, hardening and most important "ageing ". CC infinitely increases its strength by hydration as long as exposed to humidity in the atmosphere.

2

CC offer more thermal insulation and a substantially higher fire-rating than conventional concrete.

3

Minimum compressive strengths shall be 4.0 MPa.

4

The required density and strength of the CC shall be specified on the drawings and approved by the Engineer.

5

The method of production of Cellular Concrete shall be shown on the drawings or directed by the Engineer. The Contractor shall submit full technical details of the materials and method of production for the CC along with a list of previous projects where the particular system has been used.

6

After source approval of the material and system the Contractor shall submit a mix design for the CLC for the approval of the Engineer. After the review and approval of the mix theoretical mix design the Contractor shall carry out a trial mix to check the workability of the fresh concrete and to allow samples to be made for compressive strength and density.

7

The Engineer may also instruct that tests are carried out for abrasion resistance and thermal insulation properties.

8

Cellular Concrete shall not be used for structural reinforced members.

16.6

REPAIR OF CONCRETE

16.6.1

General

1

The extent and nature of the defects in concrete shall be established in accordance with Part 15 of this Section. Based on these results the Engineer shall confirm the acceptability of the work and whether remedial works are required.

2

If remedial works are required the Contractor shall submit a detailed method statement identifying the specific materials to be used and the sequence of activities for the repair.

3

Only proprietary proven materials that form part of a standard repair system shall be used.

16.6.2

Honeycombing or Spalling

1

Where there is honeycombed concrete or concrete damaged by physical forces such as impact that has caused spalling, the concrete shall be replaced using a high strength free flowing cementitious micro-concrete.

2

The areas of repair shall be marked out and agreed with the Engineer.

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Section 05: Concrete Part 16: Miscellaneous

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All honeycombed, loose, cracked or friable concrete in these areas shall be removed until sound concrete is reached. Due account shall be taken of propping or other instructions given by the Engineer regarding sequences of removal and repair.

4

The equipment and methods used to break out the concrete shall be such that no reinforcing steel or other embedded items such as conduits, lifting sockets, or other inserts are loosened or damaged unless so directed by the Engineer.

5

Where the removal of concrete by mechanical means is difficult due to reinforcement congestion, then the use of high pressure water jetting shall be considered and necessary provisions for protecting the rest of the structure shall be made.

6

The prepared void shall be profiled so that entrapment of air is avoided during the repair process using fluid micro-concrete.

7

The minimum depth of repair shall be 40 mm throughout. The perimeter of the area to be repaired shall first be cut to a depth of 10 mm using a suitable tool. Feather edges will not be accepted.

8

The prepared concrete surface shall be sound and clean and free of loose particles, dust and debris.

9

Where exposed reinforcement is sound, it shall be mechanically cleaned of rust and loose millscale.

10

Reinforcement damaged during the removal of concrete or the preparation process shall, if required by the Engineer, be repaired or replaced.

11

Adequate formwork shall be provided in accordance with of Part 9 of this Section. This shall be securely fixed to withstand the hydraulic pressures of the fluid micro-concrete repair material without distortion or movement during placement.

12

The formwork shall be watertight at all joints between panels and between the formwork and the existing concrete surface so as to prevent grout leakage.

13

The formwork shall be constructed from appropriate materials as agreed with the Engineer to achieve the required finish.

14

Formwork surfaces that are to be in contact with the repair micro-concrete shall be treated with a suitable mould release agent. This shall be used in accordance with the manufacturer's recommendations.

15

The entry point of the feed pipe into the form shall be at the lowest point of the void. Sufficient hydrostatic head or pumping pressure shall be maintained to ensure that the void is filled completely and no air remains entrapped.

16

Where necessary, provision shall be made for controllable bleed points to prevent air entrapment and enable the extent of flow of the repair material to be assessed.

17

The formwork shall be inspected by the Engineer and, if approved, filled with clean water which demonstrates that the formwork is grout-tight and saturates the prepared concrete surfaces. The formwork shall be then be completely drained and resealed

18

In situations where the completed repair will be subjected to constant immersion an epoxy bonding agent shall be applied in accordance with the manufacturers’ instructions.

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Section 05: Concrete Part 16: Miscellaneous

Page 11

19

Both the Compressive strength and Flexural strength shall be at a water:powder ratio of 0.18 and tested at 20 oC

20

The thermal conductivity and the elastic modulus of the repair material shall be compatible with the host concrete.

21

If requested by the Engineer, recent test results of the material for the following properties shall be submitted: (a)

thermal conductivity

(b)

elastic modulus, BS 1881

(c)

expansion characteristics, ASTM C 827, CRD 621-82A

(d)

flow characteristic, UK DOT BD 27/86 paragraph 4.6 B.

The micro-concrete shall be mixed and placed in accordance with the manufacturer's recommendations, particularly with regard to water content, mixing equipment and placing time.

23

As far as possible the placing of the micro-concrete shall be continuous. The mixing operation shall be timed so that there is minimal interruption in the material flow. If, however, placing is interrupted, the operation shall recommence as soon as possible while the repair material retains its flow characteristics.

24

The formwork shall not be removed until the repair micro-concrete has achieved a compressive strength of at least 10 MPa or as directed by the Engineer.

25

Immediately after removal of the formwork the repair area shall be cured in accordance with Part 10 of this Section.

26

The repair material shall:

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be shrinkage compensated in both liquid and cured states

(b)

contain no metallic expansion system

(c)

be prepacked and factory quality controlled

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be a free-flowing cementitious material that has a coefficient of thermal expansion fully compatible with the host concrete and which complies with the requirements of Table 16.3.

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(a)

Table 16.3 Property requirements of micro concrete Property

Test Method

Minimum Value

Compressive strength

BS EN 12390-3 @ 28 d

50 MPa

Flexural strength

BS 4551 @ 28 d

10 MPa

Anchorage bond

BS 8110

Passes

16.6.3

Crack injection

1

This clause of the specification covers non-active cracks within concrete elements caused by shrinkage or other structural movement. Non-active cracks shall be injected with a lowviscosity epoxy resin to fill and seal the crack and restore the structural integrity.

QCS 2014

Section 05: Concrete Part 16: Miscellaneous

Page 12

Before to starting the injection operation it shall be established by testing and investigation work that cracks manifest within concrete elements due to either or both shrinkage or structural movement are non-active.

3

The extent of the cracks to be filled will be as directed by the Engineer. The cracks to be filled shall be marked out in detail on the concrete elements by the Contractor and agreed with the Engineer before proceeding.

4

The extent of the work may be adjusted by the Engineer as the project proceeds, according to the conditions found.

5

Grease, oil or other contaminants shall be removed. Algae and other biological growth shall also be removed by scrubbing with bactericide or detergent and clean water. If necessary, wire brushes shall be used.

6

Loose or spalling areas of concrete, laitance, traces of paint or other coating materials within the marked out scope of the work shall be removed.

7

All cracks shall be thoroughly cleaned out using clean, oil-free compressed air. Both the concrete surface and the cracks shall be allowed to dry thoroughly before continuing.

8

The injection nipples shall be fixed at intervals along the length of each crack. The distance between each nipple will depend on the width and depth of the crack.

9

Spacing shall be close enough to ensure that the resin will penetrate along the crack to the next point of injection. This will normally be between 200 mm and 100 mm.

10

Each nipple shall be firmly bonded to the concrete surface by using a sealant. The sealant shall be supplied in two pans (liquid base and hardener system). The two components shall be thoroughly mixed together for 3 to 4 min until a putty-like consistency is achieved.

11

The mixed sealant shall be applied to the metal base of each surface-fixed nipple. They shall be pressed firmly into place and held for several seconds until secure. The mixed sealant shall be applied around each embedded nipple, ensuring a complete seal is made. In this way, all the nipples shall be fixed along the length of the crack.

12

In the case of a wall or slab which is cracked all the way through, nipples shall be located on both sides with those at the back placed at midway points between those it the front.

13

The surface of the cracks between the nipples shall be sealed with a band of sealant 30 to 40 mm wide and 2 to 3 mm thick. Both sides if cracks which go all the way through a wall or slab shall be sealed in this way.

14

The prepared cracks shall be allowed to cure for 12 to 24 h. At low ambient temperatures (5 °C to 12 °C) the curing time will be extended and the Contractor shall ensure that the surface sealant has adequately cured before continuing.

15

One end of the injection hose shall be attached to the lowest nipple on vertical cracks or to either end of horizontal cracks.

16

Each crack shall be treated in a single, continuous operation. Sufficient material shall therefore be made ready before the commencement of the work.

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Section 05: Concrete Part 16: Miscellaneous

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The Contractor shall to ensure that sufficient cracks are prepared to provide effective use of the mixed material.

18

The preparation, mixing and application of the materials shall be undertaken in strict accordance with the manufacturer's recommendations. The Contractor is to ensure that all necessary tools and equipment are on Site.

19

Both the compressive strength and flexural strength shall be tested at 7 d.

20

The material shall exhibit excellent bond to concrete and when tested for tensile adhesion the failure shall be in the concrete and not at the interface.

21

The injection resin shall be of a prepackaged or preweighed type and only the use of full units will be allowed. No part packs or on-Site batching will be allowed under any circumstances.

22

In all operations of storage, mixing and application, the Contractor shall comply with the health and safety recommendations of the manufacturer and governing authorities.

23

The injected system shall be allowed to cure for 24 h and shall be left undisturbed for this time.

24

The nipples and bands of surface sealant shall then be removed and damaged areas made good to the satisfaction of the Engineer.

25

The injection material shall be compatible with the host concrete and shall have the properties shown in Table 16.4 when tested in accordance with the relevant standards.

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Property

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Table 16.4 Property Requirement for Epoxy Crack Injection Material Method

BS 4551, BS 2782 BS 6319

Flexural strength

BS EN 12390-5

70 MPa

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Compressive strength

Minimum Value

POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE

16.7.1

General

1

Polyester resin concrete is a mixture formed from aggregates and fillers which are bound together using a polyester resin (also called Polymer concrete pipes), as defined in ISO 18672-1 or ASTM D 6783 with the amendments given below.

2

Polyester resin concrete is permitted for use in infrastructure drainage and sewage systems (pipes, manhalls, soakways).

16.7.2

Resin

1

The resin used in the pipe system and manufactured as per ISO 18672-1shall have a temperature of deflection of at least 85 °C, when tested in accordance with Method A of ISO 75-2 with the test specimen in the edgewise position. It shall also conform to the applicable requirements of EN 13121-1.

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Section 05: Concrete Part 16: Miscellaneous

Page 14

2

The resin used in the pipe system and manufactured as per ASTM D 6783 shall have a minimum deflection temperature of 85°C when tested at 1.82 MPa following Test Method D648. The resin content shall not be less than 7 % of the weight of the sample as determined by Test Method D2584.

16.7.3

Minimum strength

1

The minimum strength classes for different pipe shapes are given below. Table 16.4

.

Minimum strength classes for pipes designated PRC-OC or PRC-TC Strength class Sc Nominal size N/mm DN PRC-TC

150 ≤ DN ≤ 500

180

180

600 ≤ DN ≤ 1000

145

1200 ≤ DN≤ 3000

120

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160

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Table 16.5 Minimum strength classes for pipes designated PRC-OE or PRC-TE Strength class Sc N/mm

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Nominal width/height WN/HN

PRC-TE

300/450 ≤ WN/HN ≤ 600/900

180

180

700/1050 ≤ WN/HN ≤ 1000/1500

145

160

120

145

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1200/1800 ≤ WN/HN ≤ 1400/2100

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Table 16.6 — Minimum strength classes for pipes designated PRC-OK or PRC-TK Strength class Sc N/mm

Nominal size DN

PRC-OK

PRC-TK

800 ≤ DN ≤ 1000

145

160

1200 ≤ DN ≤ 1800

120

145

END OF PART

QCS 2014

Section 05: Concrete Part 17: Structural Precast Concrete

Page 1

STRUCTURAL PRECAST CONCRETE .................................................................. 2

17.1 17.1.1 17.1.2 17.1.3 17.1.4 17.1.5 17.1.6 17.1.7 17.1.8 17.1.9

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 3 Qualifications 4 Quality Assurance 4 Quality Control 5 Testing 6 Delivery, Storage and Handling 7 Design Loadings, Actions and Structural Members Selection 7

17.2 17.2.1 17.2.2 17.2.3 17.2.4

MATERIALS ............................................................................................................ 8 General 8 Reinforcing Bars 8 Bearing Pads 8 Embedded Steel 8

17.3 17.3.1 17.3.2

FORMING ............................................................................................................... 8 General 8 Tolerances 9

17.4 17.4.1 17.4.2 17.4.3 17.4.4 17.4.5 17.4.6 17.4.7 17.4.8

INSTALLATION ....................................................................................................... 9 General 9 Survey 9 Guying, Bracing and Shoring 9 Adjustment and Correction 9 Erection Tolerances 10 Welding 10 Grouting 10 Field Cutting 10

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Section 05: Concrete Part 17: Structural Precast Concrete

Page 2

STRUCTURAL PRECAST CONCRETE

17.1

GENERAL

17.1.1

Scope

1

The work included in this Section comprises furnishing all plant, labour, equipment, appliances and materials and performing all operations in connection with Structural Precast Concrete Work.

2

Related Sections and Parts are as follows:

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This Section Part 2 ............... Aggregates Part 3 ............... Cementitious materials Part 5 ............... Admixtures Part 6 ............... Property requirements Part 7 ............... Concrete Plants Part 8 ............... Transportation and placing of concrete Part 9 ............... Formwork Part 10 ............. Curing Part 11 ............. Reinforcement Part 15 ............. Hot weather concreting

.

17

References

1

The following standards and other documents are referred to in this Part:

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AASHTO ....................Standard Specification for Highway Bridges, Section 25 ACI 523.2R .................Guide for Precast Cellular Concrete Floor, Roof, and Wall Units

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ACI 533.1R .................Design Responsibility for Architectural Precast-Concrete Projects ACI 543R ....................Design, Manufacture, and Installation of Concrete Piles

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ACI 550.1R-09............Guide to Emulating Cast-in-Place Detailing for Seismic Design of Precast Concrete Structures ASCE/SEI 7-05...........Minimum Design Loads for Buildings and other Structures ACI 318-11 .................Building Code Requirements for Structural Concrete BS 8110......................The structural use of concrete. BS EN 1991-1-4 .........Eurocode 1. Actions on structures. General actions. Wind actions BS EN 1992-1-1 .........Eurocode 2. Design of concrete structures. General rules and rules for buildings ISO 9000, ..................Quality management systems. Fundamentals and vocabulary Prestressed Concrete Institute (PCI) , Manual 116

QCS 2014

Section 05: Concrete Part 17: Structural Precast Concrete

17.1.3

Submittals

1

Manufacturer's Literature: (a)

2

the Contractor shall provide copies of manufacturer's specifications and installation instructions for each item of proprietary material to be used, showing compliance with this specification. Information on equipment, embedded items and other accessories shall also be provided.

Design Mixes: (a)

copies of mix designs with support material

(b)

the requirements of the mix design shall be in accordance with Parts 6 and 7 of this Section.

Product Design Criteria:

initial handling and erection stresses

(ii)

all dead and live loads as specified on the contract drawings or as required

(iii)

all other loads specified for the member where they are applicable.

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Product Design Calculations: (a)

the design calculations shall be performed by a Structural Engineer experienced in precast concrete design. They shall cover all stages of handling, transportation and erection. The design shall be carried out in accordance with the requirements of BS EN 1992-1-1 or relevant ACI codes, and shall be accepted by the Engineer.

(b)

calculations for the design of precast members shall be supported by a statement explaining the principle of design and type of analysis adopted

(c)

the influence of individual members in achieving the overall stability of the structure should be considered

(d)

computer programmes used in the designs shall be fully described and details of input and printout shall be presented in a manner which can be readily understood and the following requirements shall be met:

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loadings for design:

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programme manuals and instructions to programme users shall be made available to the Engineer upon request

(ii)

where such programme cannot be demonstrated by the Contractor to have been fully checked or where the Engineer considers it necessary, the Contractor shall run such test examples as the Engineer may choose, in order to verify the completeness and accuracy of the programme

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(e)

members that are exposed to the weather shall be designed to provide for the movement of components without damage, failure of joint seals, undue stress on fasteners or other detrimental effects when subject to seasonal or cyclic day/night temperature ranges

(f)

precast systems shall be designed to accommodate construction tolerances, deflection of other building structural members and the clearance of intended openings

(g)

calculate structural properties of framing members in accordance with BS 8110 or BS EN 1992-1-1, or relevant ACI codes.

Shop Drawings. The Contractor shall provide the following information for the approval of the Engineer: (a)

layout plans and detailed fabrication and placement drawings for each structural precast element

QCS 2014

(b)

size, grade, profile and dimensions of all materials used

(ii)

connection and anchorage details

(iii)

lifting devices, locations and handling limitations

(iv)

steel reinforcement details

(v)

all openings, sleeves, inserts and other provisions in full co-ordination with all trades in the Contract

(vi)

identification marks.

.

detailed outline of sequence and methods of erection including but not limited to types, capacities and numbers of cranage, methods of support and transportation.

(ii)

date of pour

(iii)

concrete test results

(iv)

shop drawing reference number

(v)

type and duration of curing

(vi)

date of delivery to Site

(vii)

date of fixing in position.

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copies of all testing and inspection reports.

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the Contractor shall produce trial panels in accordance with the requirements of Part 10 of this Section. trial panels shall be retained for reference purposes for the acceptance of the production work.

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(i)

Trial Panels: (a)

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A record shall be kept for every piece of precast element produced showing the following:

Test Reports: (a)

9

(i)

Fabrication Records: (a)

8

shop drawings are to include the following information:

Erection Procedures: (a)

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Section 05: Concrete Part 17: Structural Precast Concrete

17.1.4

Qualifications

1

Structural precast work shall be executed by an approved specialist Subcontractor for casting and also for transportation, handling and erection.

2

The Contractor may execute this work himself if he can satisfy the Engineer that he has sufficient experience and expertise in this field. As a minimum the Contractor shall: (a)

provide satisfactory evidence that his tradesmen and their supervisory personnel engaged in such work have successful experience with work comparable to that shown and specified

(b)

provide details of organised quality control and testing procedures.

17.1.5

Quality Assurance

1

The precast concrete supplier shall have a quality assurance scheme that meets ISO 9000 or equivalent.

QCS 2014

Section 05: Concrete Part 17: Structural Precast Concrete

Page 5

All work shall be performed to secure for the project homogeneous concrete having the required strength, surface finish, materials, durability, and weathering resistance, without planes of weakness or other structural defects, and free of honeycombs, air pockets, voids, projections, offset of plane and other defacements of concrete.

3

No alterations or substitutions of the structural systems shown on the Drawings are permitted unless otherwise specified.

4

The Contractor shall supervise and co-ordinate all phases of the structural precast concrete construction process and be responsible for the complete manufacturing process.

5

All methods of manufacture and practices of handling raw materials and manufactured concrete shall be reviewed by the Engineer before execution of the structural precast concrete work, at least 14 days before the beginning of precasting work.

6

Only materials of known quality shall be incorporated in the work.

7

All materials shall be properly selected, reviewed and approved by the Engineer before use, and maintained during shipment, storage and use.

8

Construction systems and techniques shall be properly selected, reviewed and approved by the Engineer before use, and maintained throughout the complete structural precast concrete construction phase.

9

Adequate spare equipment, parts, additional components and repair facilities shall be available for all tools and equipment.

10

Regardless of approvals by the Engineer, the Contractor shall be responsible for all materials and methods of structural precast concrete work.

11

If work does not meet the specified requirements, the Contractor shall at no additional cost to the Employer:

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implement removal, replacement or remedial work

(b)

revise procedures or materials to prevent recurrence of unacceptable work.

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Quality Control

1

The Contractor shall prepare and provide his quality control programme for structural precast concrete work with particular attention to details, pre-checking processes, procedures and close supervision, and in particular the Contractor shall:

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17.1.6

2

(a)

in order to assure that proper work is performed to prevent later corrective actions, assign at least one experienced supervisor full time to provide quality control for structural precast concrete work

(b)

the assignment will not relieve the Contractor's other quality control personnel of their duties relative to the quality control of the structural requirements and surface finish of the structural precast concrete work.

The Contractor shall arrange for the training of his quality control personnel who will perform quality control of structural precast concrete work and whose training shall include but not be limited to: (a)

materials evaluation

(b)

special mix design techniques

(c)

mix placement

QCS 2014

Section 05: Concrete Part 17: Structural Precast Concrete

(d)

vibrator selection and use

(e)

formwork details formwork protection

(f)

release agent use

(g)

reinforcing steel

(h)

detailing and installation

(i)

finishing equipment and techniques

(j)

corrective procedures and protection of completed work.

Page 6

The Contractor's quality control personnel shall be responsible for verifying all details necessary to produce the final structural design objectives.

4

The Contractor's quality control personnel shall also verify the quality of the structural precast concrete work and guide the production of results which will be within acceptable physical tolerances

17.1.7

Testing

1

Concrete shall be tested as specified in Part 6 of this Section.

2

The Contractor shall:

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furnish labour required to facilitate testing

(b)

inform the Engineer with at least one day's advance notice when concrete is to be placed

(c)

provide storage facilities for concrete test cubes

(d)

provide material samples and access to materials as required for testing.

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(a)

Should the batching plant be located more than 500 meters away from the site offices, the Contractor shall provide suitable transport acceptable to the Engineer, for the sole use of the Engineer's staff.

4

The Contractor shall station a qualified technician at the casting site to continuously test, inspect and report on the following:

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(a)

that concrete testing is being carried out in accordance with the requirements of Part 6 of this Section

(b)

check the following and verify conformance with specified requirements and approved shop drawings:

(c)

5

(i)

all reinforcing bars

(ii)

all embedded items

(iii)

all formwork

check all openings and provisions for co-ordination with all trades in the Contract as shown on approved shop drawings.

The Contractor shall provide facilities and equipment for the conducting of all tests specified herein except for the strength test which should be carried out by an approved independent testing agency.

QCS 2014

Section 05: Concrete Part 17: Structural Precast Concrete

Page 7

Delivery, Storage and Handling

1

The structural precast elements shall be removed from the form without damaging or over stressing and stored or placed for transportation on a stable bed that will not allow distortion of the member.

2

Separate stacked members with suitable battens and bracing.

3

Mark each member with an identifying reference or piece mark, and the date of casting.

4

All piece marks are to be correlated with test reports and plan layouts or erection drawings.

5

The structural precast element shall be transported with sufficient battens, bracing, and supports so as to prevent over-stress by vibration or impact loadings. The Contractor shall submit his proposed method of transportation to the Engineer for approval.

6

Structural precast units shall be stored, handled and transported in a manner that will avoid undue strains, hair cracks, staining, or other damage.

7

The Contractor shall deliver the units from the casting site to the project Site in accordance with schedule and proper setting sequence.

8

Structural precast units shall be stored free of the ground and protected from wind or rain splashes.

9

The units shall be covered and protected from dust, dirt or other staining materials.

10

During fabrication, construction and after erection, the Contractor shall protect the castings to avoid the possibility of damage.

17.1.9

Design Loadings, Actions and Structural Members Selection

1

The provisions of this Clause shall apply if the Contractor is responsible for the design of the structural precast units.

2

The precast elements shall be designed to withstand all loading conditions against which strength and serviceability must be measured.

3

Vertical loads shall include the self-weight of precast elements, floor coverings and live loads as indicated on the contract drawings.

4

The wind loads shall be calculated based on the wind speed provided in Section 1 part 1 clause 1.5.2.

5

Account shall be taken of the loads and deformation caused by temperature and time dependent deformations. For such purpose 55 °C temperature variation and 90 % relative humidity should be considered for all members, except exterior elements and facade o elements shall consider 85 C.

6

Precast elements shall be designed in accordance with BS EN 1992-1-1 or relevant ACI code. Design tensile stresses should not exceed the design flexure tensile stress of concrete, at the particular age of the concrete.

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17.1.8

QCS 2014

Section 05: Concrete Part 17: Structural Precast Concrete

Page 8

Nominal cover to steel including links must meet the durability requirement of severe condition of exposure and to meet requirement for 2 h period of fire resistance, as provided for in BS EN 1992-1-1 or relevant ACI code.

8

Total deflection of precast elements should be limited to 1/350 of the span of this element.

9

Plan and design for openings for building services, where required or necessary.

17.2

MATERIALS

17.2.1

General

1

The Contractor shall obtain cement, aggregates and water from a single source, sufficient to complete the entire structural precast concrete work to assure regularity of appearance and uniformity of colour.

2

The Contractor shall provide all materials in accordance with and meet all applicable requirements of this section.

17.2.2

Reinforcing Bars

1

Reinforcing bars shall conform to the requirements of Part 11 of this Section

17.2.3

Bearing Pads

1

These shall be Elastomeric neoprene, conforming to AASHTO Standard Specifications for Highway Bridges (Section 25) with the following stipulations: use unfactored loads for design

(b)

maximum compressive stress, 0.70 MPa

(c)

maximum shear stress, 0.07 MPa

(d)

maximum shear deformation, 1/2 thickness

(e)

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maximum compressive strain, 15 %

17.2.4

Embedded Steel

1

All embedded items shall be of stainless steel Grade 316L.

17.3

FORMING

17.3.1

General

1

Forms and casting beds are to be firmly seated so as not to deflect or be displaced under concreting or tensioning loads.

2

Correct for thermally induced strains or forces.

3

For member penetrations larger than 150 mm, coring or field cutting is not permitted unless approved by the Engineer.

4

Clean and coat forms with release agent before installation or reinforcing or embedments.

QCS 2014

Section 05: Concrete Part 17: Structural Precast Concrete

Page 9

17.3.2

Tolerances

1

Permissible deviations of formed surfaces are not to exceed tolerances outlined in PCI Manual 116, with items as summarised or modified in Table 17.1

Table 17.1 Tolerances for Structural Precast Concrete Description

Tolerance

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5 mm 3 mm Stem 3 mm; Flange 2.0 mm. 0.2 % 3 mm. for 300 cm 3 mm

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Dimensions Length: Width: Thickness: Embedment or penetration location: Straightness: End squareness:

INSTALLATION

17.4.1

General

1

The Contractor’s erection responsibilities include the safe and proper placing, aligning, and levelling of the structural precast elements on the accepted bearing surfaces and affecting their proper fastening.

17.4.2

Survey

1

Before placement of the structural precast elements the Contractor shall survey and maintain all temporary supports shown or required to control alignment, and deflection.

2

Temporary supports shall be retained until framing elements braced thereby have attained integral stability in accordance with the design.

17.4.3

Guying, Bracing and Shoring

1

The Contractor shall install in proper sequence and maintain all temporary supports shown or required to control alignment, deflection and stress levels.

2

Temporary supports shall be retained until framing elements braced thereby have attained integral stability in accordance with the design.

17.4.4

Adjustment and Correction

1

The Contractor shall compensate and correct for the misaligning affect of temperature, draw from welding, bolting or erection sequence or grouting.

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17.4

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Section 05: Concrete Part 17: Structural Precast Concrete

Page 10

17.4.5

Erection Tolerances

1

The following erection tolerances shall apply unless otherwise specified in the Contract: (a)

Variations from plumb

6 mm in 6 m run; 12 mm total in a12 m or longer run

(b)

Variation from level or elevation

6 mm in runs; 12 mm in 12 m run; maximum 12 mm at single locations 12 mm maximum.

(c)

Variation from position in plan

(d)

Offsets in alignment of adjacent 1.5 mm in 3 m run, 6 mm maximum.

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members at joints

Welding

1

Where permission for welding is given by the Engineer, the following shall apply:

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17.4.6

welding shall not take place until all adjacent elements to be connected have been aligned, firmly seated and braced

(b)

control of heat build-up by limiting voltage, electrode size, and rate

(c)

spalled or heat damaged concrete around weldments shall not be acceptable.

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(a)

Grouting

1

Joints, gaps and connections shall be filled with grout as shown on the Drawings and as approved by the Engineer.

17.4.8

Field Cutting

1

Field cutting of holes may be done only with the Engineer's concurrence, and only with power saws or core drills. Steel reinforcement or prestressing strand shall be avoided, where the reinforcement or strand is damaged the unit shall be repaired to the satisfaction of the Engineer, or rejected.

2

The maximum hole size shall be 150 mm diameter or as limited by member size or strand location

3

Any cracks, spalls and sharp corners created by field cutting are to be ground, eased, and patched with epoxy type bonding and patching compounds.

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END OF PART

QCS 2014

Section 05: Concrete Part 18: Prestressed Concrete

Page 1

PRESTRESSED CONCRETE ................................................................................. 2

18.1 18.1.1 18.1.2 18.1.3 18.1.4

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 3 Storage and Handling 3

18.2 18.2.1 18.2.2 18.2.3 18.2.4 18.2.5 18.2.6 18.2.7 18.2.8 18.2.9

PRESTRESSING .................................................................................................... 3 General 3 Wires and Strands 4 Sheaths, Cores and Ducts 5 Anchorages 5 Jacking Equipment 5 Tensioning 6 Grouting 7 Grout Mixer 7 Grout Trials 8

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Section 05: Concrete Part 18: Prestressed Concrete

Page 2

18

PRESTRESSED CONCRETE

18.1

GENERAL

18.1.1

Scope

1

This section describes the requirements for prestressed post-tensioned concrete, including materials and procedures for installation, stressing and grouting.

2

Related Sections and Parts are as follows:

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ACI 325.7R ------------- Recommendations for Designing Prestressed Concrete Pavements ACI 343R ---------------- Analysis and Design of Reinforced Concrete Bridge Structures ACI 350.3R ------------- Seismic Design of Liquid-Containing Concrete Structures ACI 358.1R ------------- Analysis and Design of Reinforced and Prestressed-Concrete Guideway Structures ACI 372R ---------------- Design and Construction of Circular Wire- and Strand-Wrapped Prestressed-Concrete Structures ACI 373R ---------------- Design and Construction of Circular Prestressed Concrete Structures with Circumferential Tendons ACI 423.3R ------------- Recommendations for Concrete Members Prestressed with Unbonded Tendons

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Part 2 ............... Aggregates Part 3 ............... Cementitious Material Part 4, ........... Water Part 5, ........... Admixtures Part 6, ............ Property requirements Part 7, ........... Concrete Plants Part 8, ............ Transportation and placing of concrete Part 9, ........... Formwork Part 10, ........... Curing Part 11, ........... Reinforcement Part 15, ........... Hot weather concreting Part 16, ........... Miscellaneous

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This Section

ASTM A881/A881M -- Standard Specification for Steel Wire, Deformed, Stress-Relieved or Low-Relaxation for Prestressed Concrete Railroad Ties ASTM A882/A882M--- Standard Specification for Filled Epoxy-Coated Seven-Wire Prestressing Steel Strand ASTM A641/A641M – Standard Specification for Zinc-Coated (Galvanized) Carbon Steel Wire ASTM A416/A416M-10 Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete AWWA D110-------------Wire- and Strand-Wound, Circular, Prestressed Concrete Water Tanks BS 1881......................Testing Concrete. BS EN 12350,.............Testing fresh concrete

QCS 2014

Section 05: Concrete Part 18: Prestressed Concrete

Page 3

BS EN 12390,.............Testing hardened concrete BS 5896,.....................Specification for high tensile steel wire and strand for the prestressing of concrete. BS EN 1992

Eurocode 2: Design of concrete structures

GSO ISO 1920, .......... Testing of concrete 18.1.3

Submittals

1

Samples

.

Technical details of the proposed materials and equipment shall be submitted. Details of the jack type and size shall be submitted to allow for clearances to be checked. A calibrated stress-recording device shall be used. Design Data. The Contractor shall submit:

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(c)

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(b)

a 1 m length sample of strand shall be taken from every 1000 m of strand to be installed in the works with a minimum of one sample of strand per reel, on Site in the presence of the Engineer for strength test at an independent laboratory approved by the Engineer. A reel shall only be accepted if both the breaking load and the 0.1 % proof load of the sample exceed the characteristic load given in BS 5896 Table 6 a minimum of three samples of strand shall be taken at random from each reel of prestressing steel on Site in the presence of the Engineer. The reels on Site shall only be accepted if the relaxation values determined by the tests are equal to or lower than the specified relaxation class of BS 5896. Sample requirements and frequency for prestressing wire shall meet the requirements of AWWA D110 and ACI 372R.

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(a)

(b)

tendon extension calculations

(c)

vent pipe spacing and location details.

(d)

detailed execution and shop drawings

(e)

calculation notes

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details of the proposed grout mix design

Other Submittals. The Contractor shall also submit:

Safety procedures, including warning signs, barricades and communication between different stressing locations

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(b)

Curriculum vitae and experience record of the supervisor proposed, who shall have a minimum of five years experience in such a position

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(a)

(c)

The name of the proposed the prestressing company, giving details of previous projects.

18.1.4

Storage and Handling

1

Prestressing steel shall be stored on palettes at least 300 mm above the ground, and be protected from contamination by wind blown sand or rain.

2

Prestressing strand shall be in coils of sufficiently large diameter to ensure that the strand pays off straight.

18.2

PRESTRESSING

18.2.1

General

1

Prestressing operation shall be carried out only under the direction of an experienced and competent supervisor and all personnel operating the stressing equipment shall have been properly trained in its use.

QCS 2014

Section 05: Concrete Part 18: Prestressed Concrete

Page 4

In addition to the normal precautions against accident, which should be taken at all times for the whole of the Works, special care shall be taken when working with or near tendons which have been tensioned or are in the process of being tensioned.

3

The system of prestressing used shall be a system approved by the Engineer. Such system shall be used strictly in accordance with the recommendations of the system manufacturer.

4

Under no circumstances shall equipment or fittings designed for use with one system of prestressing be used in conjunction with equipment and fittings designed for use with another system.

5

Prestressing components shall be stored in clean dry conditions. They shall be clean and free form loose rust and lose mill scale at the time of fixing in position and subsequent concreting. Slight rusting of the steel, which can be removed by moderate rubbing, is acceptable, but the surface shall not show signs of pitting.

18.2.2

Wires and Strands

1

All prestressing strands shall be seven-wire super stabilised low relaxation strands with a Guaranteed Ultimate Tensile Strength (GUTS) of not less than 1770 MPa, complying with BS 5896 or relevant ASTM standards.

2

All prestressing wire shall be cold-drawn, high-carbon wire meeting the requirements of ASTM A821/A821M, Type B having a minimum ultimate tensile strength of 1,448 MPa (210,000 psi) prior to galvanizing. Zinc coating for galvanizing shall meet the requirements of ASTM A641/A641M, with a minimum weight per unit area of uncoated wire surface of 259 g/m2 (0.85 oz/ft2). The minimum ultimate strength of the wire after galvanizing shall be no less than 1,241 MPa (180,000 psi).

3

All wires or strands to be stressed at the same time shall be taken from the same parcel. The coil numbers of the steel used for each tendon shall be recorded.

4

Welding of tendons shall not be permitted.

5

All cutting of strands shall be carried out using a high-speed abrasive cutting wheel or friction saw at not less than one diameter from the anchor. Cutting shall take place only after the Contractor has submitted the stressing records and the Engineer has approved them in writing. Flame cutting will not be permitted.

6

Tendons shall be built into the Works strictly in accordance with the system which is being employed.

7

Sufficient strand shall project from the anchorage to allow jacking to take place at the stressing end of the tendon.

8

The cable (tendons) or individual strands comprising the cable shall not be kinked or bent. No strand that has become unravelled shall be used.

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Section 05: Concrete Part 18: Prestressed Concrete

Page 5

Sheaths, Cores and Ducts

1

Sheaths shall be accurately located both vertically and horizontally as described in the Specific Project Specification. Unless otherwise described in the Specific Project Specification the tolerance in the location of the centre line of the sheath shall be within 5 mm.

2

All sheaths and cores shall be maintained in their correct positions during the placing of the concrete. Unless otherwise agreed with the Engineer, sheaths shall be rigidly supported at points not less than 50 mm and not more than 500 mm apart. The method of support shall be to the approval of the Engineer.

3

Where sheaths are used, the number of joints shall be kept to a minimum and sleeve connectors shall be used for jointing. Each joint shall be adequately sealed against the ingress of material. Joints in adjacent sheaths shall be staggered by at least 300 mm

4

Sheaths shall be kept free of matter detrimental to the bond between the grout and the sheath and, except for material sealing a sheath joint, between the sheath and concrete.

5

Within 24 hours of the concrete being placed the Contractor shall satisfy the Engineer that the tendons are free to move if they are in ducts or that the ducts are free from obstruction.

6

The number and position of grout vents for entry and outlet points and for checking that the entire length of duct has been adequately grouted, shall be agreed with the Engineer before the ducts are formed.

7

Vents shall be provided at low points in the tendon profile to allow the disposal of water that may have collected as a result of rain or curing, for example. The vents shall be sealed before grouting operations beginning.

18.2.4

Anchorages

1

Anchorages, end blocks and plates shall be positioned and maintained in position during concreting so that the centre line of the duct passes axially through the anchorage assembly.

2

All bearing surfaces shall be clean before concreting and tensioning.

3

Anchoring of prestressing wires shall meet the requirements of AWWA D110 and ACI 372R.

18.2.5

Jacking Equipment

1

All jacking equipment used for stressing operations shall be of the type applicable to the system adopted.

2

Jack and pumps shall be calibrated at an independent facility, in the presence of the Engineer, before beginning stressing operations. Calibration of the equipment shall take place at six-month intervals for equipment permanently present on Site. Whenever new equipment is brought to the Site, or equipment is removed and returned, or serviced, recalibration of the equipment as described will be required.

3

All gauges, load cells, dynamometers and other devices used for measurement shall have a reading accuracy of within 2 %.

4

Stressing equipment for prestressing wires shall meet the requirements of AWWA D110 and ACI 372R.

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18.2.3

QCS 2014

Section 05: Concrete Part 18: Prestressed Concrete

Page 6

Tensioning

1

The Contractor shall submit details of the proposed stressing loads and stressing sequence to the Engineer for approval.

2

Tensioning shall be carried out only in the presence of the Engineer or his representative unless permission has been granted to the contrary.

3

The Contractor shall ensure that personnel carrying out the stressing are provided with particulars of the required tendon loads, order of stressing and extensions.

4

Immediately before tensioning, the Contractor shall prove that all tendons are free to move between jacking points.

5

Unless otherwise permitted in the Contract, concrete shall not be stressed until it has reached at least the age at which two test cubes taken from it attain the specified transfer strength. The cubes shall be made and tested as described in BS 1881 , BS EN 12350, BS EN 12390 or GSO ISO 1920. They shall be cured in similar conditions to the concrete to which they relate to, and in a manner approved by the Engineer.

6

The friction factors assumed for the calculation of tendon extension shall be verified by on Site measurement of the force-extension relationship of a typical sample of installed tendons.

7

The Contractor shall establish the datum point for measuring extension and jack pressure to the satisfaction of the Engineer.

8

The tendons shall be stressed at a gradual and steady rate until they attain the force required.

9

The maximum force exerted on the shall not exceed 75 % of the GUTS of the strand. For the purposes of cable detensioning, where the installed strand is to be discarded the jacking force may be increased to 80 % GUTS.

10

The force in the tendons shall be obtained from the readings on a load cell or pressure gauge and the extension of the tendons measured. The two readings shall conform to the limits set by the Engineer but in all cases the force in the tendon as computed from the extension measurement shall be within +5 % to -2 % of the force indicated by the gauging system.

11

When stressing from one end only the pull in at the dead end shall be accurately measured and the appropriate allowance made in the measured extension at the live end.

12

If the calculated and measured extensions vary from each other by more than 6 % then corrective action shall be taken. This may involve detensioning and retensioning of the tendons if required by the Engineer.

13

When the required force, including overloads of short duration, has been applied to the satisfaction of the Engineer, the tendons shall be anchored. The jack pressure shall then be relieved in such a way as to avoid shock to the anchorage or tendons.

14

If the pull-in of tendons at the completion of anchoring is greater than that acceptable to the Engineer, the tendons shall be detensioned and the tendon tensioned again.

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18.2.6

QCS 2014

Section 05: Concrete Part 18: Prestressed Concrete

Page 7

The Engineer may direct that the force in any tendon be tested by rejacking. This will only be instructed if there is doubt that the calibration of tensioning equipment is accurate. Care shall be exercised by the Contractor during the retensioning to ensure that the jacking load does not exceed more than 80 % of the GUTS of the strand.

16

If it is necessary to crop the tendons to enable the ducts to be grouted, this shall be delayed as long as is practicable up to the time of grouting. In all other cases, unless otherwise agreed with the Engineer, the tendons shall not be cropped less than three days after grouting.

17

The Contractor shall keep full records of all tensioning operations, including the measured extensions, pressure gauge or load cell readings and the amount of pull-in at each anchorage. Copies of these records, on suitable forms, shall be supplied to the Engineer within 24 hours of each tensioning operation.

18

Tensioning prestressing wires shall meet the requirements of AWWA D110 and ACI 372R

18.2.7

Grouting

1

Grouting shall take place only with the written approval of the Engineer.

2

All ducts shall be thoroughly cleaned by means of compressed air and all anchorages shall be sealed before grouting.

3

Ducts shall be grouted as soon as practicable after the tendons in them have been stressed and the Engineer’s written permission to commence has been obtained. Grout shall be injected in one continuous operation and allowed to flow from the vents until the consistency is equivalent to that being injected. The maximum time between mixing and injection shall not exceed 30 min.

4

The ducts shall be completely filled with grout.

5

Vents shall be sealed consecutively in the direction of flow and the injection tube sealed under pressure until the grout has set. The filled ducts shall be protected to the satisfaction of the Engineer to ensure that they are not subject to shock or vibration for one day.

6

Two days after grouting, the level of grout in the injection and vent tubes shall be inspected and made good if necessary.

7

The Contractor shall keep full records of grouting including the date each duct was grouted, the proportions of the grout and admixtures used, the pressure, details of interruptions and topping up required. Copies of these records shall be supplied to the Engineer within three days of grouting.

8

Prestressing wires shall be protected against corrosion and other damage by a shotcrete cover coat meeting the requirements of AWWA D110 and ACI 372R

18.2.8

Grout Mixer

1

The grout mixer shall produce a grout of colloidal consistency. The grout injector shall be capable of continuous operation with a sensibly constant pressure up to 0.7 MPa and shall include a system of circulating or agitating the grout whilst the actual grouting is not in progress. All baffles to the pump shall be fitted with sieve strainers size BS 14.

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QCS 2014

Section 05: Concrete Part 18: Prestressed Concrete

Page 8

The equipment shall be capable of maintaining pressure on completely grouted ducts and shall be fitted with a nozzle which can be locked off without loss of pressure in the duct.

3

The pressure gauges shall be calibrated before they are first used in the Works and thereafter as required by the Engineer. All equipment shall be thoroughly washed with clean water at least once every three hours during grouting operations and at the end of use for each day.

4

The Contractor shall ensure that standby grouting equipment is available in the event of a breakdown.

18.2.9

Grout Trials

1

The Contractor shall carry out grouting trails to the satisfaction of the Engineer before actual grouting taking place.

2

Unless otherwise directed or agreed as a result of grouting trials, the grout shall:

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consist only of ordinary Portland cement, water and an approved expansion agent

(b)

have a water: cement ratio as low as possible consistent with the necessary workability. Under no circumstances shall the water: cement ratio exceed 0.4

(c)

not be subject to bleeding in excess of 2 % after 3 h or 4 % maximum when measured o at 18 C in a covered glass cylinder approximately 100 mm diameter with a height of approximately 100 mm and the water shall be reabsorbed after 24 h.

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(a)

Admixtures containing chloride or nitrates shall not be used. Other admixtures shall be used only with the written permission of the Engineer and shall be used strictly in accordance with the manufacturer’s instructions.

4

The grout shall be mixed for a minimum of 2 minutes and until a uniform consistency is obtained.

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END OF PART

QCS 2014

Section 05: Concrete Part 19: Testing of Water Retaining Structures

Page 1

TESTING OF WATER RETAINING STRUCTURES................................................ 2

19.1 19.1.1 19.1.2 19.1.3 19.1.4

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 General 2

19.2 19.2.1 19.2.2

TESTING ................................................................................................................. 2 General 2 Cleaning 3

19.3 19.3.1 19.3.2 19.3.3

TESTING PROCEDURE ......................................................................................... 4 Walls 4 Roofs 5 Disposal of Water Used for Testing 5

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QCS 2014

Section 05: Concrete Part 19: Testing of Water Retaining Structures

Page 2

TESTING OF WATER RETAINING STRUCTURES

19.1

GENERAL

19.1.1

Scope

1

This Part of the specification applies to the testing of structures that are designed with the intention of retaining water.

2

Related Section and Parts are as follows:

References

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BS 8007......................Code of Practice for Design of concrete structures for the retaining of aqueous liquids Submittals

1

The Contractor shall record and submit to the Engineer within 24 hours the results of the watertightness tests carried out.

19.1.4

General

1

Water retaining structures shall be watertight when subjected to external groundwater pressures or to tests as specified in this Part.

19.2

TESTING

19.2.1

General

1

The Contractor shall test watertightness of water retaining structures including storage reservoirs and other miscellaneous structures that require to be watertight.

2

All water used for testing shall be potable or irrigation water and the Contractor shall make arrangements for the supply and disposal of this water.

3

Water retaining structures shall be tested for watertightness after completion, in accordance with the following method or as directed by the Engineer:

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19.1.3

(a)

the structure shall be filled with potable or irrigation water in stages not exceeding 1 m in 24 h held at each water level for such time as the Engineer may require. Should dampness or leakage occur, the water shall be drawn off and the defects remedied to the satisfaction of the Engineer

(b)

in the case of structures which are subdivided into individual tanks, each individual tank shall be tested separately. In the case of underground or partially underground structures, the testing shall take place before application of water proofing membrane, liner material or perimeter drain, filter material or backfilling is placed against the walls

QCS 2014

Section 05: Concrete Part 19: Testing of Water Retaining Structures

Page 3

in the case of hopper bottomed tanks, this shall be taken to mean that no material is placed against the vertical external walls of the tank, the sloping walls of the hopper bottoms of the tanks being assumed built directly against the excavation apart from the blinding concrete

(d)

no placing of material against the walls shall take place until the Engineer has given his written approval and acceptance of the water retaining structures as watertight

(e)

filling shall not take place earlier than 28 d after the casting of the final sections of the structure which will be stressed by the filling of the structure.

(f)

testing shall not be undertaken until the structure to be tested has been; completed structurally including roof, if any, and has been passed by the Engineer in writing as satisfactory in all respects other than watertightness, especially in regard to the final finish of the work

(g)

not withstanding the satisfactory completion of the seven day test, leakage, cracks, and damp patches and sweating visible on the outside faces of the structure shall be rectified from the water face by an injection system to the approval of the Engineer

(h)

repair making the outer face only watertight wall not be accepted, this applies to bobbin holes also

(i)

the structure shall be retested until the watertightness is approved by the Engineer.

(j)

should the structure fail a test in the above respects, the Contractor shall immediately take such steps as may be necessary to:

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(c)

ascertain the nature and positions of defects or leakage's

(ii)

empty the structure

(iii)

remedy the defects in a manner approved by the Engineer, employing workers who are specialists in this class of work

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(i)

when the remedial work has been completed in the manner approved by the Engineer, the testing and if necessary rectification shall be repeated until a satisfactory test is achieved.

(l)

if necessary, in extreme cases of lack of watertightness, the Engineer may reject the structure or portions thereof.

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Cleaning

1

All water retaining structures shall, on completion, be carefully cleaned of all debris, to the complete satisfaction of the Engineer as follows:

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(a)

shall be brushed down on all internal faces with a stiff broom while still dry

(b)

all resulting debris removed

(c)

all associated reservoir pipe work shall be cleaned in accordance with the specified requirements

(d)

the structure shall then be flooded with approximately 75 mm of clean water

(e)

whole of internal faces shall be carefully brushed down with stiff brooms using the water continuously until all faces are clean

(f)

water shall then be drained off

(g)

walls and floors hosed and flushed with clean water until perfectly clean.

QCS 2014

Section 05: Concrete Part 19: Testing of Water Retaining Structures

Page 4

TESTING PROCEDURE

19.3.1

Walls

1

After completion and cleaning of the structure and all associated pipe work, if any, the Contractor shall fill the structure up to the top water level and leave for a stabilising period of 21 d in order to allow for absorption and autogenous healing to take place.

2

Water shall be added over this period to maintain the top water level.

3

The Contractor shall ensure that all pipes and specials are available in ample time ahead of testing.

4

Two sets of evaporation trays shall be provided along with two sets of rain gauges.

5

Levels in the trays and structure shall be made and recorded by a hook gauge with vernier attachments.

6

Before and during testing, flows in the structure under drainage, if any, shall be monitored, measured and recorded.

7

Each under drain shall be numbered and observations reported by under drain number to facilitate analysis of the data.

8

All leaks shall be repaired within one month of their detection.

9

On the twenty-second day, two shallow watertight evaporation trays of area 0.4 m2 shall be filled with 75 mm of water and placed to float in the structure.

10

The water level in the structure shall be recorded and the test commenced and carried out over the next 7 d.

11

Readings of water levels in the structure and trays shall be made and recorded every 24 h over this period.

12

If the water level in the tank falls by more than indicated by the evaporation trays, or other sign of leakage occurs by the end of the test period then the Contractor shall search and mark all areas of defect.

13

The structure shall then be emptied and the defects made good as specified herein.

14

After completion of remedial measures the structure shall be refilled and the test repeated.

15

This process shall be repeated until the structure is watertight to the satisfaction of the Engineer.

16

The fall of water level in the structure over the test period of 7 d, minus the fall accounted for by evaporation and rainfall shall not exceed 1/500 of the average water depth of the full structure or 10 mm whichever is less.

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19.3

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Section 05: Concrete Part 19: Testing of Water Retaining Structures

Page 5

Roofs

1

The roofs of structures shall be tested for watertightness before laying of roof membrane.

2

Roof and fittings shall be hosed down vigorously and this shall be repeated in such a way as to keep the roof wet for three successive days.

3

Roof and fittings shall be deemed satisfactory for watertightness if no discernible leaks or damp patches show in the soffit.

4

Roof covering shall be completed as soon as possible after testing.

19.3.3

Disposal of Water Used for Testing

1

The Contractor shall provide suitable means for disposal of water used for testing, such that no damage results to facilities, structures or property.

2

These means shall be subject to the approval of the Engineer and local authorities.

3

Details shall be submitted to Engineer on request.

4

The Contractor shall be responsible for damage caused by his filling, testing, flushing and wastewater disposal operations.

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19.3.2

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END OF PART

QCS 2014

Section 05: Concrete Part 02: Aggregates

Page 1

AGGREGATES ....................................................................................................... 2

2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definitions 3 Source Approval 4 Sampling 4

2.2

QUALITY AND TESTING ........................................................................................ 5

2.3

STORAGE AT CONTRACTOR PLANT ................................................................... 5

2.4

FINE AGGREGATE FOR CONCRETE AND MORTAR ........................................... 7

2.5

COARSE AGGREGATE FOR CONCRETE............................................................. 8

2.6

COMBINED AGGREGATE FOR CONCRETE......................................................... 8

2.7

WASHING AND PROCESSING .............................................................................. 9

2.8

LIGHTWEIGHT AGGREGATES.............................................................................. 9

2.9

COARSE RECYCLED AGGREGATES ................................................................... 9

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QCS 2014

Section 05: Concrete Part 02: Aggregates

Page 2

AGGREGATES

2.1

GENERAL

2.1.1

Scope

1

This part covers the requirements of aggregates for use in structural concrete.

2

Related Sections and Parts are as follows:

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References

ASTM C33 ..................Standard Specification for Concrete Aggregates

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ASTM C40 ..................Test Method for Organic Impurities in Fine Aggregates for Concrete

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ASTM C88 ..................Test Method for Soundness of Aggregates by Use of Sodium Sulphate or Magnesium Sulphate

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ASTM C123 ................Test Method for Lightweight Pieces in Aggregate ASTM C127 ................Test Method for Specific Gravity and Absorption of Coarse Aggregate

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ASTM C128 ................Test Method for Specific Gravity and Absorption of Fine Aggregate

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ASTM C131 ................Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

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ASTM C136 ................Standard Test Method for Sieve Analysis of Fine and Coarse Aggregate ASTM C142 ................Test Method for Clay Lumps and Friable Particles in Aggregates.

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2.1.2

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This Section..... Part 3, .............. Cementitious Materials Part 4, .............. Water Part 6, .............. Property Requirements Part 7, .............. Concrete Plants Part 8, .............. Transportation and Planning of Concrete Part 15, ............ Hot weather Concreting Part 17, ............ Structural Precast Concrete Part 18, ............ Prestressed Concrete

.

2

ASTM C535 ................Test Method for Resistance to Degradation of Large-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine ASTM C702 ................Standard Practice for Reducing Samples of Aggregate to Testing Size ASTM D75 ..................Standard Practice for Sampling Aggregates BRE Digest 330-2.......Alkali-Silica Reaction in Concrete – Detailed Guidance for New Construction. BS 933-3 ....................Tests for geometrical properties of aggregates Determination of particle shape. Flakiness index BS 933-7 ....................Tests for geometrical properties of aggregates Determination of shell content. Percentage of shells in coarse aggregates BS 933-9 ....................Tests for geometrical properties of aggregates Assessment of fines. Methylene blue test

QCS 2014

Section 05: Concrete Part 02: Aggregates

Page 3

BS 933-11 ..................Tests for geometrical properties of aggregates Classification test for the constituents of coarse recycled aggregate BS 1097-6 ..................Tests for mechanical and physical properties of Determination of particle density and water absorption

aggregates

BS 8500 part 2 ...........Concrete. Complementary British Standard to BS EN 206-1. Specification for constituent materials and concrete BS EN 12620 ..............Aggregates for concrete BS EN 1744-1 ............Tests for chemical properties of aggregates, Chemical analysis BS EN 1744-5 ............Tests for chemical properties of aggregates. Determination of acid soluble chloride salts aggregates. of drying

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BS EN 1367-2 ............Tests for thermal and weathering properties of Magnesium sulphate test. BS EN 1367-4 Determination shrinkage BS EN 933 ..................Tests for geometrical properties of aggregates

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BS EN 1097-2 ............Tests for mechanical and physical properties of aggregates. Methods for the determination of resistance to fragmentation

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BS EN 1097-6 ............Tests for mechanical and physical properties of aggregates. Determination of particle density and water absorption

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BS EN13055-1 ...........Lightweight aggregates. Lightweight aggregates for concrete, mortar and grout. BS PD 6682-1 ............Aggregates for concrete. Guidance on the use of BS EN 12620

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BS PD 6682-4 ............Aggregates Lightweight aggregates for concrete, mortar and grout. Guidance on the use of BS EN 13055-1

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EN 13139 ..................Aggregates for mortar EN 998-1 ...................Specification for mortar for masonry Rendering and plastering mortar

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EN 998-2 ...................Specification for mortar for Masonry mortar ISO 9001:2008 ...........Quality management systems -- Requirements

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ISO 17025 ..................General requirements for the competence of testing and calibration laboratories RILEM AAR1 ..............RILEM Recommended Test Method AAR-1 “Detection of potential alkali-reactivity aggregates”, Petrographic method RILEM AAR3 ..............RILEM Recommended Test Method AAR-3 “Detection of potential alkali-reactivity - 38°C test method for aggregate combinations using concrete prisms 2.1.3

Definitions

1

Aggregate: granular material used in construction and may be natural, manufactured or recycled.

2

Natural aggregate: aggregate from mineral sources which has been subjected to nothing more than mechanical processing.

QCS 2014

Section 05: Concrete Part 02: Aggregates

Page 4

Manufactured aggregate: aggregate of mineral origin resulting from an industrial process involving thermal or other modification.

4

Recycled aggregate: aggregate resulting from the processing of inorganic material previously used in construction.

5

Lightweight aggregate: aggregate of mineral origin having a particle density not exceeding 2,000 kg/m3 or a loose bulk density not exceeding 1,200 kg/m3.

2.1.4

Source Approval

1

The Contractor shall use only those imported materials sourced from an Accredited Quarry Producer or Accredited Supplier and which have been approved by Qatar Standards or their representatives.

2

The accredited aggregate suppliers shall provide the source name(s) for every shipment of aggregates delivered to the concrete supplier.

3

The source of material supply may be changed by the Contractor during the project, provided that the replacement materials shall be sourced from an Accredited Quarry Producer and the replacement materials are not significantly different in terms of physical and chemical properties, thus ensuring that the resultant concrete continues to comply fully with the specified requirements.

4

When considering whether an aggregates supplier and aggregates producer are suitable to be Accredited, preference will be given to organisations with a proper quality management system, such as ISO 9001 or another quality management system approved by Qatar Standards.

5

When requested by the engineer, the aggregate supplier shall provide a geotechnical analysis on the rock samples before blasting and grinding to ensure the proper quality of materials.

6

The aggregates shall be properly stocked and labelled without intermingling at any storage area.

7

When requested by the engineer, the aggregates supplier shall provide data for the past 6 months that shows the consistency of materials and conformity with this specification.

8

The supplier shall verify the compliance of aggregates as per QCS by an independent qualified testing agency accredited to ISO 17025, and approved by Qatar Standards.

2.1.5

Sampling

1

The Contractor shall provide samples of both fine and course aggregate to the Engineer, in accordance with the requirements of relevant standards in QCS for sampling, sample reducing and testing of Aggregates, for testing at least two weeks before beginning deliveries to the Site.

2

All samples shall be taken in the presence of the Engineer or an approved testing agency assigned by the Engineer.

3

Aggregate sampling and testing shall be conducted by qualified staff.

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QCS 2014

Section 05: Concrete Part 02: Aggregates

Page 5

QUALITY AND TESTING

1

Aggregates shall consist of tough, hard, durable and uncoated particles containing no harmful material in quantities sufficient to adversely affect the concrete or reinforcing steel, and shall contain no materials likely to cause staining or otherwise disfigure the concrete surface.

2

Aggregates shall be obtained from a source approved by the Engineer.

3

Aggregate shall meet the requirements given in Table 2.1. Additional tests detailed in BS EN 12620 with BS PD 6682, EN 13139, EN 998-1, EN 998-2, or relevant ACI and ASTM standards and codes of practice may be required by the Engineer to satisfy certain requirements.

4

Contractor shall provide all data as specified in QCS.

5

Sampling of the aggregates shall be carried out in accordance with the requirements of BS EN 12620, BS EN 933, or ASTM D75 and ASTM C702.

6

Fine aggregates shall be natural sand or manufactured crushed rock sand. Crushed rock sand shall be the direct product of a manufacturing process, not the by-product of coarse aggregate production.

7

Beach sand shall not be permitted for use in concrete mixes.

8

The use of clean Dune Sand, blended with coarser sand, may be permitted providing it can be shown that the sand is free from contaminants. The use of local Dune sand shall be preapproved by the Ministry of Environment.

9

Samples of aggregates shall be taken in accordance with the requirements of Table 1.1- Part 1.

10

Frequency of routine testing shall meet the requirements as listed in Section 2. Frequency of testing may be increased by the engineer’s request if testing results show inconsistency, and frequency may be reduced if approved by the engineer if materials are highly consistent.

11

Mineralogical tests are to be carried out as instructed by the Engineer.

12

No aggregate deliveries shall be made to the Site until the Engineer has approved the samples as complying with this specification.

2.3

STORAGE AT CONTRACTOR PLANT

1

Aggregate shall be stored as follows:

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2.2

(a)

each nominal size of coarse aggregate and fine aggregate shall be kept separated and clearly labelled at all times.

(b)

The height of stockpiles shall be controlled to prevent harmful segregation and breakage of the aggregate.

(c)

stockpiles shall be on hard and clean surfaces with not more than 5 % slope

QCS 2014

Section 05: Concrete Part 02: Aggregates

Page 6

(d)

contamination of the aggregates by the ground or other foreign matter shall be effectively prevented at all times

(e)

each heap of aggregate shall be capable of draining freely

(f)

stockpiles shall be protected from direct sunlight

(g)

unloading of aggregate shall be controlled to prevent harmful segregation and breakage.

2

The Contractor shall maintain the stockpiles of coarse aggregate in separate gradings.

3

At the construction site, the preparation, location and size of any stockpile shall be approved by the Engineer.

Test Methods Requirement BS / EN

Permissible Limits

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No.

1

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Table 2.1 Limits for Physical, Chemical and Mechanical Properties of Aggregates for Normal Concrete

ASTM

Fines

Coarse

933-1

2. Natural: materials finer than 0.063 mm.

933-1

Crushed rock: materials finer than 0.063mm. 3. Fines quality a) Structural concrete Sand Equivalent (%)

933-8

60% min

933-9

2% max

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1. Grading

Non-structural concrete Methylene blue adsorption 3 value (0/2mm)

Standard

Standard

3% max 7% max

2% max 2% max

2

C142

5. Lightweight pieces

C123

0.5% max

0.5% max

C40

NA

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4. Clay lumps and friable particles

1.0 (g/kg) max 2% max

7. Water absorption (saturated surface

1097-6

Colour standard not darker than 4 plate No. 3 2.3% max

8. Particle density for normal weight

1097-6

2.0 min

2.0 min

9. Shell Content:

933-7

3% max

3% max

10. Flakiness index

933-3

11. Acid-soluble chlorides:

1744-5

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6. Organic impurities for fine aggregates

2.0% max

concrete

35% max

a) Reinforced and mass concrete

0.06% max

0.03% max

b) Prestressed concrete and steam 5 cured structural concrete

0.01%

0.01%

QCS 2014

Section 05: Concrete Part 02: Aggregates

Page 7

Test Methods No.

1

Permissible Limits

Requirement BS / EN

ASTM

Fines

Coarse

12. Acid-soluble sulphate

1744-1

0.4% max

0.3% max

13. Soundness by magnesium sulphate (5

1367-2

15% max

15% max

cycles)

Resistance to fragmentation: Los

1097-2

30% max

15. Drying shrinkage

1367-4

0.075% max

.

14. Angeles abrasion

16. Potential reactivity:

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See Note 6 below

Notes:

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3. 4.

Use of BS EN or relevant GSO standards. If the Sand Equivalent value is less than 60% and greater than or equal to 50%, the sand shall be considered non-harmful and is accepted provided that the Methylene Blue value is less than or equal to 1.0 (g/kg). Not required when the fines content in the fine aggregate, or in the all-in aggregate, is 3% or less. Organic impurities: use of a fine aggregate failing in the test is not prohibited, provided that: a. The discoloration is due principally to the presence of small quantities of coal, lignite, or similar discrete particles. b. When tested for the effect of organic impurities on strength of mortar, the relative strength at 7 days, calculated in accordance with ASTM C87, is not less than 95 %. If the chloride content is higher than 0.01% the following steps may be taken: a- The aggregates may be washed by suitable water (Sec 5 Part 4) before mixing to lower the chloride content to the specified value (0.01%). b- If the washing process does not reduce the chloride content to the required value, then the Acid Soluble Chloride content in the concrete ingredients (the sum of the contributions from the constituent materials) shall be tested as mentioned in BS 8500-2. The allowable Acid Soluble chloride content limit shall not exceed the values given in Section 5, Part 6, Para 6.5.3. The alkali-aggregate reactivity shall be assessed at source in accordance with BS 206-1 and BS 85002. Certification shall be obtained from the aggregate source indicating absence of deleterious expansion of concrete due to alkali aggregate reactivity.

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1. 2.

2.4

FINE AGGREGATE FOR CONCRETE AND MORTAR

1

Fine aggregate consist of natural clean sand, stone screenings or a combination and can be produced from natural disintegration of rock or gravel and/or by the crushing of rock or gravel or processing of manufactured aggregate or artificial, conforming to the requirements of physical and chemical properties complying with Table 2.1 and subject to the Engineer's acceptance.

2

Crushed fine aggregates may be blended with local washed sand provided that the final aggregate complies with the requirements in Table 2.1.

3

The gradation of fine aggregate for concrete and mortar shall be in accordance with the gradation designations in BS EN 12620 with BS PD 6682, EN 13139 , EN 998-1 , EN 998-2, or relevant ACI and ASTM standards and codes of practice and subject to the Engineer’s acceptance.

QCS 2014

Section 05: Concrete Part 02: Aggregates

Page 8

4

Each batch of aggregate delivered to the Site shall be kept separate from previous batches, and shall be stored to allow for inspection and tests to be carried out.

5

Local natural sand shall be mechanically washed to remove salts and other impurities in order to meet the specified requirements.

6

The storage area for the clean washed sand shall be shaded from the direct rays of the sun and shall be screened for protection from dust. The area in the neighbourhood of stockpile/mixing plant shall be watered as necessary, to reduce the rising of dust.

7

The usage of Dune sand shall be accepted as governed by the regulations of Qatar Ministry of Environment and shall be: Not used for any reinforced concrete

(b)

Used only for blocks, block mortar, plasters, soil cement, shotcrete and insulation concrete.

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(a)

COARSE AGGREGATE FOR CONCRETE

1

The coarse aggregate is granular material and may be natural, manufactured, recycled or a combination. It shall be free from deleterious matter and conforming to the requirements of physical and chemical properties in Table 2.1 as a minimum requirements and subject to the Engineer's acceptance within BS EN 12620, BS PD 6682 or ASTM C33

2

For imported aggregate, Qatar Standards may publish more requirements and stringent limits than specified in Table 2.1.

3

For other types of concrete mixes and subject to Engineer's acceptance, coarse aggregate shall comply with the relevant BS EN or relevant ACI and ASTM standards and codes. The nominal maximum size of coarse aggregate shall be not larger than: (a) 1/5 the narrowest dimension between sides of forms, nor (b) 1/3 the depth of slab, nor (c) 3/4 the minimum clear spacing between individual reinforcing bars or wires, bundles of bars, individual tendons, bundled tendons, or ducts.

4

These limitations shall not apply if, in the judgment of the licensed design professional, workability and methods of consolidation are such that concrete can be placed without honeycombs or voids.

5

As requested by the Engineer, the Contractor shall mechanically wash the aggregates to remove salts and other impurities in order to meet the requirements specified.

2.6

COMBINED AGGREGATE FOR CONCRETE

1

The material passing the 0.063mm sieve shall not exceed 3.0 % of the combined aggregate

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2.5

(by weight). The combined aggregate gradation used in the work shall be as specified, except when otherwise approved or directed by the Engineer. 2

Changes in the approved gradation shall not be made during the progress of the works unless approved or directed by the Engineer.

QCS 2014

Section 05: Concrete Part 02: Aggregates

Page 9

WASHING AND PROCESSING

1

Where aggregates have been washed shortly before delivery to the Site, or if stockpiles have been sprayed to cool them, samples of the aggregate shall be taken frequently to determine the correct amount of water to add to the mix.

2.8

LIGHTWEIGHT AGGREGATES

1

Lightweight aggregates are those having particle densities not exceeding 2,000 kg/m3 or 3 loose bulk densities not exceeding 1200 kg/m .

2

Lightweight aggregates include natural aggregate, aggregate manufactured from natural materials and/or a by product of industrial processes, and some recycled aggregate.

3

Lightweight aggregates shall be in accordance with BS EN13055-1 and BS PD 6682-4, or equivalent ASTM standards.

2.9

COARSE RECYCLED AGGREGATES

1

Excavation Waste (EW), coarse recycled aggregates (RA), and coarse recycled concrete aggregates (RCA) shall meet with the requirements of Table 2.1, with the exception that water absorption shall not exceed;

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2.7

3% for structural concrete

(b)

4% for non-structural concrete.

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(a)

For structural concrete EW and/or RCA may be used in designated concrete of maximum C30. Its proportion shall be not more than a mass fraction of 20% of coarse aggregate (BS 8500-2 sec 6.2.2), except where approved by Qatar Standards to use a higher proportion.

3

For non-structural concrete, such as crash barriers and soakaways, EW and/or RCA may be used in designated concrete of maximum C40. Its proportion shall be not more than a mass fraction of 50% of coarse aggregate (BS 8500-2 sec 6.2.2), except where approved by Qatar Standards to use a higher proportion.

4

For non-structural concrete RA may be used in designated concrete of maximum C25. Its proportion shall be not more than a mass fraction of 20% of coarse aggregate (BS 8500-2 sec 6.2.2), except where approved by Qatar Standards to use a higher proportion.

5

When the composition of coarse RCA and coarse RA is tested in accordance with BS EN 933-11, the test result obtained for each type of particle shall not exceed the maximum value specified in Table 2.2.

6

EW aggregate shall meet the same requirements for RCA, as given in Table 2.2.

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QCS 2014

Section 05: Concrete Part 02: Aggregates

Page 10

Table 2.2 Requirements for coarse RCA and coarse RA, (mass fraction, %)

RCA

1, 3

5.0

5.0

0.5

5.0

1.0

1.0

100

3

1.0

10.0

-4

Maximum acid soluble sulphate (SO3)

1.0

Where the material to be used is obtained by crushing hardened concrete of known composition that has not been in use, e.g. surplus precast units or returned fresh concrete, and not contaminated during storage and processing, the only requirements are those for grading and maximum fines. Material with a density less than 1,000 kg/m3 The provisions for coarse RCA may be applied to mixtures of natural coarse aggregates blended with the listed constituents. The appropriate limit and test method needs to be determined on a case-by-case basis (see Note 6 to 4.3 of BS 8500-2).

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4.

Maximum Asphalt

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2. 3.

Maximum lightweight 2 material

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1.

Maximum fines

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RA

Maximum masonry content

Maximum foreign material e.g. glass, plastic, metals

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Type of Aggregate

1

.

Requirement

3

The floating material (FL) content, as per BS EN 933-11, shall not exceed 5.0 cm /kg.

8

RCA should be treated as highly reactive aggregate. The alkali contribution from RCA shall be determined as given in BS 8500-2.

9

For manufacturing of masonry concrete blocks, the usage of recycled aggregates is permitted up to 100% as given in Sec. 13 in accordance with ACI 555.

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END OF PART

QCS 2014

Section 05: Concrete Part 20: Personnel Qualifications and Certification

Page 1

PERSONNEL QUALIFICATIONS AND CERTIFICATIONS ..................................... 2

20.1

GENERAL ............................................................................................................... 2

20.2

AUDITORS .............................................................................................................. 2

20.3 20.3.1 20.3.2

READY MIXED CONCRETE COMPANIES ............................................................. 2 Technical Department 2 Production and Operation Department 4

20.4 20.4.1

TESTING LABORATORIES .................................................................................... 5 Concrete Laboratory Department 5

20.5 20.5.1

CONTRACTORS ..................................................................................................... 6 Concrete Construction Department 6

20.6 20.6.1 20.6.2

CONSULTANTS ...................................................................................................... 7 Site Supervision Department 7 Site Supervision / Design Office Department 7

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20

QCS 2014

Section 05: Concrete Part 20: Personnel Qualifications and Certification

Page 2

PERSONNEL QUALIFICATIONS AND CERTIFICATIONS

20.1

GENERAL

1

The qualification requirements given in this part are optional unless otherwise mentioned below. The purpose of the qualifications is to prepare the industry to cope with the required quality of construction. The requirements will become compulsory as and when stated by Qatar Standards.

2

Qualifications shall be approved by Qatar Standards or their representatives.

20.2

AUDITORS

1

Qatar Standards auditors and their approved representatives shall be qualified for inspecting concrete ready mix plants and testing laboratories.

20.3

READY MIXED CONCRETE COMPANIES

20.3.1

Technical Department

1

Position:

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20

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Technical Manager / QC Manager

Qualifications:

Concrete specification review and concrete mixture proportioning

(b)

Concrete constituent materials, their characteristics, and effects on concrete properties

(c)

Fresh and hardened concrete properties

(d)

Durability of concrete

(e)

Production and delivery of Ready Mixed Concrete

(f)

Handling, placing and curing of concrete

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Specifying and evaluation of concrete strength Testing of concrete and its constituents

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(a)

2

(i)

Quality control procedures and statistical analysis

(j)

Hot weather concreting

(k)

Troubleshooting concrete problems

Position:

Site Supervisor

Qualifications: (a)

The supervisor shall be capable of satisfactorily reading, understanding and performing the below fresh concrete tests:

BS EN 12350-1 ..........Testing fresh concrete - Sampling ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete

QCS 2014

Section 05: Concrete Part 20: Personnel Qualifications and Certification

Page 3

BS EN 12350-2 ..........Testing fresh concrete – Slump test BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete 3

Position:

Lab Supervisor

Qualifications:

BS EN 12350-1 .........Testing fresh concrete - Sampling

.

The supervisor shall be capable of satisfactorily reading, understanding and performing the below fresh and hardened concrete tests:

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(a)

ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-6 .........Testing fresh concrete – Density

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BS EN 12350-2 .........Testing fresh concrete – Slump test

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BS EN 12350-7 .........Testing fresh concrete – Air content (Pressure Method)

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BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests

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ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete BS EN 12390-3 ..........Testing hardened concrete - Compressive strength of test specimens

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BS EN 932-1 .............Aggregates - Methods of sampling BS EN 932-2 .............Aggregates – Methods of reducing laboratory samples

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BS EN 933-1 .............Aggregates – Determination of particle size distribution (and dust content) BS EN 1097-6 ...........Aggregates – Determination of particle density and water absorption

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BS EN 1097-3 ...........Aggregates – Determination of loose bulk density and voids

Position:

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ASTM C566 – ............Method of determination of moisture content

Site Technician (compulsory if requested by the Engineer)

Qualifications: (a)

The technician shall be capable of satisfactorily performing the below fresh concrete tests:

BS EN 12350-1 .........Testing fresh concrete - Sampling ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-2 .........Testing fresh concrete – Slump test BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete

QCS 2014

5

Section 05: Concrete Part 20: Personnel Qualifications and Certification

Position:

Page 4

Lab Technician (compulsory if requested by the Engineer)

Qualifications: (a)

The technician shall be capable of satisfactorily performing the below fresh and hardened concrete tests:

BS EN 12350-1 .........Testing fresh concrete - Sampling ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-2 .........Testing fresh concrete – Slump test BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12350-7 .........Testing fresh concrete – Air content (Pressure Method)

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BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete

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BS EN 12390-3 .........Testing hardened concrete - Compressive strength of test specimens BS EN 932-1 .............Aggregates - Methods of sampling

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BS EN 932-2 .............Aggregates – Methods of reducing laboratory samples

qa

BS EN 933-1 .............Aggregates – Determination of particle size distribution (and dust content) BS EN 1097-6 ...........Aggregates – Determination of particle density and water absorption

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BS EN 1097-3 ...........Aggregates – Determination of loose bulk density and voids

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ASTM C566 – ............Method of determination of moisture content

Production and Operation Department

1

Position:

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20.3.2

Plant/Production/Operation Manager and/or Supervisor

Materials management

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(b)

Properties of concrete and its constituents

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(a)

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Qualifications:

2

(c)

Plant design, function and maintenance

(d)

Batching operations, procedures and dispatching

(e)

Materials management and inventory

(f)

Safety regulations and procedures

Position:

Plant Operator

Qualifications: (a)

Basic concrete properties and characteristics of its constituents

(b)

Scales, meters and batching sequence and control system

(c)

Central mixing and discharging

(d)

Tolerances, overweight/underweight controls

QCS 2014

Section 05: Concrete Part 20: Personnel Qualifications and Certification

(e)

Troubleshooting scales, gates and other plant components

(f)

Safety procedures

20.4

TESTING LABORATORIES

20.4.1

Concrete Laboratory Department

1

Position:

Page 5

Laboratory Manager / QC Manager

Qualifications: Concrete specification review and concrete mixture proportioning

(b)

Concrete constituent materials, their characteristics, and effects on concrete properties

(c)

Fresh and hardened concrete properties

(d)

Durability of concrete

(e)

Production and delivery of Ready Mixed Concrete

(f)

Handling, placing and curing of concrete

(g)

Evaluation of concrete strength

(h)

Testing of concrete and its constituents

(i)

Quality control procedures and statistical analysis

(j)

Hot weather concreting

(k)

Troubleshooting concrete problems

Position:

Supervisor

The supervisor shall be capable of satisfactorily reading, understanding and performing the below fresh and hardened concrete tests:

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(a)

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Qualifications:

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(a)

BS EN 12350-1 .........Testing fresh concrete - Sampling ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-2 .........Testing fresh concrete – Slump test BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12350-7 .........Testing fresh concrete – Air content (Pressure Method) BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete BS EN 12390-3 .........Testing hardened concrete - Compressive strength of test specimens BS EN 932-1 .............Aggregates - Methods of sampling BS EN 932-2 .............Aggregates – Methods of reducing laboratory samples BS EN 933-1 .............Aggregates – Determination of particle size distribution (and dust content)

QCS 2014

Section 05: Concrete Part 20: Personnel Qualifications and Certification

Page 6

BS EN 1097-6 ...........Aggregates – Determination of particle density and water absorption BS EN 1097-3 ...........Aggregates – Determination of loose bulk density and voids ASTM C566 – ............Method of determination of moisture content

3

Position:

Technician (compulsory if requested by the Engineer)

Qualifications: (a)

The technician shall be capable of satisfactorily performing the below fresh and hardened concrete tests:

BS EN 12350-1 .........Testing fresh concrete - Sampling

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BS EN 12350-6 .........Testing fresh concrete – Density

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BS EN 12350-2 .........Testing fresh concrete – Slump test

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ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete

BS EN 12350-7 .........Testing fresh concrete – Air content (Pressure Method)

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BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests

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ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete BS EN 12390-3 .........Testing hardened concrete - Compressive strength of test specimens

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BS EN 932-1 .............Aggregates - Methods of sampling BS EN 932-2 .............Aggregates – Methods of reducing laboratory samples

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BS EN 933-1 .............Aggregates – Determination of particle size distribution (and dust content)

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BS EN 1097-6 ...........Aggregates – Determination of particle density and water absorption

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BS EN 1097-3 ...........Aggregates – Determination of loose bulk density and voids

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ASTM C566 – ............Method of determination of moisture content

CONTRACTORS

20.5.1

Concrete Construction Department

1

Position:

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20.5

Site Engineer

Qualifications: (a)

The site engineer shall be capable of satisfactorily reading, understanding and performing the below fresh concrete tests:

BS EN 12350-1 .........Testing fresh concrete - Sampling ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-2 .........Testing fresh concrete – Slump test BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12350-7 .........Testing fresh concrete – Air content (Pressure Method) BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete

QCS 2014

2

Section 05: Concrete Part 20: Personnel Qualifications and Certification

Position:

Page 7

QC Manager/ QC Engineer/ Material Engineer

Qualifications: Concrete specification review and concrete mixture proportioning

(b)

Concrete constituent materials, their characteristics, and effects on concrete properties

(c)

Fresh and hardened concrete properties

(d)

Durability of concrete

(e)

Production and delivery of Ready Mixed Concrete

(f)

Handling, placing and curing of concrete

(g)

Specifying and evaluating of concrete strength

(h)

Testing of concrete and its constituents

(i)

Quality control procedures and statistical analysis

(j)

Hot weather concreting

(k)

Troubleshooting concrete problems

20.6

CONSULTANTS

20.6.1

Site Supervision Department

1

Position:

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Site Inspector/ Material Inspector

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Qualifications:

The site engineer shall be capable of satisfactorily reading, understanding and performing the below fresh concrete tests:

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(a)

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(a)

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BS EN 12350-1 .........Testing fresh concrete - Sampling

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ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete BS EN 12350-2 .........Testing fresh concrete – Slump test

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BS EN 12350-6 .........Testing fresh concrete – Density BS EN 12390-2 .........Testing hardened concrete – Making and curing specimens for strength tests ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete

20.6.2

Site Supervision / Design Office Department

1

Position:

Material Engineer

Qualifications: (a)

Concrete specification review and concrete mixture proportioning

(b)

Concrete constituent materials, their characteristics, and effects on concrete properties

(c)

Fresh and hardened concrete properties

(d)

Durability of concrete

QCS 2014

Section 05: Concrete Part 20: Personnel Qualifications and Certification

(e)

Production and delivery of Ready Mixed Concrete

(f)

Handling, placing and curing of concrete

(g)

Specifying and evaluating of concrete strength

(h)

Testing of concrete and its constituents

(i)

Quality control procedures and statistical analysis

(j)

Hot weather concreting

(k)

Troubleshooting concrete problems

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END OF PART

Page 8

QCS 2014

Section 05: Concrete Part 03: Cementitious Materials

Page 1

CEMENTITIOUS MATERIALS................................................................................. 2

3.1 3.1.1 3.1.2 3.1.3

GENERAL ............................................................................................................... 2 Scope 2 References 2 Terms and Definitions: 3

3.2

SOURCE APPROVAL ............................................................................................. 3

3.3

SAMPLING .............................................................................................................. 3

3.4

QUALITY AND TESTING ........................................................................................ 3

3.5

DELIVERY, STORAGE AND HANDLING ................................................................ 4

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QCS 2014

Section 05: Concrete Part 03: Cementitious Materials

Page 2

3

CEMENTITIOUS MATERIALS

3.1

GENERAL

3.1.1

Scope

1

This Part covers the requirements for the testing and use of cement in structural concrete.

2

Related Sections and Parts are as follows:

3.1.2

References

1

The following standards are referred to in this Part:

.

Property Requirements

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Part 6

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ASTM C10 ..................Standard specification for natural cement ASTM C91 ..................Specification for Masonry cement

ASTM C114 ................Test methods for chemical analysis of Hydraulic Cement

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ASTM C115, ...............Test method for fineness of Portland cement by the Turbidimeter

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ASTM C150 ................Standard specification for Portland cement

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ASTM C183 ................Standard Practice for sampling and the amount of testing of Hydraulic cement ASTM C188 ................Test method for density of Hydraulic cement

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ASTM C186 ................Test method for heat of hydration of Hydraulic cement ASTM C204 ................Test method for fineness of Hydraulic cement by air permeability

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ASTM C348 ................Test method for flexural strength of Hydraulic cement mortar

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ASTM C349 ................Test method for compressive strength of Hydraulic cement mortar using portion of prism broken in flexure

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ASTM C430 ................Test method for fineness of Hydraulic cement by the 45mm (No.325)

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ASTM C595 ................Standard specification for blended Hydraulic cement

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ASTM C618 ................Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete ASTM C845 ................Specification for Expansive Hydraulic cement ASTM C989 ..............Standard Specification for Slag Cement for Use in Concrete and Mortars ASTM C1157 ..............Standard performance specification for Hydraulic cement ASTM C1240 .............Standard Specification for Silica Fume Used in Cementitious Mixtures ASTM C1328 ..............Specification for plastic cement (Stucco) ASTM C1329 ..............Specification for Mortar cement BS 146 ........................Portland blast furnace cement BS 1370 ......................Low heat Portland cement BS 4027 ......................Sulphate-resisting Portland cement BS EN 196, .................Methods for testing cement

QCS 2014

Section 05: Concrete Part 03: Cementitious Materials

Page 3

BS EN 197-1, .............Cement, Composition, specifications and conformity criteria for common cements. BS EN 197-4 .............Cement. Composition, specifications and conformity criteria for low early strength blastfurnace cements Terms and Definitions:

1

Cementitious Materials: Portland cement in combination with one or more of the following: blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag, silica fume and Metakaolin; subject to compliance with requirements of this specification.

2

PC: shall mean Portland cement or CEM I.

3

FA or PFA: shall mean fly ash or pulverised fuel ash.

4

GGBS: shall mean ground granulated blast furnace slag.

3.2

SOURCE APPROVAL

1

The Contractor shall submit to the Engineer for approval full details of the proposed source of cement. These sources of cement supply shall be regularly and thoroughly investigated to ensure that the quality of the material supply is satisfactory and that it does not deteriorate during the performance of the project.

2

The cement source shall not be changed without the Engineer's acceptance.

3

The Contractor shall supply the Engineer with the manufacturer’s test certificates certifying that the cement is in compliance with the relevant standards.

4

For imported cement the manufacturer’s test certificates shall be provided with each consignment. The Contractor shall submit to the Engineer the date of manufacture and proof that the specifications have been complied with, certified by an independent agency in the country of origin.

5

Cement manufacturers shall label their packaging and delivery documents and shall provide, where applicable, information on the packing/dispatch date, storage conditions and the storage period appropriate to maintaining the activity of any reducing agent and to keeping the content of soluble chromium (VI) below the 2 ppm limit. The Engineer has the right to test the cement for presence of chromium at the contractor’s expense.

3.3

SAMPLING

1

The methods of obtaining samples of cement for testing shall be carried out as described in EN 196 or ASTM C183

3.4

QUALITY AND TESTING

1

The cementitious material shall fully comply with the relevant standard(s) from the following list:

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3.1.3

ASTM C150 ................Standard specification for Portland cement ASTM C595 ................Standard specification for blended Hydraulic cement

QCS 2014

Section 05: Concrete Part 03: Cementitious Materials

Page 4

ASTM C618 ...............Standard specification for coal fly ash and raw natural pozzolan for use in concrete ASTM C989 ...............Standard specification for ground granulated blastfurnace slag for use in concrete and mortars ASTM C1157 ..............Standard performance specification for Hydraulic cement ASTM C1240 ..............Standard specification for silica fume used in cementitious mixtures BS 146 ........................Portland-blast furnace cement BS 1370 ......................Low heat Portland cement BS 4027 ......................Sulphate-resisting Portland cement BS EN 197-1, ............minimum grade 42.5

.

BS EN 450 .................Fly ash for concrete.

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BS EN 15167 .............Ground granulated blastfurnace slag for use in concrete, mortar and grouts. EN 12363 ..................Silica fume for concrete.

ta

Relevant GSO

The water-soluble chromium (VI) content shall not exceed 2ppm (0,0002%) by total dry weight of cementitious materials.

3.5

DELIVERY, STORAGE AND HANDLING

1

Cement shall be delivered to the Site in sealed and branded bags, or in the manufacturer’s containers, bearing the manufacturer’s name, cement type and date of manufacture, in batches not exceeding 100 tons.

2

Cement shall be stored at the site in such a manner, as to prevent its deterioration, intrusion of moisture and foreign matter. It must be kept dry at all times. Immediately upon arrival at the Site the Contractor shall store the cement in

dry, weather tight and properly ventilated structures with floors raised a minimum of 450 mm above the ground with adequate provision to prevent absorption of moisture.

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(b)

bins or silos designed for the purpose. It shall be tight and provide for free movement to discharge opening, or

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(a)

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2

3

All storage facilities shall be subject to the approval of the Engineer, and shall be such as to permit easy access for inspection and identification. Prolonged storage of cement at site is to be avoided.

4

For bagged cement, each consignment of cement shall be kept separately, and the Contractor shall use the consignments in the order in which they are received.

5

The Contractor shall keep records of the various consignments of cement in store, giving quantities received and used, and the sections of the work in which the cement has been used, on a daily basis and make a weekly return to the Engineer accordingly. Cement used in the Works shall be free flowing and free from lumps.

6

In no case shall bagged cement be stored in stacks more than eight bags high.

QCS 2014

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Section 05: Concrete Part 03: Cementitious Materials

Page 5

A free passage of at least 1 m shall be left between the cement and the side walls of the structure. Different types of cement shall be kept in clearly marked separate storage facilities.

9

Cement delivered to Site in drums or bags by the supplier or manufacturer shall be stored in the drums or bags until used in the Works.

10

Any cement in drums or bags which have been opened shall be used immediately.

11

Cement that has partially or fully caked in storage will not be permitted in work and shall be immediately removed from the storage area. Any bag or package or sample of cement which has been damaged, or rebagged or in any way has deteriorated shall be rejected either as an individual bag or package or as the whole consignment in which such bag, package or sample is contained, as advised by the Engineer.

12

Where Site limitations preclude the storage of cement on Site, cement shall be stored at a central location and shall be delivered daily as required to specific job sites.

13

The Contractor shall provide weighing machines which shall be kept permanently in each shed for checking the weight of the bags or barrels of cement. The weighing machines shall be calibrated by an independent agency. The Engineer shall have access at all times to the cement storage sheds.

14

During transport and storage the cement shall be fully protected from all weather elements.

15

Any consignment of cement not used within two months from the date of manufacture and cement which in the opinion of the Engineer is of doubtful quality shall not be used in the Works until it has been retested and test result sheets showing that it complies in all respects with the specification and relevant standards have been delivered to the Engineer.

16

Cement stored for longer than 28 days shall be tested for “loss on ignition" prior to use to check for deterioration, and any cement which fails the test shall not be used in the works.

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END OF PART

QCS 2014

Section 05: Concrete Part 04: Water

Page 1

WATER ................................................................................................................... 2

4.1 4.1.1 4.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

4.2 4.2.1 4.2.2 4.2.3 4.2.4

QUALITY OF WATER ............................................................................................. 3 General 3 pH of Water 3 Permissible Temperatures 3 Supply and Storage 3

4.3 4.3.2

TESTING AND SAMPLING ..................................................................................... 3 Health and Safety 5

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Section 05: Concrete Part 04: Water

Page 2

4

WATER

4.1

GENERAL

4.1.1

Scope

1

This Part includes water used for concrete mixtures, washing of aggregates and equipment, wetting of surfaces or ponding during curing or for wetting formwork and washing reinforcement.

2

Related Sections and Parts are as follows:

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This Section Part 2, .............. Aggregates Part 6, .............. Property Requirements Part 9, .............. Formwork Part 10, ............ Curing Part 11, ............ Reinforcement References

1

The following standards are referred to in this Part:

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4.1.2

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ASTM C109 ................test Method for Compressive Strength of Hydraulic Cement Mortars (using 2-in or 50 mm Cube Specimens) BS 1377 ......................Methods of test for soils for civil engineering purposes.

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BS 2690 ......................Methods of testing water used in industry

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BS 6068 ......................Water quality

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BS EN ISO 9963-1 .....Determination of total and composite alkalinity

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BS EN ISO 9963-2 .....Determination of carbonate alkalinity

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EN 196-1 ....................Determination of strength EN 196-2 ....................Methods of testing cement - Part 2: Chemical analysis of cement EN 196-3 ....................Determination of setting time and soundness EN 1008 .....................Mixing water for concrete, Specification for sampling, testing and assessing the suitability of water, including water recovered from processes in the concrete industry, as mixing water for concrete SM 5220 B ................. Chemical Oxygen Demand (COD) SM 4500 ....................Standard Methods for the Examination of Water and Wastewater ISO 7890

...............Water quality -- Determination of nitrate -- Part 1: 2,6-Dimethylphenol spectrometric method

SM 3125B (ICP/MS) ...Metals by Inductively Coupled Plasma/Mass Spectrometry

QCS 2014

Section 05: Concrete Part 04: Water

Page 3

QUALITY OF WATER

4.2.1

General

1

Potable water is suitable for use in concrete, while water of other origin such as underground water, natural surface water, recovered water, as well as municipal treated water or mixed water shall be tested to prove that its quality shall conform to water quality requirements as given below in 4.3.

2

On site, where a permit is issued for Municipal Treated Effluent use for concrete, the effluent shall be treated by tertiary treatment stage: Reverse Osmosis (R.O.), and disinfection (Ultraviolet Radiation, or ozonation).

3

The water shall be examined in accordance with the test procedures stated in Table 1, EN 1008. Water not conforming to one or more of the requirements in Table 1, EN 1008 may be used only, if it can be shown to be suitable for use in concrete, in accordance with the physical tests of Table 1 below.

4

The site health and safety services and Treated Effluent Quality shall fulfil the requirements of 5

4.2.2

pH of Water

1

The pH of water used in concrete works shall be as shown in Table 4.2.

4.2.3

Permissible Temperatures

1

Temperature of water for concrete shall not be less than 5 °C and not more than 40 °C

2

Water may be cooled to not less than 5 °C by the gradual addition of chilled water or ice as

(b)

alternatively, flaked ice may be used ice to be used shall be crushed and shall be a product of frozen water which complies with the acceptance criteria of Tables 4.1 and 4.2 and 4.3.

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(c)

no ice particles shall be present in the mix

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(a)

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follows:

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4.2

3

Every effort should be made to protect water pipes and tanks from the sun; e.g., burying, shading, insulation or painting white.

4.2.4

Supply and Storage

1

The Contractor shall make his own arrangements and obtain the approval of the Engineer for the supply of water.

2

Storage of water should be such that contamination is prevented from occurring. Any measures taken to avoid contamination of the water shall be to the approval of the Engineer.

4.3

TESTING AND SAMPLING

1

Whenever required to do so by the Engineer, the Contractor shall take samples of the water being used, or which it is proposed to use, for mixing concrete and test them for quality.

QCS 2014

2

Section 05: Concrete Part 04: Water

Page 4

Samples of water of not less than 5 l shall be taken, sealed and sent for testing at an approved independent laboratory, prior to the approval of any water source, and whenever the sources of water is changed periodically during the continuance of its use.

3

Water of questionable quality should comply with the physical tests of Table 4.1 and chemical limitations listed in Table 4.2 & Table 4.3.

4

No source of water shall be used until the required tests have demonstrated its suitability for concreting.

5

The use of water from a municipal or government supply does not preclude the requirement for testing.

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Test Method

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Table 4.1 Acceptance Criteria and Physical Tests for Mixing Water

EN 196-1

Setting time, max. deviation from control, (h:min)

EN 196-3

90 % from 1:00 early to 1:30 later

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Compressive strength at 7 d, min % of control

Limits

er

BS 6068-1.37 (ISO 9297)

(a-1) for Prestressed concrete.

500

(a-2) for reinforced concrete.

1000

(a-3) for concrete without reinforcement.

4500

(b)

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(c)

Alkali

2-

Sulphates (as SO4 )

(c-1) Alkali carbonates and bicarbonates

(c-2) Alkali equivalent sodium oxides (d)

Total dissolved ions, including a, b and c above

EN 196-2

pH

2000

BS 6068-2.51 BS EN ISO 9963-1 BS EN ISO 9963-2

500

EN 196-2

1500

BS 1377 : Part 3

1000 2000 5000

(d-1) for prestressed concrete (d-2) reinforced concrete. (d-3) for concrete without reinforcement. (e)

Maximum Limit, mg/l

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Chloride (as CI)

Test Method

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(a)

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Parameter

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Table 4.2 Chemical Limitations for Mixing Water

BS 6068-2.50

6.5 - 9.0

QCS 2014

Section 05: Concrete Part 04: Water

Page 5

Table 4.3 Maximum limit of Harmful Contaminants Parameter

Test Method

Maximum Limit, mg/l

SM 5220 B

50

Phosphate; expressed as PO4 - P

SM 4500 P B, C, SM 4500 PD by subtraction

30

ISO 7890-1

100

Lead; expressed as Pb

SM 3125B (ICP/MS)

2+

100

SM 3125B (ICP/MS)

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Zinc; expressed as Zn

2+

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Nitrate; expressed as NO3 -N

.

COD

100

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SM: Standards Methods for the Examination of Water and Wastewater.

Health and Safety

1

On site, where a permit is issued for Municipal Treated Water use in construction works, the effluent should be treated by tertiary treatment stage including filtration and disinfectant (Chlorine alone, or Ultraviolet Radiation, or ozonation). Furthermore, the following site health and safety services and the Treated Effluent Quality shall be fulfilled:

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4.3.2

Residual chlorine level shall be within the range of 0.5 – 1.0 mg/l. For water to be used for concrete, the disinfectant shall be Ultraviolet Radiation, or ozonation.

(b)

Coliform level shall fulfil one of the following:

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(a)

Fecal Coliform < 200 CFU/100 ml, in case there is no direct exposure on site labour.

(ii)

Total Coliform < 23 CFU/100 ml, in case there is direct exposure on site labour.

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(c)

The site shall be facilitated by health and safety guidelines signs, where it is indicated by Arabic, English, and any other languages where there are 5 workers or more on the site, that “Water not for Human Consumption”

(d)

The site shall be facilitated by health and safety equipment, as well as, personal health and safety protection equipment.

(e)

Labour shall follow health and safety guidelines and instructions and use their health and safety personal protection equibment.

END OF PART

QCS 2014

Section 05: Concrete Part 05: Admixtures

Page 1

ADMIXTURES ......................................................................................................... 2

5.1 5.1.1 5.1.2 5.1.3 5.1.4

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definitions 2 Submittals 2

5.2 5.2.1 5.2.2

USE OF ADMIXTURES ........................................................................................... 3 General 3 Trials 3

5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7

WATER PROOFING ADMIXTURES ....................................................................... 3 General 3 Water resisting admixtures 4 Permeability reducing admixture 4 Submittals 4 General 4 Organic Corrosion Inhibitors 4 Inorganic Corrosion Inhibitors 5

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QCS 2014

Section 05: Concrete Part 05: Admixtures

Page 2

5

ADMIXTURES

5.1

GENERAL

5.1.1

Scope

1

This Part includes materials added to the concrete materials during mixing.

2

Related Sections and Parts are as follows:

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This Section Part 1 ............... General Part 6 ............... Property Requirements Part 7 ............... Concrete Plants Part 16 ............. Miscellaneous References

1

The following standards and other documents are referred to in this Part:

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5.1.2

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ACI 212.3R-10............Report on Chemical Admixtures for Concrete ACI 302 ......................Guide for Concrete Floor and Slab Construction

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ACI 305 ......................Hot Weather Concreting

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ACI 308 ......................Standard Practice for Curing Concrete ASTM C494, ...............Standard Specification for Chemical Admixtures for Concrete

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ASTM C1582, .............Standard Specification for Admixtures to Inhibit Chloride-Induced Corrosion of Reinforcing Steel in Concrete BS EN 934 ..................Admixtures for concrete, mortar and grout (Parts: 2, 6) BS EN 196, ................Methods of testing cement

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BS EN 14889 .............Fibres for concrete Polymer fibres. Definitions, specifications and conformity

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NSF ............................ Standard 61

5.1.3

Definitions

1

Admixtures are materials added during the mixing process of concrete to modify the properties of the concrete mix in the fresh and/or hardened state.

5.1.4

Submittals

1

In addition to the specified general requirements for approval of materials, approval of admixtures shall be subject to extensive trials to demonstrate the suitability, adequacy of dosing arrangements and performance.

QCS 2014

Section 05: Concrete Part 05: Admixtures

Page 3

5.2

USE OF ADMIXTURES

5.2.1

General

1

Admixtures are materials added to the concrete materials during the mixing process to modify its properties in the fresh and/or hardened state.

2

Where approved and or directed by the Engineer, admixtures shall be used as a means of: enhancing concrete durability

(b)

increasing workability of the concrete without increasing the water:cement ratio

(c)

controlling retardation and setting time.

(a)

water reducing/plasicizing admixture

(b)

high range water reducing/plasticizer admixture

(c)

set retarding admixtures

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Admixtures shall comply with the following BS EN 934 – 2 requirements or the equivalent ASTM C494:

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(a)

The methods and the quantities of admixture used shall be in accordance with the manufacturer’s instruction and subject to the Engineer’s approval after evaluation in trial mixes and shall in no way limit the Contractor’s obligations under the Contract to produce concrete with the specified strength, workability and durability.

5

The effects of accidental overdose of the admixture and measure to be taken if an overdose occurs shall be provided by the Contractor to the Engineer.

6

No admixtures containing chlorides shall be used. In particular, the use of acceleration admixtures containing calcium chloride shall not be used.

7

The use of the admixtures shall be controlled; i.e., strict quality control to ensure correct dosages as prescribed by the manufacturer and justified by trial mixes to be used. A calibrated dispenser or flowmeter shall be used for the addition of the admixture.

5.2.2

Trials

1

In addition to the standard requirements for the approval of materials, approval of admixtures shall be subject to extensive trials to demonstrate the suitability, adequacy of dosing arrangements and performance, when a proven history of performance cannot be provided to the satisfaction of the Engineer.

5.3

WATER PROOFING ADMIXTURES

5.3.1

General

1

The admixture shall be suitable for use in the Gulf condition, and specially formulated for higher ambient temperature.

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Section 05: Concrete Part 05: Admixtures

Page 4

The admixture shall be added as per manufacturer’s datasheet. Approved third party laboratory verification shall be conducted prior to use of material for the works. The manufacturer’s technical representative shall be present to ensure proper dosage of admixture during the trial mix.

5.3.2

Water resisting admixtures

1

Water resisting admixtures may be used with the permission of the Engineer and shall comply with the requirements of BS EN 934-2.

2

The admixture is to be added as per the Manufacturer’s supplier data sheet at the time of mixing. An approved lab verification shall be made prior to use,

5.3.3

Permeability reducing admixture

1

The admixture shall be a permeability reducing admixture for Non-Hydrostatic Conditions (PRAN) and for hydrostatic conditions (PRAH) as indicated by ACI 212.3R-10, or crystalline waterproofing admixture.

2

For PRAH, independent testing shall be performed according to NSF Standard 61 and approval for use of waterproofing material on structures holding potable water shall be evidenced by NSF certification.

5.3.4

Submittals

1

The Contractor shall submit manufacturers' specifications, installation instructions and other data to show compliance with the requirements of this part of the specification and the Contract Documents.

2

The Contractor shall submit comprehensive test results for the water proofing admixture as per the tests in the specification, and evidence of their ability to meet all the requirements specified.

3

The Contractor shall submit a guarantee for the water proofing admixture. The guarantee shall be worded to reflect the required performance of the material and shall be approved by the Engineer.

4

CORROSION INHIBITING ADMIXTURES

5.3.5

General

1

Where reinforced concrete structures are exposed to aggressive environment such as underground and marine structures, the use of a corrosion inhibiting admixture shall be used.

2

Corrosion Inhibiting Admixtures shall comply with ASTM C1582 Standard Specification for Admixtures to Inhibit Chloride-Induced Corrosion of Reinforcing Steel in Concrete.

5.3.6

Organic Corrosion Inhibitors

1

The admixture shall be based on either aqueous emulsion of amines and esters or amine carboxylates and shall be capable of forming a protective corrosion resistant film around the steel reinforcement.

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Section 05: Concrete Part 05: Admixtures

Page 5

The corrosion inhibitor shall be capable of effecting protection to the steel where concrete has cracked and allows access to the elements responsible for corrosion.

3

Organic corrosion inhibitors have a fixed dosage rate independent of chloride levels and shall be incorporated at the dosage rate recommended and tested by the Manufacturer.

5.3.7

Inorganic Corrosion Inhibitors

1

Inorganic corrosion inhibitors shall be based on calcium nitrites capable of oxidizing steel to a more stable form increasing its passivity in the presence of chlorides.

2

Dosage of inorganic corrosion inhibitors ranges from 10 to 30L/m3 depending on the expected chloride levels as defined by ACI 212 Table 13.1.

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END OF PART

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 1

PROPERTY REQUIREMENTS ............................................................................... 2

6.1 6.1.1 6.1.2 6.1.3 6.1.4

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definitions: 6 Submittals 7

6.2 6.2.1 6.2.2

EXPOSURE CLASSES ......................................................................................... 10 General 10 Reinforcement corrosion and sulphate classes 10

6.3 6.3.1

FRESH CONCRETE ............................................................................................. 12 General 12

6.4

GRADES OF CONCRETE..................................................................................... 13

6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.5.6 6.5.7

DURABILITY REQUIREMENTS ............................................................................ 13 General 13 Maximum acid soluble chloride content 14 Type of cementitious material 14 Resistance to alkali-silica reaction 15 Recommendations to resist reinforcement corrosion 15 Recommendations to resist sulphate attack 16 Durability-Related Properties 16

6.6 6.6.1

DESIGN OF CONCRETE MIXES .......................................................................... 17 Concrete 18

6.7

TRIAL MIXES ........................................................................................................ 25

6.8 6.8.1 6.8.2 6.8.3 6.8.4

QUALITY AND TESTING ...................................................................................... 27 General 27 Tests for Concrete 27 Hardened Tests for Fiber-Reinforced Concrete 29 Quality Control charts 29

6.9

WORKS TEST CUBES ......................................................................................... 30

6.10 6.10.1 6.10.2

REJECTION OF CONCRETE MIXES ................................................................... 30 Rejection of Concrete Mixes: 30 Unsatisfactory Concrete Works 31

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Section 05: Concrete Part 06: Property Requirements

Page 2

PROPERTY REQUIREMENTS

6.1

GENERAL

6.1.1

Scope

1

This Part includes Grades 15 MPa and above of concrete to be used in the civil works, with the requirements for workability, permeability, and drying shrinkage.

2

Related Sections and Parts are as follows:

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This Section Part 2, ........... Aggregates Part 3, ........... Cementitious Materials Part 4, ............ Water Part 5, ........... Admixtures Part 7, ............ Concrete Plants Part 8, ........... Transportation and Placing of Concrete Part 9, .............. Formwork Part 13, ............ Inspection and Testing of Hardened Concrete

.

6

References

1

The following standards are referred to in this Part. The designer along with contractor are responsible to use the latest update standard as published by the organization:

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ACI 207.1R .................Guide to Mass Concrete

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ACI 207.2R .................Report on Thermal and Volume Change Effects on Cracking of Mass Concrete ACI 207.5R .................Roller - Compacted mass concrete

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ACI 213, .....................Guide for Structural Lightweight-Aggregate Concrete

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ACI 214, .....................Evaluation of Strength Test Results of Concrete

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ACI 221, .....................Guide for Use of Normal Weight and Heavyweight Aggregates in Concrete ACI 237R 07 ..............Self Consolidating Concrete ACI 301, .....................Specifications for Structural Concrete ACI 304, .....................Guide for Measuring, Mixing, Transporting, and Placing Concrete ACI 304.2, ..................Placing Concrete by Pumping Methods ACI 318, .....................Metric Building Code Requirements for Structural Concrete & Commentary ACI 506, ....................Guide to Shotcrete ACI 506.1, ..................Guide to Fiber-Reinforced Shotcrete ACI 506.2, ..................Specification for Shotcrete ACI 555, .....................Removal and Reuse of Hardened Concrete ASTM A 820, ..............Specification for Steel Fibers for Fiber-Reinforced Concrete ASTM C 31, ................Practice for making and curing concrete test specimens in the field ASTM C 33, ...............Specification for Concrete Aggregates

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 3

ASTM C 39, ................Test Method for Compressive Strength of Cylindrical Concrete Specimens ASTM C 42, ................Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete ASTM C 94, ................Specification for Ready-Mixed Concrete ASTM C192, ...............Practice for Making and Curing Concrete Test Specimens in the Laboratory ASTM E 119, ..............Test Methods for Fire Tests of Building Construction and Materials ASTM C 138, ..............Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete ASTM C 150, .............Specification for Portland Cement ASTM C 172, ..............Practice for Sampling Freshly Mixed Concrete

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ASTM C 173, ..............Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method

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ASTM C 231 ...............Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

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ASTM C 232, .............Test Methods for Bleeding of Concrete

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ASTM C 311, .............Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for Use in Portland-Cement Concrete

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ASTM C 387, ..............Specification for Packaged, Dry, Combined Materials for Mortar and Concrete ASTM C 597, ..............Test Method for Pulse Velocity through Concrete

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ASTM C 617, .............Practice for Capping Cylindrical Concrete Specimens

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ASTM C 618, .............Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

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ASTM C 637, ..............Specification for Aggregates for Radiation-Shielding Concrete Constituents

of

Aggregates

for

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ASTM C 638, .............Descriptive Nonmenclature of Radiation-Shielding Concrete

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ASTM C 803, .............Test Method for Penetration Resistance of Hardened Concrete ASTM C 805, .............Test Method for Rebound Number of Hardened Concrete

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ASTM C 856, .............Practice for Petrographic Examination of Hardened Concrete ASTM C 900, .............Test Method for Pullout Strength of Hardened Concrete ASTM C 989, ..............Standard Specification for Slag Cement for Use in Concrete and Mortars ASTM C 1018, ............Test Method for Flexural Toughness and First-Crack Strength of FiberReinforced Concrete ASTM C 1116, ...........Specification for Fiber-Reinforced Concrete ASTM C 1140, ............Practice for Preparing and Testing Specimens from Shotcrete Test Panels ASTM C 1152 .............Standard Test Method for Acid-Soluble Chloride in Morter and Concrete. ASTM C 1218 .............Standard Test Method for Water-Soluble Chloride in Morter and Concrete. ASTM C 1231, ............Practice for Use of Unbonded Caps in Determination of Compressive Strength of Hardened Concrete Cylinders

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 4

ASTM C 1240, ............Specification for Silica Fume Used in Cementitious Mixtures ASTM C 1385, ............Practice for Sampling Materials for Shotcrete ASTM C 1399, ............Test Method for Obtaining Average Residual-Strength of FiberReinforced Concrete ASTM C 1480, ............Specification for Packaged, Pre-Blended, Dry, Combined Materials for Use in Wet or Dry Shotcrete Application ASTM C 1550, ............Test Method for Flexural Toughness of Fiber Reinforced Concrete (Using Centrally Loaded Round Panel) ASTM C 1604, ............Test Method for Obtaining and Testing Drilled Cores of Shotcrete ASTM C 1609, ............Test Method for Flexural Performance of Fiber-Reinforced Concrete (Using Beam With Third-Point Loading) ASTM C 1611, ............Test Method for Slump Flow of Self-Compacting Concrete

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ASTM C 1666, ............Specification for Alkali Resistant (AR) Glass Fiber for GFRC and Fiber-Reinforced Concrete and Cement

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ASTM D 5759, ............Guide for Characterization of Coal Fly Ash and Clean Coal Combustion Fly Ash for Potential Uses

BRE digest 433, .........Recycled Aggregates

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ASTM D 6942, ............Test Method for Stability of Cellulose Fibers in Alkaline Environments

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BS 4027, ....................Specification for Sulphate-Resisting Portland Cement

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BS 6073-2:2008, ........Precast concrete masonry units. Guide for specifying precast concrete masonry units

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BS 8500, ....................Concrete, Complementary British Standard to BS EN 206-1.

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BS 8666,.....................Specification for scheduling, dimensioning, bending and cutting of steel reinforcement for concrete BS EN 206-1, ............Concrete. Specification, Performance, Production And Conformity

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BS EN 450,.................Fly Ash for Concrete. Definition, Specifications And Conformity Criteria

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BS EN 771-3, .............Specification for masonry units. Aggregate concrete masonry units (dense and light-weight aggregates

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BS EN 772-2, ............. Methods of test for masonry units. Determination of percentage area of voids in masonry units (by paper indentation) BS EN 12350,.............Testing Fresh Concrete BS EN 12350-1, .........Testing fresh concrete - Part 1: Sampling BS EN 12350-2, .........Testing fresh concrete - Part 2: Slump test BS EN 12350-3, .........Testing fresh concrete - Part 3: Vebe test BS EN 12350-4, .........Testing fresh concrete - Part 4: Degree of compactability BS EN 12350-5, .........Testing fresh concrete - Part 5: Flow table test BS EN 12350-6, .........Testing fresh concrete - Part 6: Density BS EN 12350-7, .........Testing fresh concrete - Part 7: Air content - Pressure methods BS EN 12390,.............Testing Hardened Concrete BS EN 12390-1, .........Testing hardened concrete - Part 1: Shape, dimensions and other requirements for specimens and moulds BS EN 12390-2, .........Testing hardened concrete - Part 2: Making and curing specimens for strength tests

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 5

BS EN 12390-3, .........Testing hardened concrete - Part 3: Compressive strength of test specimens BS EN 12390-4, .........Testing hardened concrete - Part 4: Compressive strength Specification for testing machines BS EN 12390-5, .........Testing hardened concrete - Part 5: Flexural strength of test specimens BS EN 12390-6, .........Testing hardened concrete - Part 6: Tensile splitting strength of test specimens BS EN 12390-7, .........Testing hardened concrete - Part 7: Density of hardened concrete BS EN 12390-8, .........Testing hardened concrete - Part 8: Depth of penetration of water under pressure BS EN 12620,.............Aggregate For Concrete

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BS EN 15167 .............Ground Granulated Blast Furnace Slag For Use In Concrete, Mortar And Grout. Conformity Evaluation

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BS EN 1744, ..............Tests For Chemical Properties Of Aggregates

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BS EN 1992-3:2006 ...Eurocode 2. Design of concrete structures. Liquid retaining and containing structures

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BS EN 1992-3:2006 ...UK National Annex to Eurocode 2. Design of concrete structures. Liquid retaining and containment structures

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BS PD 6682-1, ...........Aggregates for Concrete. Guidance on the Use of BS EN 12620

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Concrete Society Report No. 31, Permeability testing of site concrete EN 1011, .................... Welding. Recommendation for welding of metallic materials

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EN 1992-1-1, ..............Eurocode 2: Design of concrete structures. General rules and rules for buildings

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GSO ISO 1920-1 ........Testing of concrete —Part 1: Sampling of fresh concrete GSO ISO 1920-2 ........Testing of concrete – part 2: properties of fresh concrete

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GSO ISO 1920-3 ........Testing of concrete – part 3: Making and curing test specimens. GSO ISO 1920-4 .......Testing of concrete – part 4: strength of hardened concrete. GSO ISO 1920-5 .......Testing of concrete – part 5: properties hardened concrete other than strength. GSO ISO 1920-6 ........Testing of concrete – part 6: sampling, preparing and testing of concrete core . GSO ISO 1920-7 .......Testing of concrete – part 7: Non –destructive test on hardened concrete. ISO 1920-8 .................Testing of concrete -- Part 8: Determination of drying shrinkage of concrete for samples prepared in the field or in the laboratory ISO 1920-9 .................Testing of concrete -- Part 9: Determination of creep of concrete cylinders in compression ISO 1920-10 ...............Testing of concrete -- Part 10: Determination of static modulus of elasticity in compression

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 6

CSTR11......................Concrete core testing – The concrete Society RILEM CPC 11.3 .......Absorption of water by immersion under vacuum The Concrete Society CS163. Guide to the design of concrete structures in the Arabian Peninsula. The European Guidelines for Self-Compacting Concrete Specification, Production and Use 6.1.3

Definitions:

1

Exposure conditions will apply as follows: Class X0: No risk of corrosion or attack. Non saline conditions. Blinding concrete, nonreinforced concrete or slab on ground.

(b)

Class X1: Mild exposure – Non saline conditions (dry or wet, rarely dry) External concrete at least 3m above ground level, internal concrete in dry conditions, concrete permanently submerged in non-saline water or non-aggressive groundwater.

(c)

Class X2: Moderate exposure – Non saline conditions (Cyclic wet and dry). External reinforced concrete less than 3m above ground level, water-retaining structures exposed to fluctuating water levels.

(d)

Class X3: Aggressive exposure – Permanently submerged or wet (rarely dry) Concrete in contact with groundwater including capillary rise zone, concrete containing or permanently exposed to saline water.

(e)

Class X4: Severe exposure – Moderate humidity External concrete within 1km from the sea or in contact with high saline water table or sabkhas. Concrete not affected by condensation, irrigation or leakage, which are more than 3m above ground level.

(f)

Class X5: Extreme exposure – Cyclic wet and dry, external concrete within 1km from the sea or in contact with high saline groundwater or sabkhas. Concrete affected by condensation, irrigation or leakage, which are less than 3m above ground level or within capillary zone. Concrete surfaces exposed to sea water splash or in sea water tidal zone.

(g)

Sulphate exposure classes S1 to S4: the exposure classes are related to sulphate attack in relation to sulphate and pH of the ground water.

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(a)

Concrete is a mixture (mix) of cementitious materials, coarse and fine aggregate, and water, with or without admixtures, which develops its properties by cement hydration.

3

"Cementitious Materials": Portland cement in combination with one or more of the following: blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag and silica fume; subject to compliance with requirements of this specification.

4

“Water/Cementitious Ratio” shall mean the ratio between the total weight of water in the concrete (less the water absorbed by the aggregate) and the weight of cementitious materials, expressed as a decimal fraction.

5

“Admixtures” shall mean a material other than water, aggregate, cementitious materials or fiber reinforcement, used as an ingredient of concrete or mortar. Admixtures are added during the mixing process of concrete to modify the properties of the concrete mix in the fresh and/or hardened state.

6

“Hot Weather” shall mean any combination of the following conditions that tends to impair the quality of freshly mixed or hardened concrete by accelerating the rate of moisture loss and rate of cement hydration, or otherwise causing detrimental results such as: a. High ambient temperature (when the shade temperature is above 40 deg C on a rising thermometer, 43 deg C on a falling thermometer), b. High concrete temperature, c. Low relative humidity, d. 2 High wind speed and e. whenever the rate of evaporation exceeds 0.75 kg/m /h

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“Mass concrete” is defined as any volume of concrete with dimensions large enough to require that measures be taken to cope with generation of heat form hydration of the cement and attendant volume change to minimize cracking. Reinforced Massive concrete structures include pile caps, transfer plates, and structural members where the least dimension exceeds 1.5 meters.

8

“Coarse Aggregate” shall be considered as that size passing a 20mm sieve (or larger sieve size) and predominately retained on a 4mm sieve.

9

“Fine Aggregate” shall be considered as that size predominately passing a 4mm sieve and predominately retained on a 0.063mm size.

10

“PC” shall mean Portland cement or CEM I.

11

“FA” shall mean pulverised fuel ash or fly ash.

12

“GGBS” shall mean ground granulated blastfurnace slag.

13

“SF” shall mean silica fume. Other names are condensed silica fume and microsilica

14

“Gap-graded aggregate” shall mean graded aggregate without one or more of the intermediate sizes.

15

“Single-size aggregate” shall mean aggregates containing a major proportion of particles of one sieve size.

16

“Target Mean Strength” shall mean the specified characteristic strength plus the margin.

17

“Margin” shall mean the difference between the specified characteristic strength and the target mean strength.

18

“Acceptable or Accepted” shall mean acceptable or accepted by the Engineer.

19

“Approval or Approved” shall mean approval from the Engineer.

20

“All-in” aggregate shall mean the materials composed of a mixture of coarse and fine aggregates.

21

Self-Compacting Concrete (SCC): concrete that is able to flow and consolidate under its own weight, completely fill the formwork even in the presence of dense reinforcement, whilst maintaining homogeneity and without the need for any additional compaction.

6.1.4

Submittals

1

The Contractor shall submit details of mix designs to the Engineer for approval.

2

Material Safety Data Sheet MSDS or equivalent for all products. test results and other information as required to prove compliance with the specification shall be submitted to the Engineer for approval according to the relevant sections of QCS on at least the following products

3

Cement:

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(a)

Recent independent test results acceptable to the Engineer confirming compliance with the specified requirements and referenced standards.

(b)

Manufacturer's certificates shall also be supplied for each batch of production of cement or on a weekly basis, whichever is more frequent, certifying compliance with the BS EN 197 or other equivalent standard.

QCS 2014

(c)

Page 8

The early compressive strength of each consignment of cement shall conform to the requirements of QCS part 3 at the independent site laboratory. Deviation of more than 10% from either the previous consignment value or the rolling average shall be immediately reported to the Engineer. Testing at an independent laboratory shall be as instructed by the Engineer.

GGBS: (a)

Recent independent test results acceptable to the Engineer confirming compliance with the specified requirements and referenced standards.

(b)

Manufacturer's certificates with all information necessary to verify compliance shall also be supplied for each consignment of GGBS or on weekly basis, whichever is more frequent.

(c)

The early compressive strength of each consignment of GGBS shall be determined in accordance with BS EN 197 and BS EN 15167 or ASTM C989 at the independent site laboratory based on a blend of 50/50 % GGBS and CEM 1. Deviation of more than 5% in strength from either the previous consignment value or the rolling average shall be immediately reported to the Engineer. Testing at an independent laboratory shall be in accordance with per BS EN 197 and BS EN 15167 standards, and approved by the Engineer.

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FA:

Recent independent test results acceptable to the Engineer confirming compliance with specified requirements of BS EN 450 or ASTM C618.

(b)

Manufacturer's certificates with all information necessary to verify compliance with internationally recognized standards shall also be supplied with each consignment of FA.

(c)

The materials shall comply with QCS part 3. Deviation of the strength factor by more than 5% from either the previous consignment value or the rolling average shall be immediately reported to the Engineer and the Technical Manager of the premix company.

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(a)

Silica fume:

Manufacturer's certificates with all information necessary to verify compliance with internationally recognized standards shall also be supplied with each consignment of silica fume.

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(b)

Recent independent test results acceptable to the Engineer confirming compliance with specified requirements and referenced standards.

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Section 05: Concrete Part 06: Property Requirements

(c)

7

8

7 day pozzolanic activity test in accordance with BS EN 13263-1 or ASTM C 1240 on each consignment of silica fume at the Independent site laboratory. Deviation of the activity index by more than 5% from either the previous consignment value or the rolling average shall be immediately reported to the Engineer and the Technical Manager of the premix company.

Aggregates: (a)

Recent independent test results acceptable to the Engineer confirming compliance with the specified requirements and referenced standards.

(b)

Full details of the proposed sources of aggregates.

Water: Recent independent test results acceptable to the Engineer confirming compliance with the specified requirements and referenced standards.

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 9

9

Admixtures: Manufacturer’s technical specifications and recommendations. Recent trial results acceptable to the Engineer illustrating the efficiency of the product for its particular application. Tests on specific gravity and solids content shall be conducted at the Independent site laboratory on each consignment.

10

Mix Designs: Submit concrete mix designs for each type and strength of concrete required at least thirty (30) days before placing concrete.

11

New mix designs, with historic data less than 6 months, shall be verified by an approved independent testing laboratory in accordance with requirements of QCS Part 05 and shall be coordinated with design requirements and Contract Documents.

12

Submit complete mix design data for each separate mix to be used on the Project in a single submittal with at least the following information: Type of cement*.

(b)

Portland cement content*.

(c)

Cementitious content* (GGBS, FA, natural pozzolan, rice husk ash and/or silica fume).

(d)

Max. aggregate size*.

(e)

Combined grading curve for coarse aggregate

(f)

Quantities of all individual materials*

(g)

Type of admixture(s)*

(h)

Target slump/slump flow (at discharge)* as per BS EN 12350-2

(i)

Initial and final concrete setting time for each mix design as per ASTM C403 or equivalent BS EN standards, if specified

(j)

Fresh density of concrete as per BS EN 12350-6

(k)

Air content as per BS EN 12350-7

(l)

Target temperature*

(m)

Bleeding, if specified

(n)

Chloride and sulphate (SO3) contents

(o)

Details of calculated water/cementitious material (w/c) ratio*

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Compressive strength grade* Hardened density

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(p)

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(a)

(r)

Water absorption (%) and water penetration (mm), if specified

(s)

Rapid chloride permeability - Coulomb value, if specified

(t)

Chloride migration coefficient (m /sec), if specified

2

*Include on delivery ticket as a minimum 13

Data shall be from the same production facility that will be used for the Project.

14

Mix Design data shall include but not be limited to the following: (a)

Locations on the Project where each mix design is to be used corresponding to Structural General Notes on the Drawings.

(b)

Proportions: Concrete constituent materials shall be proportioned to yield 1 m

(c)

Submit strength test records, mix design materials, conditions, and proportions for concrete used for record of tests, standard deviation calculation, and determination of required average compressive strength, if required by the Engineer.

3

QCS 2014

Page 10

(d)

If early concrete strength is required, contractor shall submit trial mixture results as required.

(e)

Test records to support proposed mixtures shall be no more than 12 months old and use current cement and aggregate sources. Test records to establish standard deviation may be older if necessary to have the required number of samples.

(f)

Manufacturer's product data for each type of admixture.

(g)

Manufacturer’s certifications that all admixtures used are compatible with each other.

(h)

All information indicating compliance with Contract Documents including method of placement and method of curing.

Mass Concrete: (a)

Submit mix design for mass concrete elements in conformance with requirements of ACI 301 Section 8. The concrete mix design shall not be designed with a high early strength unless otherwise demonstrated by the Contractor for capability of maintaining proper temperature and approved by the Engineer.

(b)

Submit proposed methods of temperature control, including cementitious material content control in mix design to reduce heat-generating potential of concrete, precooling of ingredients to lower concrete temperature as placed, and methods to protect mass concrete elements from excessive temperature differentials.

(c)

Submit analysis of anticipated thermal development within mass concrete elements with the proposed mix design for these elements. Results of the analysis, using methods in ACI 207.1R and ACI 207.2R such as the Schmidt model and site specific data, shall address the maximum differential temperature and the maximum temperature during curing

(d)

Submit proposed number and locations of temperature monitoring devices to record temperature development between the interior and the exterior of mass concrete elements.

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Section 05: Concrete Part 06: Property Requirements

EXPOSURE CLASSES

6.2.1

General

1

The exposure classes are related to the environmental conditions surrounding the concrete in service.

2

The concrete may be subject to more than one of the classes described below, and the environmental conditions to which it is subjected need to be expressed as a combination of exposure classes.

3

Where two or more aggressive characteristics lead to the same class, the exposure shall be classified into the next higher class; unless a special study for this specific case proves that it is not necessary.

4

For a given structure, different concrete elements may be subject to different environmental classes.

6.2.2

Reinforcement corrosion and sulphate classes

1

The classification system described below is based on the approach in BS EN 206-1, BS 8500-1, and the Concrete Society CS 163.

2

The exposure classes related to reinforcement corrosion are associated with carbonation and chlorides as per Table 6.1.

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3

The exposure classes related to sulphate attack are given in Table 6.2 in relation to sulphate and pH of the ground water.

4

The sulphate content as S04 mg/l shall be determined as per BS EN 196-2.

5

The pH shall be determined as per ISO 4316. Table 6.1. Exposure classes for reinforcement corrosion Exposure Class

Class description No risk of corrosion or attack. Non saline conditions. Blinding concrete, non-reinforced concrete or slab on ground

X1

Mild exposure – Non saline conditions (dry or wet, rarely dry). External concrete at least 3m above ground level, internal concrete in dry conditions, concrete permanently submerged in non-saline water or nonaggressive groundwater (Class S1).

X2

Moderate exposure – Non saline conditions (cyclic wet and dry). External reinforced concrete less than 3m above ground level, water-retaining structures exposed to fluctuating water levels.

X3

Aggressive exposure – Permanently submerged or wet (rarely dry). Concrete in contact with groundwater including capillary rise zone, concrete containing or permanently exposed to saline water.

X4

Severe exposure – Moderate humidity. External concrete within 1km from the sea or in contact with high saline water table or sabkhas. Concrete not affected by condensation, irrigation or leakage, which are more than 3m above ground level.

X5

Extreme exposure – Cyclic wet and dry. External concrete within 1km from the sea or in contact with high saline groundwater or sabkhas. Concrete affected by condensation, irrigation or leakage, which are less than 3m above ground level or within capillary zone. Concrete surfaces exposed to sea water splash or in sea water tidal zone.

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X0

Table 6.2. Sulphate exposure classes

m

Sulphate and magnesium

Exposure class

2:1 water/soil or groundwater SO4 (mg/l)

Mg (mg/l)

Natural soil Static water pH

Mobile 2 water pH

Brownfield Static water pH

1

Mobile 2 water pH

S1

< 1500

> 3.5

Not mobile

> 5.5

Not mobile

S2

1500-3000

> 3.5

Not mobile

> 5.5

Not mobile

S3

3001-6000

≤ 1000

> 3.5

Not mobile

> 5.5

Not mobile

S4

> 6000

≤ 1000

> 3.5

> 5.5

> 5.5

> 6.5

S5

> 6000

> 1000

> 3.5

> 5.5

> 5.5

> 6.5

Notes 1. 2.

Brownfield sites are those previously occupied and contain chemical residues into the ground or groundwater The mobility of water shall be determined as described in the Concrete Society CS 163.

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6.3

FRESH CONCRETE

6.3.1

General

1

Where adequate workability is difficult to obtain at the maximum water/cementitious ratio allowed, the use of plasticisers or water reducing admixtures may be considered. Alternatively an increase in cementitious content may be considered where this will not adversely affect the durability of the concrete.

2

Cementitious contents in excess of 400 kg/m shall not be used unless special consideration has been given to the effect for heat of hydration and reduce thermal stress in the concrete, and approval has been obtained from the Engineer. The maximum cementitious content shall not exceed 500kg/m³

3

The proportioning, mixing and placing of the mixture shall be in accordance with Parts 7 and

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3

Temperature (at placement):

Maximum fresh concrete temperature shall not exceed 32°C unless construction testing to verify a proposed concrete mixture will function satisfactorily at a concrete temperature greater than 32°C. No concrete shall be placed if the concrete temperature is above 35°C

(b)

For mass concrete, the concrete producer shall demonstrate that temperature of concrete due to hydration shall comply with the maximum fresh concrete temperature specified. The supplier may use in his demonstration testing heat sensors and simulation technologies which measure the concrete heat of hydration and its rate versus concrete curing age.

ta

(a)

er

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as

qa

4

rw

8 of this Section

The Contractor is responsible for ensuring that the concrete is able to be fully compacted within the concrete element regardless of reinforcing density or other limitations. This may involve reducing the maximum aggregate size, increase the level of concrete workability or use self-compacting concrete.

6

Where the consistence of concrete is to be determined, it shall be measured either by means of:

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et it

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ov

5

(a)

Slump test conforming to BS EN 12350-2

(b)

Flow table test conforming to BS EN 12350-5

7

The consistence of concrete shall be determined at the time of use of the concrete or in the case of ready-mix concrete, at the time of delivery.

8

The tolerances for the different consistence tests and target values are given in Table 6.3. Table 6.3. Tolerances for target values of consistence Slump*

Flow diameter*

Target value (mm)

≤ 40

50 to 90

≥ 100

Tolerance (mm)

-30, +40

-40, +50

-50, +60

Target value (mm)

All values

Tolerance (mm)

-60, +70

* For spot samples taken from initial discharge.

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 13

6.4

GRADES OF CONCRETE

1

Where strength is classified with respect to compressive strength, Table 6.4 gives the concrete grade with the requirements for w/c ratio and cementitious content.

2

The characteristic compressive strength at 28 days of 150mm cubes (f ck, cube) or 150mm diameter by 300mm cylinders (fck, cyl) may be used for the classification.

3

Exception will be made for concrete mixtures containing fly ash, silica fume or GGBS, where testing shall be requested at 56 days, or 90 days as approved by the Engineer.

(N/mm )

B 15

15

12

B 20

20

16

C 25

25

20

C 30

30

C 35

35

C 40

40

C45

45

C 50

50

3

qa

(kg/m )

Maximum

Water : Cementitious Ratio

(w/c)

-

-

-

260

0.60

300

0.58

28

320

0.55

32

335

0.50

35

355

0.47

40

370

0.45

60

50

380

0.40

75

60

390

0.35

se

as

-

o

ov

er

25

m

C 75

2

et it

C 60

2

rw

(N/mm )

Minimum cementitious content

ta

Concrete Grade

Minimum characteristic cylinder strength (fck, cyl)

Minimum characteristic cube strength (fck, cube)

.l. l

.

Table 6.4: Concrete grades and composition requirements

6.5

DURABILITY REQUIREMENTS

6.5.1

General

1

Constituent materials shall not contain harmful ingredients in such quantities as may be detrimental to the durability of concrete or cause corrosion of the reinforcement.

2

For reinforced concrete in the ground, the need for protection from chlorides must be balanced against the need for protection from sulphates.

3

Protective measures include the use of surface treatment, alternative reinforcement and increasing the concrete cover. In every case, the need for good quality concrete with low permeability is paramount.

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 14

6.5.2

Maximum acid soluble chloride content

1

The chloride content of the concrete, expressed as the percentage of chloride ions by mass of cementitious materials, shall not exceed the values given in Table 6.5.

2

Calcium chloride and chloride based admixtures shall not be used in concrete containing steel reinforcement or other embedded metal.

3

The determination of the chloride content in the concrete shall be conducted by the sum of the contributions from the constituent materials as described in BS EN 206-1 and BS 8500-2. Table 6.5. Maximum chloride content of concrete (by weight of cementitious materials) Concrete made with sulphate resisting Portland cement

Concrete made with other cementitious materials than SRPC

Reinforced concrete

0.15 %

0.3 %

Pre-stressed concrete

0.08 %

rw

.l. l

.

Concrete type

ta

0.10 %

Type of cementitious material

1

Different types of cementitious materials offer different resistance to sulphate attack and penetration of chlorides

2

The minimum cementitious content for different concrete grades is given in Table 6.4.

3

Table 6.6 gives the different types of cementitious materials and their combinations.

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se

as

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6.5.3

ov

Table 6.6. Cementitious materials and combinations

et it

o

Cementitious material

Percentage of components 100% PC

Sulphate-resistance Portland cement

100% SRPC

m

Portland cement

PC/fly ash

PC/ground granulated blastfurnace slag

Triple blend PC/FA/SF

65-79% PC 35-21% FA 35-65% PC 65-35% GGBS 55-70% PC 35-25% FA 10-5% SF 30-45% PC

Triple blend PC/GGBS/SF

60-50% GGBS 10-5% SF

BS EN 197-1 designation

ASTM standard

CEM I

Type 1

-

Type 5

CEM II/B-V

CEM III/A

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 15

Resistance to alkali-silica reaction

1

Alkali-silica reaction is the most common form of alkali-aggregate reaction.

2

Dry concrete is not prone to cracking by alkali-silica reaction, as it needs an external source of water to develop sufficiently to cause cracking.

3

Where aggregate contain varieties of silica susceptible to attack by alkalis from cement and other sources and the concrete is exposed to humid conditions, actions shall be taken to prevent deleterious alkali-silica reaction using recommendations and procedures given in BS EN 206-1 and BS 8500-2.

6.5.5

Recommendations to resist reinforcement corrosion

1

Durability design should start at the concept design stage, continuing through the design, detailing, specification and execution phases.

2

This section covers the concrete grade, cementitious type, and minimum concrete cover for various exposure classes as given in Table 6.1.

3

Table 6.7 provided recommended values of concrete grade and cover thickness to resist reinforcement corrosion at different exposure classes.

qa

ta

rw

.l. l

.

6.5.4

se

as

Table 6.7. Recommended durability requirement to resist reinforcement corrosion

Mild

X2

Moderate

X3

ov

X1

25

o

No risk of corrosion

All

40

35

30

-

50

45

40

35

Aggressive

-

70

65

60

55

  

PC/FA PC/GGBS Triple blend

X4

Severe*

-

75

70

65

60

  

PC/FA PC/GGBS Triple blend

X5

Extreme*

-

80

75

70

65



Triple blend

C30

C40

C50

C60

C75

m

45

et it

X0

Cementitious type (Table 6.6)

Minimum concrete cover (mm)

er

Exposure Class

Minimum concrete grade



All

All

*High level of cement replacement is required for severe and extreme exposure conditions. Other protection measures such as coated reinforcement or surface treatment may be considered.

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 16

Recommendations to resist sulphate attack

1

The exposure classification shall be identified based on the sulphate and magnesium contents in the ground and groundwater, pH and mobility of groundwater as given in Table 6.2.

2

The recommended concrete specification requirements in terms of concrete grade and cementitious type are given in Table 6.8.

3

Unless stated otherwise by the Engineer or project designs, all concrete below ground shall have surface protection to prevent the movement of moisture from the ground, through the foundations into the superstructure. The method of protection shall be in accordance with Section 15 of the QCS or as approved by Qatar Standards.

.

6.5.6

Minimum concrete grade

S1

C35

C50

Triple blend SRPC, PC/FA, PC/GGBS

as

SRPC, PC/FA, PC/GGBS

C60

er

C75

ov

1

Triple blend

C50

C60

S4

All

se

S3

S5

qa

C40

S2

Cementitious type

ta

Exposure class

rw

.l. l

Table 6.8 Recommended durability requirement to resist sulphate attack

See Note

Triple blend See Note

et it

o

Note: 1 S5 requires special treatment when the sulphate content exceeds 6000 mg/l and the magnesium content exceeds 1000 mg/l. Durability-Related Properties

1

The durability of concrete is greatly influenced by the ability of the concrete cover to resist the movement of liquid and gas through concrete.

2

The commonly used test for assessing the transport properties of concrete are listed in Table 6.9 together with typical values. Lower value indicates more durable concrete.

3

No values are currently specified for various exposure classes, but may be requested by the Engineer. Table 6.9 gives the recommended durability-related properties and typical values for the development of mix design and comparative performance as given in the Concrete Society CS163.

4

For Severe and Extreme exposures, it is recommended to use high durable concrete (Table 6.9)

m

6.5.7

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 17

Table 6.9 Recommended properties and typical values for concrete Concrete property

Age range between 28 and 90 days

Test method

Water absorption Water penetration, Rapid chloride permeability (RCP), Chloride migration

High durability

Minimum durability

BS 1881: Part 122

2%

4%

BS EN 12390-8

5 mm

30 mm

ASTM C 1202

500 coulombs

NT Build 492

2.0 x10

-12

2

(m /s)

4000 coulombs 9.0 x10

-12

2

(m /s)

1. Concrete shall be tested for any of the transport properties when requested by the Engineer and shall be tested at 28 days.

2. Exception will be made for concrete mixtures containing fly ash, silica fume or GGBS, where testing

.l. l

.

shall be requested at 56 days, or 90 days.

DESIGN OF CONCRETE MIXES

1

At the start of the construction period, the Contractor shall design a mix for each grade of concrete as stated hereafter.

2

Each mix design shall be such that:

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ta

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6.6

the aggregate shall comprise fine aggregate and coarse aggregate with size specified in Section 5, Part 2.

(b)

the combined aggregate grading shall be continuous

(c)

the aggregate quantity shall be calculated by weight.

se

as

(a)

Where a concrete production facility has strength test records not more than 12 months old, a sample standard deviation, Ss, shall be established. Test records from which Ss is calculated shall consist of at least 30 consecutive tests or two groups of consecutive tests totalling at least 30 tests

4

Where a concrete production facility does not have strength test records meeting requirements of 6.6 (3) above, but does have test records not more than 12 months old based on 15 to 29 consecutive tests, a sample standard deviation Ss shall be established as the product of the calculated sample standard deviation and modification factor of Table 6.10

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3

Table 6.10 Modification Factor for Sample Standard Deviation When Less Than 30 Tests Are Available No. of tests

Modification factor for sample standard deviation

Less than 15

Use para 7. Below

15

1.16

20

1.08

25

1.03

30

1.00

1- Interpolate for intermediate number of tests 2- Modified sample standard deviation, Ss, to be used to determined required average strength f’cr

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 18

5

To determine the correction factor between cube strength and cylinder strength, the contractor shall establish at least 30 consecutive strength tests from each proposed mix design. This correction will remain valid thru the project providing that no change in the properties of the materials and no change in source occurred.

6

Required average compressive strength (Target Mean Strength) f’cr used as the basis for selection of concrete proportions shall be determined from Table 6.11 using the sample standard deviation, Ss

Required average compressive strength, Target 2 Mean Strength, N/mm or MPa

.l. l

strength,

rw

Specified compressive N/mm2 or MPa

.

Table 6.11: Required Target Mean Strength when data are available to establish a sample Standard Deviation

F’cr = f’c + 1.34Ss ------------------ Eq. 1

ta

F’c < 35 MPa --- see footnote

qa

F’cr = f’c + 2.33Ss – 3.5 ---------- Eq. 2 F’c > 35 MPa --- see footnote

F’cr = f’c + 1.34Ss ------------------ Eq. 1

as

F’cr = 0.90f’c + 2.33Ss ------------ Eq. 3

When a concrete production facility does not have field strength test records for calculation of Ss, Required average strength (Target Mean Strength) f’cr shall be determined as follow:

ov

er

7

se

Note: Use the larger value computed from any equation

F’cr = f’c + 8.5 MPa when 20 < f’c < 35 MPa

(b)

F’cr = 1.10f’c + 5 MPa when f’c > 35 MPa

et it

o

(a)

Concrete

1

Portland cement concrete shall consist of a mixture of cementitious materials, fine aggregate, coarse aggregate, water, and additives (when required). It shall be classified as in Table 6.4 unless otherwise stated hereafter and requested by the Engineer.

2

Blinding concrete

m

6.6.1

(a)

Blinding concrete shall be of minimum Grade C15 and above.

(b)

The thickness of the blinding concrete shall be as shown on the Drawings, but shall in no instance be less than 75 mm.

(c)

The surface finish to blinding concrete shall be Class U4 as specified in Clause 9.3.1 of Part 9 of this Section or as directed by the Engineer.

QCS 2014

3

Page 19

Mass Concrete (a)

The fresh concrete temperature at placing shall not exceed 21°C to minimise thermal cracking. A higher temperature of up to 27°C may be accepted with a demonstration of the satisfactory performance of concrete including mock up and thermal calculations. The maximum allowable differential temperature between the interior and the exterior of the mass concrete element shall not exceed 20 ° C. The maximum temperature in any location within the mass concrete structure during curing shall not exceed 70 °C. The drop in concrete surface temperature during, and at the conclusion of the specified curing period, shall not exceed 11 °C in any 24 hour period.

Self-Compacting Concrete (a)

General: Self-Compacting Concrete (SCC) is a special concrete that requires minimum or no vibration for placing and compaction. It is able to flow under its own weight, completely filling formwork and achieving full compaction, even in the presence of congested reinforcement. The hardened concrete is dense, homogeneous and has the same engineering properties and durability as traditional vibrated, fully compacted concrete.

(b)

Self-Compacting Concrete Supplier: SCC shall be supplied by a competent concrete producer with a record of successfully producing this type of concrete at considerable volume and with high consistency.

(c)

Constituent Materials, General: The constituent materials for SCC are the same as those used in traditional concrete conforming to EN 206-1, as specified in part 2 of this section.

(d)

To achieve these requirements the control of the constituent materials needs to be increased and the tolerable variations restricted, so that daily production of SCC is within the conformity criteria without the need to test and/or adjust every batch.

(e)

Recommended Test Requirements for SCC:

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.

4

Section 05: Concrete Part 06: Property Requirements

Field Tests

600 – 750 mm

550 – 750 mm

6 – 25 sec

N.A

L-Box (3 bars)

> 0.80

N.A

J-Ring

< 10mm

N.A

o

Laboratory tests

et it

Slump-flow

m

V-Funnel

5

(f)

Concrete specimens shall be moulded in single layer without rodding and tapping

(g)

Slump flow and VSI testing shall be performed as outlined in the European Guidelines for SCC, BS EN 12350-8 and BS EN 12350-9 or ACI 237R 07 and ASTM C 1611/C 1611M

Pile Concrete 3

(a)

The cementitious content shall not be less than 380 kg/m , as specified in Section 4.

(b)

The water-cementitious ratio shall not exceed 0.45

QCS 2014

Page 20

(c)

The concrete mixture shall be designed of high slump not less than 150 mm allowing proper free fall with excellent homogeneity. When concrete mixture requires slump of greater than 230 mm, it shall be designed as Self-Compacting Concrete or as instructed by the Engineer.

(d)

The concrete slump shall have adequate workability retention using approved type of retarder and shall be submitted in the design mix.

(e)

The increase in workability shall not permit any decrease in the specified design strength

(f)

The concrete in a pile shall, if at all possible, be placed in one continuous operation.

Underwater Concrete Shall comply with ACI 304 Chapter 8

(b)

The Cementitious content shall not be less than 390 kg/m

(c)

The water-cementitious ratio must not exceed 0.40

(d)

Fine aggregate contents of 45 to 55% by volume of total aggregate and air contents of up to approximately 5% are generally specified.

(e)

Concrete shall be more cohesive and less prone to washout of cement or fines from the concrete during placement. Antiwashout admixtures or alternative concrete mix shall be used for underwater concrete.

(f)

Trial placements shall be conducted to verify that the concrete proportioned with the antiwashout admixture can maintain adequate slump life and can flow for the required distance.

(g)

The concrete mixture shall be designed of high slump not less than 150 mm allowing proper free fall with excellent homogeneity. The use of air-entraining admixture shall be evaluated as it increases the workability. When concrete mixture requires slump of greater than 230 mm, it shall be designed as Self Compacted Concrete. The increase in slump shall be made using proper admixtures.

(h)

.l. l

.

(a)

et it

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3

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6

Section 05: Concrete Part 06: Property Requirements

The increase in workability shall not permit any decrease in the specified design strength

m

(i)

The concrete slump shall have adequate retention using approved type of retarder and shall be submitted in the design mix.

7

(j)

The concrete shall be placed in one continuous operation

(k)

The final selection of a concrete mixture shall be based on test placements made under water in a placement box or in a pit that can be dewatered after the placement. Test placements shall be examined for concrete surface flatness, amount of laitance present, quality of concrete at the extreme flow distance of the test, and flow around embedded items, if appropriate.

Shotcrete (a)

The classification of shotcreting shall be in accordance to the process used (wet-mix or dry-mix) and the size of aggregates used.

(b)

All materials shall be as per QCS except for aggregate where gradation shall be as per ACI 506R and 506.2R

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 21

(c)

Steel and synthetic fibers will be used to reduce propagation of cracks. Fibers shall be as per Manufacturer supplier data sheet and shall conform to ASTM A 820 for steel fibers and ASTM C1116 for synthetic fibers.

(d)

The nozzle operator should be certified (refer to ACI CP-60) and have completed at least one similar application as a nozzle operator on a similar project. The nozzle operator should also be able to demonstrate, by test, an ability to satisfactorily perform the required duties and to apply shotcrete as required by specifications

(e)

Before shotcreting the surface shall be prepared and maintained before and during shotcrete application. Surface preparation shall conform to ACI 506 R chap. 5

(f)

The cementitious content shall not be less than 360 kg/m where wet-mix is applied the slump shall be in the range of 40 to 80 mm

(g)

Normal testing ages for compressive strength are 7 and 28 days; however, shorter periods may be required for particular applications or conditions as directed by the 3 Engineer. Testing shall be on daily production or every 30 m whichever is greater.

(h)

Sampling and testing, however, should be varied according to the size and complexity of the project. Sampling should be done in accordance with ASTM C 1385. Making extra cylinders or panels shall be at the request of Engineer if testing results vary.

(i)

Testing for water absorption and drying shrinkage shall be at the request of the Engineer.

(j)

Fiber-reinforced shotcrete requires fiber washout tests or flexural toughness testing according to ASTM C 1018.

(k)

Acceptance of shotcrete should be based on results obtained from drilled cores or sawed cubes (ASTM C 42). The use of data from nondestructive testing devices, such as impact hammers or probes (ASTM C 805, ASTM C 803), ultrasonic equipment (ASTM C 597), and pull-out devices (ASTM C 900) may be useful in determining the uniformity and quality of the in-place shotcrete. These tests, however, may not provide reliable values for compressive strength.

(l)

Core grading is a method used to evaluate encasement of reinforcement. Core grading shall be used for nozzle operator evaluation. Core grading should not be used to evaluate structures.

o

et it

No-Fines Concrete and Pervious concrete

m

8

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as

qa

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.l. l

.

3

(a)

No-fines concrete shall be made using a coarse aggregate conforming QCS section 5 part 3

(b)

Proportion of aggregate, cement and water shall be determined by trial mixes by the Contractor and to be accepted by the Engineer.

(c)

All the aggregate particles are to be coated with a film of cement grout.

(d)

No-fines concrete when placed shall contain no layers of laitance.

(e)

No-fines concrete shall not be mixed by hand.

(f)

Mechanical vibration shall not be used to compact no-fines concrete.

(g)

Three test cubes of no-fines concrete shall be made of each preliminary mix.

(h)

Minimum crushing strength of the chosen mix shall be 5 MPa at 28 days.

QCS 2014

(i)

Section 05: Concrete Part 06: Property Requirements

Page 22

The porosity of no-fines concrete shall be such that water will pass through a slab 2 300 mm thick at the rate of not less than 7 l/m • s of slab with a constant 100 mm depth of water on the slab. Where a slab incorporating vertical weep holes or drain holes is casted above a layer of no-fines concrete; any polyethylene sheeting shall be pierced below the pipes forming such drain holes and the edges of the sheeting sealed to the lower end of the pipe to prevent the ingress of grout and fine particles from the slab concrete into the no-fines concrete.

(k)

The limit for the maximum height of drop while placing is not applicable for no fines concrete.

(l)

Formwork shall remain in place until the no fines concrete has gained adequate strength to support itself as per the requirements of Part 10 of this Section.

(m)

Curing shall be carried out in accordance with the provisions of Part 11 of this Section

(n)

The fresh density of Pervious concrete shall be tested as per ASTM C1688 and the infiltration rate shall be tested as per ASTM C1701 and to follow ACI 522.1R for testing and quality control scheme.

qa

Concrete with recycled aggregates shall be generally approved once the source of recycled aggregates is identified based on type and approved by the Engineer. The recycled aggregates shall meet with BS EN 12620 and QCS requirements.

(b)

The concrete made with recycled aggregates shall be limited to design strength of C40 MPa cube strength; unless otherwise accepted by the Engineer. BS EN 206-1 shall be the code of practice and guide for the usage of recycled concrete aggregates in concrete or ACI 555 and BRE digest 433.

(c)

The Water-cementitious ratio shall not exceed 0.50

(d)

To determine a target mean strength on the basis of a required strength, a higher standard deviation (increased by 40%) shall be used when designing a concrete with recycled aggregates of variable quality than when recycled aggregate of uniform quality or virgin aggregates are used

as

(a)

Specific gravity, unit weight, and absorption of aggregates should be determined before mixture proportion studies

m

(e)

et it

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9

ta

rw

.l. l

.

(j)

10

(f)

The mixture proportion should be based on the measured density of the recycled aggregates intended in the job concrete

(g)

Trial mixes shall be made to verify the requirements with project specification and QCS.

Heavyweight and radiation shielding concrete (a)

The quality of the aggregates should comply with the requirements of QCS for normal weight aggregates, ASTM C 637 for heavyweight aggregates and ASTM C638 for aggregates to be used in radiation-shielding concrete.

(b)

When ferrophosphorous aggregates are used, tests shall be made to determine if gases (nontoxic) might be released during construction.

(c)

Aggregates shall be checked for every delivery to ensure that they conform completely with purchase specifications

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 23

Aggregates shall be frequently evaluated for the effects of deleterious substances or aggregate coatings on concrete strength or the promotion of corrosion in metallic aggregates or embedment’s

(e)

The chemical properties of all high-density aggregates must be provided to the Engineer for evaluation before use with due consideration given to chemical reactivity, particularly in highly alkaline environment as found in cement paste.

(f)

Tests for alkali-aggregate reactivity shall be determined from each source and supplier and shall be made every 3 months.

(g)

The fresh density of high-density concrete shall be made from each truck

(h)

Lead shot concrete shall not be use for structural concrete.

(i)

Thermal conductivity, elastic behaviour and shrinkage, hardened density, strength as well as other hardened concrete properties shall be tested and verified before the use of concrete.

ta

Classification of fiber-reinforced concrete shall be made based on the material type of the fiber incorporated: Type I Steel Fiber-Reinforced Concrete—Contains stainless steel, alloy steel, or carbon steel fibers conforming to Specification of BS EN 14889-1 or ASTM A820 /A820M .

(ii)

Type II Glass Fiber-Reinforced Concrete—Contains alkali-resistant (AR) glass fibers conforming to Specification C 1666/C 1666M.

(iii)

Type III Synthetic Fiber-Reinforced Concrete— Contains synthetic fibers for which documentary evidence can be produced confirming their long-term resistance to deterioration when in contact with the moisture and alkalis present in cement paste and the substances present in admixtures and shall conform to BS EN 14889-2

(iv)

Type IV Natural Fiber-Reinforced Concrete— Contains natural fibers for which documentary evidence can be produced confirming their long-term resistance to deterioration when in contact with the moisture and alkalis present in cement paste and the substances present in admixtures. Test Method ASTM D 6942 shall be used to determine the susceptibility of these fibers to deterioration as a result of exposure to alkalis in concrete

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(i)

et it

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(a)

rw

Fiber-Reinforced Concrete

m

11

.l. l

.

(d)

(v)

(b)

When the purchaser chooses to permit the use of fibers other than those complying with the above classifications, the manufacturer or supplier shall show evidence satisfactory to the purchaser that the type of fiber proposed for use shows long-term resistance to deterioration when in contact with the moisture and alkalis present in cement paste and the substances present in admixtures

The contractor shall submit: (i)

Type of fiber-reinforced concrete required

(ii)

Designated size, or sizes, of coarse aggregates

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 24

Slump or time of flow required at the point of delivery, or when appropriate the point of placement, subject to the tolerances hereinafter specified Slump shall be specified when it is anticipated to be 50 mm or more. Except as otherwise specifically permitted by the Engineer, cement, supplementary cementitious materials, fine and coarse aggregates, mixing water, and admixtures shall be measured in accordance with the applicable requirements of QCS

(d)

Fibers shall be measured by mass. When the fibers are to be measured by mass, bags, boxes, or like containers are acceptable provided that such like containers are sealed by the fiber manufacturer and have the mass contained therein clearly marked. No fraction of a container delivered unsealed, or left over from previous work, shall be used unless weighed.

(e)

Prepackaged, dry, combined materials, including fibers, shall comply with the packaging and marking requirements of Specification ASTM C 387 or C 1480 and shall be accepted for use provided that after addition of water, the resulting fiber reinforced concrete meets the performance requirements of this specification

(f)

Batching plant used for the preparation of continuously mixed fiber-reinforced concrete shall comply with the applicable requirements of NRMCA. Fiber-reinforced concrete shall be added directly to the concrete at the time of batching in amounts in accord with approved submittals for each type of concrete required. Mix concrete in strict accord with fiber-reinforced concrete manufacturer, instructions and recommendations

(g)

Fiber-reinforced concrete shall be free of fiber balls when delivered

(h)

The manufacturer of the fiber-reinforced concrete shall furnish to the purchaser a delivery ticket or statement of particulars on which is printed, stamped, or written, information with details of the type, brand, and amount of fibers used.

(i)

The contractor shall afford the inspector all reasonable access, without charge, for the procurement of samples of freshly mixed fiber-reinforced concrete at the time of placement to determine compliance with the requirements of this specification.

(j)

Samples of batch-mixed fiber-reinforced concrete shall be obtained in accordance with Practice ASTM C 172 or C 1385/C 1385M for shotcrete as appropriate, except that wet-sieving shall not be permitted. Sampling for uniformity tests shall be in accordance with specification ASTM C 94/C 94M If the measured slumps, time of flow, or air content fall outside the limits permitted by this specification, make a check test immediately on another portion of the same sample. If the results again fall outside the permitted limits, the material represented by the sample fails to meet the requirements of this specification

m

(k)

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.

(c)

(l)

The following shall apply to all forms of fiber-reinforced concrete except dry-mix shotcrete. When applicable, the slump shall be in tolerance with this section para 6.4.2.5 (a) and (b).

(m)

The time of flow shall be in the tolerances as follow: (i)

When the project specifications for time of flow are written as a “minimum” or “not less than” requirement

Plus Tolerance Minus Tolerance

Specified time of flow If 15sec or less If more than 15 sec 5s 10s 0s 0s

QCS 2014

Section 05: Concrete Part 06: Property Requirements (ii)

When the project specifications for time of flow are not written as a “minimum” or “not less than” requirement: For specified time of flow 8 to 15 s More than 15 s

Tolerances for time of flow Tolerance + 3s + 5s

Finishability - Pre-project trials shall be utilized to determine acceptable surface finishability by the Engineer. The manufacturer shall provide the services of a qualified technician to instruct the concrete supplier in proper batching and mixing of materials to be provided.

(o)

Provide fibers for concrete reinforcing capable of achieving a two hour fire resistance rating when tested under ASTM E 119. Fire tests must be certified.

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This clause of the specification refers to lightweight concrete with improved insulation properties where the practical range of densities is between about 300 and 1850 kg/m3.

(b)

The required density and strength of the lightweight concrete will be specified on the drawings or directed by the Engineer.

(c)

The method of production of lightweight concrete will be shown on the drawings or directed by the Engineer. The Contractor shall submit full technical details of the materials and method of production for the lightweight concrete along with a list of previous projects where the particular system has been used.

(d)

After source approval of the material and system the Contractor shall submit a mix design for the lightweight concrete for the approval of the Engineer. After the review and approval of the mix theoretical mix design the Contractor shall carry out a trial mix to check the workability of the fresh concrete and to allow samples to be made for compressive strength and density.

(e)

The Engineer may also instruct that tests are carried out for abrasion resistance and thermal insulation properties.

(f)

Iightweight concrete shall be made with lightweight aggregates as approved in part 2 of section 05 in QCS for its use in concrete

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The performance of lightweight concrete shall follow ACI 213R

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6.7

TRIAL MIXES

1

As soon as the Engineer has approved the concrete mix design for each grade of concrete and during or following the carrying out of the preliminary tests, the Contractor shall prepare a trial mix of each grade in the presence of the Engineer at least 35 days before commencement of concreting. Trial mix shall be mixed and handled by means of the same plant which the Contractor proposes to use in the Works. The trial mix shall comprise not 3 less than 50% from the central mixing drum capacity but not less than 3.0 m of concrete. The trial mix can be exempted if concrete supplier provides through an independent approved testing agency adequate history on strength:

2

(a)

Not less than 30 strength test results as in para 6.6 of this specification

(b)

The results shall valid by no more than 6 months from the date of approval

Batch the field concrete trial mixture within -5°C of the proposed maximum allowable fresh 3 concrete temperature in a truck-mixer with a minimum batch size of 3 m .

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Page 26

The concrete mixture shall be held in the mixer for 120 minutes, unless otherwise specified by the Engineer. During the entire 120-minute period, agitate the mixer at 1 to 6 rpm. At the end of 120 minutes, mix the concrete mixture at full mixing speed designated by the manufacturer (6 to 18 rpm) for 2 minutes.

4

For each trial mix, a plant production trial shall be carried out and the slump of the concrete checked immediately after discharge from the mixer and thereafter at 30 min intervals up to the maximum time period envisaged for delivery and standing on site. Based on this trial the mix design shall identify any adjustments to the range of plasticiser for acceptable workability for different times after batching. Where ready mix concrete is being used, the above requirement may be waived at the discretion of the Engineer if the Contractor has documented previous experience of a particular mix design with test results available.

5

The proportions of cement, aggregate and water shall be carefully determined by weight in accordance with the Contractor's approved mix design (or modified mix design after preliminary tests).

6

Each sample shall consist of at least 9 specimens for strength analysis where 3 specimens for each age will be tested to determine the concrete strength at the required age.

7

If either or both the average value of the strength of the three cubes tested at 28 d is less than the required strength (target strength) or the difference between the greatest and the least strengths is more than 15 % of the average strengths, as per BS EN 206-1, the Contractor shall take measures as deemed necessary such as:

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Propose new mix design

(b)

Provide new materials and prepare and test further trial mixes until specified requirements are achieved.

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(a)

Additionally, the Contractor shall measure the temperature, workability of concrete in each batch.

9

When requested by engineer, a mock-up of 2x2x2 m shall be made at jobsite and full scale tests of the workability of each trial mix shall be made by the Contractor in the presence of the Engineer. The following tests shall be made on the Site by filling trial moulds to confirm the suitability of:

3

(a)

mix for the works type of plant used for mixing

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(c)

face intended for use in the works

(d)

type of form oil

(e)

type of protective coatings.

10

Redesign of the concrete mixes and trial mixes of concrete shall be repeated for each grade of concrete until the concrete meets the requirements in this specification and it is verified by full scale mockup test as described above.

11

Approval of the job-mix proportions by the Engineer or his assistance to the Contractor in establishing those proportions, in no way relieves the Contractor of the responsibility of producing concrete which meets the requirements of this Specification.

12

All costs connected with the preparations of trial mixes and the design of the job mixes shall be borne by the Contractor.

13

The Contractor shall declare any change in the source of the material and any changes in the cement content consumption greater than 20.0kg/m³ from that used in the trial mixes.

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QUALITY AND TESTING

6.8.1

General

1

In order to ensure that the quality of materials and mix proportions are maintained throughout concreting operations, sampling and testing shall be carried out using the relevant standard procedures and all other relevant codes quoted in this specification in accordance with a routine testing program that shall be agreed with the Engineer before the start of concrete work.

2

The Contractor, through a third party approved testing agency, shall supply all necessary tools for tests, shall cast all concrete specimens, strip and store them in water as stated in BS EN 12390-2. The Contractor shall also arrange for the transport of samples to the place of testing and shall supply the Engineer with duplicate copies of all test certificates.

6.8.2

Tests for Concrete

1

Unless the Engineer directs otherwise, the program shall include at least the tests specified below.

2

Tests on aggregates shall be as described in Part 2 of this Section.

3

Concrete shall be tested in accordance with the requirements of this specification by qualified field testing technicians or engineer. Concrete testing laboratory personnel shall be certified from a recognised Institution. Field personnel’s in charge of sampling concrete; testing for slump, and temperature; and making and curing test specimens shall be certified from a recognised Institution too.

4

Slump tests (and VSI testing when applicable) shall be carried out at the rate of one test per 3 load of concrete delivered to the Site, or one test per 10 m whichever is the lesser for the 3 3 first 50 m of concrete then at a rate of 1 slump test for every 50 m if concrete was consistent during production. In the event of inconsistent slump values, the Engineer may instruct the Contractor to check the slump test on each truck of concrete at the plant. The Contractor shall carry out an investigation to establish the cause of the high variation in slump and shall take any necessary corrective measures. The slump requirements for the fresh concrete are to be approved by the Engineer.

5

The adjustment for the slump of concrete to fit the job requirement can be conducted only one time using a proper additive at jobsite provided that such addition does not increase the water-cement ratio and setting time above the maximum permitted by the specifications. This addition will only be made at the approval of Engineer.

6

Concrete shall be available within the permissible range of slump for a period of 30 min starting either on arrival at the job site or after the initial slump adjustment as permitted 3 above, whichever is later. The first and last quarter m discharged are exempt from this requirement. If the user is unprepared for discharge of the concrete from the vehicle, the producer shall not be responsible for the limitation of minimum slump after 30 min have elapsed starting either on arrival of the vehicle at the prescribed destination or at the requested delivery time, whichever is later.

7

When air-entrained concrete is desired the purchaser shall specify the total air content of the concrete. The air content of air-entrained concrete when sampled from the transportation unit at the point of discharge shall be within a tolerance of +1.5% of the specified value.

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6.8

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Concrete strength test: (a)

Each concrete strength sample shall consist of at least seven specimens, two to be tested at 7 days, three at 28 days and two to be tested at the discretion of the Engineer. Additional samples may be prepared as directed by the Engineer to be tested at the discretion of the Engineer for strength and/or durability.

(b)

When concrete cylinders have been specified, the concrete specimens shall not be capped using sulphur for environmental effect. The Contractor shall follow one of the following procedures and as approved by the Engineer: (i)

Cap the specimens in accordance with ASTM C617 using neat cement paste and/or High-strength gypsum cement paste

(ii)

Saw cut and Grind the surface of the concrete to the desired planeness and perpendicular

(iii)

Test the concrete cylinders using Unbonded Caps in accordance with ASTM C1231

(iv)

For field specimens, the contractor has the right to either use the conversion listed in EN 206 or determine the conversion factor for each specified concrete mix design by testing at least 36 comparative specimens (i.e. 18 cubes versus 18 cylinders sampled from 3 consecutive batch trial mix).

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A minimum of one sample shall be taken of each mix every day the mix is used

(d)

Samples shall be taken at the average rate of the followings:

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One sample every 30 m3, if the pour is less than or equal to 90 m

(ii)

One sample every 100 m3, if the pour is greater than 90m and equal to or less than 2000 m3,

(iii)

One sample every 200 m3, if the pour exceeds 2000 m .

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3

Test specimens for compressive strength testing shall be prepared and cured in accordance with BS EN 12390-2. The compressive strength of the specimens shall be determined in accordance with BS EN 12390-3.

(f)

A test shall be the average of the strength of the specimens tested at the age specified. If a specimen shows definite evidence other than low strength, of improper sampling, moulding, handling, curing, or testing, it shall be discarded and the strength of the remaining cubes shall then be considered the test result. Identity criteria of concrete strength shall be assessed for each individual test result and the average of non-overlapping results as per BS EN 206-1 and explained below:

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(i)

The average strength tests (average of two specimens or more) shall be equal to or greater than the characteristic (fck) + 2 MPa, and

(ii)

Any individual test result shall be equal to or greater than fck – 4 MPa. The test result shall be that obtained from the average of the results of two or more specimens made from one sample for testing at the same age.

If works test specimens fail at 28 days the Contractor shall suspend concreting operations and shall not proceed further without approval. The Contractor shall carry out in-situ testing of the suspect concrete in accordance with Part 13 of this Section, in the presence of the Engineer. All defective work shall be replaced and retested to the satisfaction of the Engineer.

QCS 2014

Page 29

Hardened Tests for Fiber-Reinforced Concrete (a)

When post-crack flexural performance is used as the basis for acceptance of fiberreinforced concrete, make, condition, and test sets of test specimens in accordance with Test Method ASTM C1399, C1550 or C1609/C1609M as specified.

(b)

When flexural strength is used as the basis for acceptance, make and test sets of at least three test specimens in accordance with the requirements for sampling and conditioning given in Test Method ASTM C1609/C1609M. Test specimens representing thin sections, as defined in C1609/C1609M, or specimens representing fiber-reinforced shotcrete of any thickness, shall be tested as cast or placed without being turned on their sides before placement on the support system. Acceptance shall not be based on flexural strength alone when post-crack performance is important. Test Method C1609/C1609M provides for the determination of first peak flexural strength when required by the purchaser. For many type-amount fiber combinations, the first peak flexural strength is not significantly greater than the peak strength in flexure.

(c)

When compressive strength is used as part of the basis for acceptance of fiberreinforced concrete, make sets of at least two test specimens in accordance with the applicable requirements of Practices ASTM C31/C31M and C192/C192M and as specified in this section, or Test Methods C42/C42M or C1604/C1604M and condition and test in accordance with Test Methods BS EN 12390, C39/C39M, C42/ C42M, or C1604/C1604M. Acceptance shall not be based on compressive strength alone.

(d)

The frequency of tests on hardened fiber-reinforced concrete shall be in accordance with the following requirements:

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6.8.3

Section 05: Concrete Part 06: Property Requirements

Batch-Mixing: Tests shall be made with same frequency as in conventional concrete. Each test shall be made from a separate batch. On each day fiberreinforced concrete is mixed, at least one test shall be made for each class of material.

(ii)

When fibers are added, subject for approval of the Engineer, at the truck mixer 3 the tests shall be made for each 20 m or fraction thereof, or whenever significant changes have been made in the proportioning controls. On each day fiber-reinforced concrete is mixed, at least one test shall be made for each class of material.

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(i)

(iii)

3

For Shotcrete: Tests shall be made for each 38 m placed using specimens sawed or cored from the structure or from corresponding test panels prepared in accordance with Practice ASTM C1604 and C 1140. On each day fiberreinforced shotcrete is prepared; at least one test shall be made for each class of material.

6.8.4

Quality Control charts

1

The Contractor shall submit a continuous statistical analysis, on a monthly basis, for strength showing the potential strength of the concrete, variations in measured strength by determining the standard deviation (margin), batch-to-batch variations of the proportions and characteristics of the constituent materials in the concrete, the production, delivery, and handling process, and climatic conditions; and variations in the sampling, specimen preparation, curing, and testing procedures (within-test).

QCS 2014

Section 05: Concrete Part 06: Property Requirements

Page 30

The Contractor shall provide in his analysis the mean strength, calculated standard deviation, the normal distribution of concrete strength and the frequency histogram. The Contractor shall draw the upper and lower lines for warning line (Target mean strength + 2 x standard deviation) and control line (Target mean strength + 3 x standard deviation)

3

The contractor shall use the methods, of computing standard deviation along with coefficient of variation and factors for computing within-test standard deviation from range, addressed in ACI 214

4

This recalculated margin, if adopted by the Engineer, becomes the current margin for the judgement of compliance with the specified characteristic strength of concrete

6.9

WORKS TEST CUBES

1

Test cubes shall be taken as specified from fresh mixed concrete which is being used in the Works and which has been prepared in the normal way.

2

Cubes shall be numbered sequentially and marked: Time, date and name of individual

(b)

Section of work from which samples are taken

(c)

Mix reference and delivery note number

(d)

Name of technician

(e)

and any other relevant information.

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Tests for slump, as per BS EN 12350-2, and temperature shall be made and recorded whenever samples are taken.

4

The cube manufacture shall be in accordance with BS EN 12390-2.

5

When Self Compacting Concrete is used, the concrete specimens shall not be consolidated in moulds and it shall be placed in a single lift then levelled with minimum manipulation.

6

All samples shall be moulded at jobsite on a levelled surface area to within 20 mm per meter

7

Immediately after moulding and finishing, the specimens shall be stored for a period up to 48 ° h in a temperature range from 20 to 26 C and in an environment preventing moisture loss from the specimens

8

Specimens shall not be transported or handled until at least 14 h after casting

9

Transportation time from site to laboratory for final curing and strength testing shall not exceed 4 hours. Specimens shall be protected from direct sun or rapid evaporation and placed on cushion layer to reduce vibration

6.10

REJECTION OF CONCRETE MIXES

6.10.1

Rejection of Concrete Mixes:

1

Concrete mixes shall be rejected if they fail to meet one or more requirements, which cannot be brought into compliance as related to any of the following:

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Section 05: Concrete Part 06: Property Requirements

(a)

Improper class or grade of concrete

(b)

Slump or temperature not within specified limits

(c)

Oversized aggregate

(d)

Maximum water-cementitious ratio is exceeded

Page 31

Concrete shall not be rejected unless it has been visually inspected by the Engineer or representatives.

6.10.2

Unsatisfactory Concrete Works

1

A test shall be the average of the strengths of the specimens tested at the age specified. If a specimen shows definite evidence other than low strength, of improper sampling, moulding, handling, curing, or testing, it shall be discarded and the strength of the remaining specimens shall then be considered the test result and where the range of the test values is more than 15 % of the mean, the results shall be disregarded unless an investigation reveals an acceptable reason to justify disregarding an individual test value. To conform to the requirements of this specification, strength tests representing each class of concrete must meet the following requirements:

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The average of any three consecutive strength tests shall be equal to, or greater than, the specified strength, f ‘c, and

(b)

When the specified strength is 35 MPa or less, no individual strength test (average of at least two specimen tests) shall be more than 3.5 MPa below the specified strength, f ‘c

(c)

When the specified strength is greater than 35 MPa, no individual strength test (average of two specimen tests) shall be less than 0.90 f ‘c.

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(a)

Should any of the test results be unsatisfactory, the Engineer may order the work to be stopped pending his further instructions. Executed work for which test results are unsatisfactory shall be liable to rejection and if so advised the work shall be rebuilt at the Contractor's expense.

3

In the case of the 7-day works cube tests proving unsatisfactory, the work may be stopped liable to rejection pending the result of the 28-day test. If the test results fail to comply with the requirements, the work represented shall be immediately liable to rejection.

4

The cost of all such cuttings, preparation of specimens, transportation and testing, and of making good the portions of the structure affected shall be borne by the Contractor.

5

Regardless of satisfactory test cube results, any concrete work which, in the Engineer's opinion, is excessively honeycombed or in any other way is defective, shall be liable to rejection. Minor defects apparent on stripping the formwork must be made good at the Contractor's expense. No such repair work shall be carried out until after inspection by the Engineer and his acceptance of the proposed treatment has been given. Work which has not been previously inspected but which shows signs of such treatment shall be liable to rejection as defective work.

6

The cost of all delays on site due to faulty concrete work shall be met by the Contractor.

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END OF PART

QCS 2014

Section 05: Concrete Part 07: Concrete Plants

Page 1

CONCRETE PLANTS.............................................................................................. 2

7.1 7.1.1 7.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6

BATCHING .............................................................................................................. 3 General 3 Plant Type 5 Bins and Weight Batchers 5 Tolerances of Measuring Equipment 5 Batching Tolerances 6 Charging the Mixer 7

7.3 7.3.1 7.3.2 7.3.3 7.3.4

MIXING.................................................................................................................... 7 Charging Concrete Materials 7 Mixing Time for Stationary Mixers 7 Mixing 8 Limitation of Water : Cement Ratio 8

7.4 7.4.1

READY-MIXED CONCRETE ................................................................................... 9 General 9

7.5

APPENDIX A: CONCRETE PLANT INSPECTION – CHECKLIST ........................ 11

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Section 05: Concrete Part 07: Concrete Plants

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7

CONCRETE PLANTS

7.1

GENERAL

7.1.1

Scope

1

This Part covers batching and mixing of concrete together with inspection of concrete plants.

2

Related Sections and Parts are as follows:

References

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ACI 304 ......................Guides for Measuring, Mixing, Transporting, and Placing Concrete

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ASTM C94 ..................Specification for ready-mixed concrete

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BS 1881......................Testing concrete

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BS 8500......................Concrete Specification complementary to EN 206 BS EN 12390..............Testing of hardened concrete

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BS EN 12390-1:2000 .Testing hardened concrete — Part 1: Shape, dimensions and other requirements for specimens and moulds BS EN 12390-2:2000 .Testing hardened concrete — Part 2: Making and curing specimens for strength tests

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Part 1 ............... General Part 2 ............... Aggregates Part 3 ............... Cementitious materials Part 4 ............... Water Part 5 ............... Admixtures Part 6 ............... Property Requirements Part 8 ............... Transporting and Placing of Concrete Part 15 ............. Hot Weather Concreting Part 16 ............. Miscellaneous

.

This Section

BS EN 12390-3:2000 .Testing hardened concrete — Part 3: Compressive strength of test specimens BS EN 12390-4:2000 .Testing hardened concrete — Part 4: Compressive strength Specification for testing machines BS EN 12390-5:2000 .Testing hardened concrete — Part 5: Flexural strength of test specimens BS EN 12390-6:2000 .Testing hardened concrete — Part 6: Tensile splitting strength of test specimens BS EN 12390-7:2000 .Testing hardened concrete — Part 7: Density of hardened concrete BS EN 12390-8:2000 .Testing hardened concrete — Part 8: Depth of penetration of water under pressure BS EN 12350..............Testing fresh concrete BS EN 12350-1:2000 .Testing fresh concrete - Part 1: Sampling

QCS 2014

Section 05: Concrete Part 07: Concrete Plants

Page 3

BS EN 12350-2:2000 .Testing fresh concrete - Part 2: Slump test BS EN 12350-3:2000 .Testing fresh concrete - Part 3: Vebe test BS EN 12350-4:2000 Testing fresh concrete - Part 4: Degree of compatibility BS EN 12350-5:2000 Testing fresh concrete - Part 5: Flow table test BS EN 12350-6:2000 Testing fresh concrete - Part 6: Density BS EN 12350-7:2000 Testing fresh concrete - Part 7: Air content - Pressure methods GSO EN 206-1, ..........Concrete. Specification, performance, production and conformity GSO ISO 1920-1 ........Testing of concrete —Part 1: Sampling of fresh concrete GSO ISO 1920-2 ........Testing of concrete – part 2: properties of fresh concrete GSO ISO 1920-3 ........Testing of concrete – part 3: Making and curing test specimens.

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GSO ISO 1920-5 ........Testing of concrete – part 5: properties hardened concrete other than strength.

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GSO ISO 1920-6 ........Testing of concrete – part 6: sampling, preparing and testing of concrete core.

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GSO ISO 1920-7 ........Testing of concrete – part 7: Non–destructive test on hardened concrete.

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ISO 1920-8 .................Testing of concrete -- Part 8: Determination of drying shrinkage of concrete for samples prepared in the field or in the laboratory

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ISO 1920-10 ...............Testing of concrete -- Part 10: Determination of static modulus of elasticity in compression

BATCHING

7.2.1

General

1

During measurement operations, aggregates shall be handled in a manner to maintain their desired grading, and all materials shall be weighed to the tolerances required for the desired reproducibility of the selected concrete mix.

2

The coarse aggregate shall be controlled to minimize segregation and undersized material. Fine aggregate shall be controlled to minimize variations in gradation, giving special attention to keeping finer fractions uniform and exercising care to avoid excessive removal of fines during processing

3

Avoid blending two sizes of fine aggregate by placing alternate amounts in bins or stockpiles or when loading cars or trucks. Satisfactory results are achieved when different size fractions are blended as they flow into a stream from regulating gates or feeders. A more reliable method of control for a wide range of plant and job conditions, however, is to separate storage, handling, and batching of the coarse and fine fractions

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Page 4

Stockpiling of coarse aggregate shall be kept to a minimum because fines tend to settle and accumulate. When stockpiling is necessary use of correct methods minimizes problems with fines, segregation, aggregate breakage, excessive variation in gradation, and contamination. Stockpiles shall be built up in horizontal or gently sloping layers, not by end-dumping. Trucks, loaders, and dozers, or other equipment shall not be operated on the stockpiles because, in addition to breaking the aggregate, they frequently track dirt onto the piles

5

Stockpiles located to prevent contamination; arranged to assure that each aggregate as removed from its stockpile is distinct and not intermingled with others. The concrete supplier is asked to separate storage bins or compartments for each size and type of aggregate properly constructed and charged to prevent mixing of different sizes or types

6

Sequencing and blending of the ingredients during charging of the mixers shall be carried out in such a way as to obtain uniformity and homogeneity in the concrete produced as indicated by such physical properties as unit weight, slump, air content, strength and air-free mortar content in successive batches of the same mix proportions and as stated in ASTM C94 Annex A.

7

The mix recipe for the mixes to be produced shall be readily available to the mixer operator. Only authorised personnel shall be allowed to make changes to the mix design.

8

All cement bags shall be stored in weathertight, properly ventilated structures to prevent absorption of moisture.

9

Storage facilities for bulk cement shall include separate compartments for each type of cement used. The interior of a cement silo shall be smooth, with a minimum bottom slope of 50 degrees from the horizontal for a circular silo and 55 to 60 degrees for a rectangular silo. Silos shall be equipped with non-clogging air-diffuser flow pads through which small quantities of dry, oil-free, low-pressure air can be introduced intermittently at approximately 3 to 5 psi (20 to 35 kPa) to loosen cement that has settled tightly in the silos. Storage silos shall be drawn down frequently, preferably once per month, to prevent cement caking.

10

Each bin compartment from which cement is batched shall include a separate gate, screw conveyor, air slide, rotary feeder, or other conveyance that effectively allows both constant flow and precise cutoff to obtain accurate batching of cement

11

Fly ash, ground slag, or other pozzolans shall be handled, conveyed, and stored in the same manner as cement. The bins, however, shall be completely separate from cement bins without common walls that could allow the material to leak into the cement bin.

12

All bins and silos shall be properly tagged at silos, bins and near charging hose.

13

Bags of cement should be stacked on pallets or similar platforms to permit proper circulation of air. For a storage period of less than 60 days, stack the bags no higher than 14 layers, and for longer periods, no higher than seven layers.

14

The water batcher and the water pipes should be leak-free. If ice is used, the ice facilities, including the equipment for batching and transporting to the mixer, should be properly insulated to prevent the ice from melting before it is in the mixer.

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Section 05: Concrete Part 07: Concrete Plants

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Plant Type

1

Manual control batching. Manual plants are acceptable for small jobs having low batching 3 3 rate requirements, generally for jobs up to a total concrete quantity of 1000 m and 10 m /h.

2

Semi-automatic control batching. In this system, aggregate bin gates for charging batchers are opened by manually operated push buttons or switches. Gates are closed automatically when the designated weight of material has been delivered.

3

Automatic control batching. Automatic batching of all materials is electrically activated by a single starter switch. However, interlocks shall interrupt the batching cycle when the scale has not returned to 0.3 % of zero balance or when weighing tolerances detailed in Clause 7.2.5 of this Part are exceeded.

7.2.3

Bins and Weight Batchers

1

Batch plant bins shall be of sufficient size to effectively accommodate the production capacity of the plant. Compartments in bins separate the various concrete materials, and the shape and arrangement of aggregate bins shall prevent aggregate segregation and leakage.

2

Weight batchers shall be charged with easy-operating clam shells or undercut radial-type bin gates.

3

Gates used to charge semi-automatic and fully automatic batchers shall be power operated and equipped with a suitable in flight correction to obtain the desired weighing accuracy. They shall be calibrated by the plant supplier for the types of aggregate used at the standard range of moisture contents.

4

Weigh batchers shall be accessible for obtaining representative samples, and they shall be arranged to obtain the proper sequencing and blending of aggregates during charging of the mixer.

5

The amount of concrete mixed in any one batch shall not exceed the rated capacity of the mixer.

6

All mixing and batching plants shall be maintained free of set concrete or cement and shall be clean before commencing mixing.

7

For each different type of cement at use at the plant a separate silo shall be provided.

7.2.4

Tolerances of Measuring Equipment

1

Scales for weighing concrete ingredients shall be accurate when in use within 3 % and 1.5 % for additives. Standard test weights shall be available to permit the checking of scale accuracy.

2

Testing of the weighers shall be at three-month intervals. If water is dispensed by flow meter the frequency of testing shall be at three-month intervals. Such testing shall be undertaken by a calibration company approved by the Central Materials Laboratory, and calibrated to recognized international standards.

3

Test certificates shall be displayed in the plant in prominent positions.

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7.2.2

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Section 05: Concrete Part 07: Concrete Plants

Page 6

Batching Tolerances

1

Operation of batching equipment shall be such that the concrete ingredients are consistently measured within the following tolerances. The plant shall have the ability to flag values that are outside these limits. The operator shall make manual adjustments to the batching and the final weights shall be within the given limits stated in table 7.1. Any adjustments shall be displayed on the batch weight printouts.

2

Cementitious materials shall be measured by mass. When supplementary cementitious materials are used in the concrete mixtures, the cumulative mass is permitted to be measured with hydraulic cement, but in a batch hopper and on a scale which is separate and distinct from those used for other materials.

3

Aggregate shall be measured by mass. Batch mass measurements shall be based on dry materials and shall be the required masses of dry materials plus the total mass of moisture (both absorbed and surface) contained in the aggregate

4

Mixing water shall consist of water added to the batch, ice added to the batch, water occurring as surface moisture on the aggregates, and water introduced in the form of admixtures. The added water shall be measured by weight or volume.

5

Added ice shall be measured by weight. In the case of truck mixers, any wash water retained in the drum for use in the next batch of concrete shall be accurately measured; if this proves impractical or impossible the wash water shall be discharged prior to loading the next batch of concrete

6

Chemical admixtures in powdered form shall be measured by mass. Liquid chemical admixtures shall be batched by mass or volume

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7.2.5

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Table 7.1 Typical batching tolerances Ingredient

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Typical batching tolerances Ingredient

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Cement and other cementitious Materials

Water (by volume or weight), %

Batch weights greater than 30% of scale capacity

Individual Cumulative batching batching ±1% of required mass or ±0.3% of scale capacity, whichever is greater ±1

Not recommended

Batch weights less than 30% of scale capacity Individual batching

Cumulative batching

Not less than required weight or 4% more than required weight

±1

Not recommended

Aggregates, %

±2

±1

±2

±0.3% of scale capacity or ±3% of required cumulative Weight, whichever is less

Admixtures (by volume or weight), %

±3

Not recommended

±3

Not recommended

QCS 2014

Section 05: Concrete Part 07: Concrete Plants

Page 7

Cement supplied in bags shall be placed directly from the bag into the intake of the mixing plant and each batch must contain one or more complete bags of cement. No mixer having a rated capacity of less than a one-bag batch shall be used and the mixer shall not be charged in excess of its rated capacity.

7.2.6

Charging the Mixer

1

Each batch shall be so charged into the mixer that some of the water will enter in advance of the cement and aggregates. Controls shall be provided to prevent batched ingredients from entering the mixer before the previous batch has been completely discharged.

2

The first batch of concrete through the mixer shall contain an excess of cement to allow for coating of the inside of the mixing drum without reducing the required mortar content of the mix.

3

Mixing plant that has been out of action for more than 30 minutes shall be thoroughly cleaned before any fresh concrete is mixed in it.

4

When a change of mix is made to one using a different type of cement, the mixing plant shall be thoroughly cleaned of all traces of the previously used cement, whatever is the time interval between successive mixes.

7.3

MIXING

7.3.1

Charging Concrete Materials

1

Water shall enter the mixer first with continuous flow while other ingredients are entering the mixer. Water charging pipes must be of the proper design and of sufficient size so that water enters at a point well inside the mixer and charging is completed within the first 25% of the prescribed mixing time and where concrete uniformity shall be verified by approved inspector.

2

Admixtures shall be charged to the mixer in accordance with the instructions of the manufacturer. Automatic dispensers shall be used.

7.3.2

Mixing Time for Stationary Mixers

1

The mixing time required shall be based upon the ability of the mixer to produce uniform, homogeneous, consistent mixture throughout the batch and from batch to batch.

2

Final mixing times shall be based on the results of mixer performance tests made at the start of the project and the time fixed unless a change is authorised by the Engineer. The time shall however not be less than 60 Sec unless otherwise verified as stated hereafter. Where no mixer performance tests are made, the acceptable mixing time for mixers having 3 capacities of 0.75 m or less shall be not less than 1 min. For mixers of greater capacity, this minimum shall be increased 15 s for each cubic meter or fraction thereof of additional capacity.

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QCS 2014

Section 05: Concrete Part 07: Concrete Plants

Page 8

Where mixer performance tests have been made on given concrete mixtures in accordance with the testing program ASTM C94 Annex A and NRMCA certification, and the mixers have been charged to their rated capacity, the acceptable mixing time is permitted to be reduced for those particular circumstances to a point at which satisfactory mixing defined in ASTM C94 and NRMCA certification for central mixing plants shall have been accomplished. When the mixing time is so reduced the maximum time of mixing shall not exceed this reduced time by more than 60 s for air-entrained concrete. The mixing time shall be measured from the time all ingredients are in the mixer.

4

Batch mixers with audible indicators used in combination with interlocks which prevent mixer discharge prior to completion of a preset mixing time shall be provided on automatic plants and are also desirable on manual plants.

5

The mixer shall be designed for starting and stopping under full load.

7.3.3

Mixing

1

All structural concrete to be placed in-situ shall be manufactured in a computer controlled batching plant of the types described in Clause 7.2.2 of this Part.

2

The plant shall be complete with suitable water chilling or ice making facilities, or both, to ensure concrete temperatures are maintained as specified in Parts 6 and 15 of this Section.

3

Concrete shall be mixed in batches in plant capable of combining the aggregates, cement and water (including admixtures, if any) into a mixture of uniform colour and consistency and of discharging the mixture without segregation.

4

Automatic moisture content probes, set in the hoppers shall be used to continuously determine the moisture content of the aggregates.

5

Contractor shall make due allowance for the water contained in the aggregates when determining the quantity of water to be added to each mix.

6

The amount of water added to each mix shall be adjusted to maintain the constant approved water : cement ratio of the mixed concrete.

7.3.4

Limitation of Water : Cement Ratio

1

No concrete shall exceed the water : cement ratio as given in Part 6 of this Section.

2

The quantity of water used in mixing shall be the least amount that will produce a workable homogeneous plastic mixture which can be worked into the forms and around the reinforcement.

3

Excess water over the maximum allowed by the mix design shall not be permitted and any batch containing such excess will be rejected.

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QCS 2014

Section 05: Concrete Part 07: Concrete Plants

Page 9

7.4

READY-MIXED CONCRETE

7.4.1

General

1

The manufacture of readymix concrete for use in government projects may only be carried out in batching plants that have an approval certificate issued by the Central Materials Laboratory. When this certificate is under renewal process by the readymix concrete manufacturer, other certificate such as NRMCA shall be considered by the Engineer as approval on the uniformity and consistency of the facility. The engineer may request to revalidate the uniformity tests under his supervision. In addition, the use of readymix concrete in any part of the work shall require the Engineer’s written approval.

2

The Contractor shall satisfy the Engineer on the following: materials used in ready-mixed concrete comply with the specification in all respects

(b)

manufacturing and delivery resources of the proposed supplier are adequate to ensure proper and timely completion.

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(a)

The specified requirements as to the sampling, trial mixing, testing and quality of concrete, of various grades as described in Part 6 of this Section, shall apply equally to ready-mixed concrete.

4

Every additional facility, including but not limited to testing equipment, labour, laboratory facilities and transport, which the Engineer or persons authorised by him may require for the supervision and inspection of the batching, mixing, testing and transporting to Site of readymixed concrete shall be provided by the Contractor at no extra cost.

5

Copies of all delivery notes shall be submitted to the Engineer in duplicate, on computer generated forms and shall include at least the following information.

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name of supplier, serial number of ticket and date

(b)

truck number

(c)

name of Contractor name of Contract and location of office grade of concrete

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(e)

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(a)

(f)

specified workability

(g)

type and source of cement

(h)

source of aggregate

(i)

nominal maximum size of aggregate

(j)

quantity of each concrete ingredient

(k)

type of admixture and quantity

(l)

water content

(m)

time of loading and departure from ready-mix plant

(n)

arrival and departure times of truck

(o)

time of completion of discharge

QCS 2014

(p)

Section 05: Concrete Part 07: Concrete Plants

Page 10

notations to indicate equipment was checked and found to be free of contaminants prior to batching.

A copy of the delivery note shall be given to the Engineer's site representative for each load.

7

Unless approved otherwise in advance of batching all concrete of single design mix for any one day's pour shall be from a single batch plant of a single supplier.

8

Ready-mix concrete shall conform to BS 8500 in addition to GSO EN 206-1, except materials, testing and mix design shall be as specified in this Section.

9

Transit mixers equipped with automatic devices for recording the number of revolutions of the drum shall be used.

10

Excess water over the maximum allowed by the mix design shall not be added.

11

Each mixer truck shall arrive at the job site with its water container full.

12

In the event that a container is not full or concrete tests give a greater slump than acceptable, the load shall be rejected.

13

Shade temperature and concrete temperature shall be recorded at the point of discharge of the mixer and at placement for each load of concrete delivered to site.

14

Maximum and minimum temperatures and wet bulb temperatures shall be recorded daily.

15

Slump tests shall be performed in accordance with BS EN 12350 or relevant GSO standard at the point of placement as stated in Part 6.

16

No water shall be added at the Site.

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6

END OF PART

QCS 2014

Page 11

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APPENDIX A: CONCRETE PLANT INSPECTION – CHECKLIST

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7.5

Section 05: Concrete Part 07: Concrete Plants

Qatar General Organization for Standards and Standardization

CONCRETE PLANT INSPECTION CHECK LIST

New Approval





Renewal

Regular Inspection

1.0 GENERAL INFORMATION OF PLANT

:

1.3

Plant Location

:

1.4

Plant No/s

:

1.5

Plant Manufacturer

:

1.6

Plant ID No.

:

1.7

Approval Certificate No :

1.8

Contact a Plant

AM / PM

.

Inspection Date

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:

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Company Name

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1.1

2.0 FACTORY CONDITION

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:

Yes ☐ No ☐

Concrete Floor Under Mixer and silos

2.2

Concrete floor with Slope under materials

2.3

Hard and stable surface for Access and ramps

2.4

Floors Clean

2.5

Cleaning plan implements

Yes ☐ No ☐

2.6

Drainage System

Yes ☐ No ☐

2.7

Separated Place of Waste materials

2.8

Separated Place of wash tank

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Yes ☐ No ☐ Yes ☐ No ☐

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Yes ☐ No ☐

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Yes ☐ No ☐ Yes ☐ No ☐

3.0 MATERIAL STORAGE AND HANDLING 3.1

Cement and Cementations materials (including blended cements, fly ash, GGBS, silica fume..)

3.1.1 The Silos of Cement ☐ No



A.

Outside Cleaning for Cement silo

Yes

B.

Cement scale calibration

Current ☐ Expired ☐

C.

Reflective color for cement silo

Yes

☐ No



D.

Board clarify the cement type

Yes

☐ No



3.1.2 The silos of cementations materials A.

Outside Cleaning for Cementations silo

Yes

☐ No



Page 12 of 15



Cementations scale calibration

Current ☐ Expired ☐

C.

Reflective Color for Cementations Silo

Yes

☐ No



D.

Board Clarify the Cementations Type

Yes

☐ No



E.

All Cementations Materials Excess of use protected under shad

Yes

☐ No



3.2

Aggregates:

A.

Aggregate Shading

Yes

☐ No



B.

Aggregate Separation under shad

Yes

☐ No



C.

Aggregate Separation in bins

Yes

☐ No



D.

Aggregate scale calibration

Current ☐ Expired ☐

E.

Cover for Conveyer Belts

Yes

☐ No

F.

Board Clarify the Aggregate Type

Yes

☐ No

G.

Effective method for checking the level of material inside the bins

Yes

☐ No



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Yes

☐ No



Yes

☐ No



Yes

☐ No



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Water supply Water pipe insulated

B.

Chiller using

C.

Ice plant or Nitrogen cooling

D.

Water gauge calibration

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Current ☐ Expired ☐

Admixture supply

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4.2



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4.0 Water & Admixture Supply 4.1

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B.



Additive storage silos

B.

Additive Gage calibration

C.

Board Clarify the Admixture Type

Yes

☐ No



D.

All admixture excess of use protected under shad

Yes

☐ No



E.

Agitation system for all storage tanks or silos more than 5000 liter

Yes

☐ No



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Yes

☐ No

A.

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Current ☐ Expired ☐

5.0 Requirements of the Concrete batching plant 5.1

Certificate validity

Yes



No



5.2

Computer controlled

Yes



No



5.3

Plant type

Wet mix ☐

5.4

Computer printout

Yes

5.5

Calibration validity

Current ☐

5.6

Cleaning of plant blades

Yes





Dry mix ☐ No



Expired ☐ No



Page 13 of 15

6.0 Laboratory Records for raw materials and cube tests Frequency of Tests

Was Test Performed?

Yes ☐ No ☐

6.1.3 Fines quality

Yes ☐ No ☐

6.1.4 Clay lumps and friable particles

Yes ☐ No ☐

6.1.5 Lightweight pieces

Yes ☐ No ☐

6.1.6 Organic impurities

Yes ☐ No ☐

6.1.7 Water Absorption

Yes ☐ No ☐

6.1.8 Particle density

Yes ☐ No ☐

6.1.9 Shell Content

Yes ☐ No ☐

6.1.10 Flakiness Index (%)

Yes ☐ No ☐

6.1.11 Chloride content (%)

Yes ☐ No ☐

6.1.12 Sulphate content (%)

Yes ☐ No ☐

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Yes ☐ No ☐

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6.1.13 Soundness (%)

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6.1.2 Fines content (%)

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Yes ☐ No ☐

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6.1.1 Grading

W

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D

Comments of Inspection

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Required Tests to QCS 2014

qa

6.1

Yes ☐ No ☐

6.1.15 Moisture Content (%)

Yes ☐ No ☐

6.1.16 Compressive Strength

Yes ☐ No ☐

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6.1.14 Los Angeles abrasion

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6.1.17 Other test*

*Such as recycled aggregate

6.2

Specimens testing at inspection time ITEMS

CASE

6.2.1 Method of slump test

Yes ☐

No ☐

6.2.2 Curing of samples

Yes ☐

No ☐

6.2.3 Water Temperature Of Curing Tank Yes ☐

No ☐

6.2.4 Concrete Temperature at plant

Yes ☐

No ☐

6.2.5 Concrete Slump at plant

Yes ☐

No ☐

COMMENTS

Page 14 of 15

6.3

Laboratory equipment calibration EQUIPMENT

CASE

COMMENTS

6.3.1 Compression Testing Machine

Yes ☐

No ☐

6.3.2 Sieves

Yes ☐

No ☐

6.3.3 Balance

Yes ☐

No ☐

6.3.4 Thermometers

Yes ☐

No ☐

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8.0 Plant representative information

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Name of representative Contract number

: :

Signature

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9.0 Inspector team

:

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Signature

Inspected by

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7.0 Recommendations

Page 15 of 15

QCS 2014

Section 05: Concrete Part 08: Transportation and Placing of Concrete

Page 1

TRANSPORTATION AND PLACING OF CONCRETE ............................................ 2

8.1 8.1.1 8.1.2 8.1.3

GENERAL ............................................................................................................... 2 Scope of Work 2 References 2 Submittals 2

8.2 8.2.1 8.2.2 8.2.3

TRANSPORTATION ............................................................................................... 3 General 3 Pumped Concrete 3 Records 4

8.3 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5

PLACING CONCRETE ............................................................................................ 4 General 4 Preparation 4 Placing 5 Compaction 7 Continuity of Concrete Work 8

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QCS 2014

Section 05: Concrete Part 08: Transportation and Placing of Concrete

8

TRANSPORTATION AND PLACING OF CONCRETE

8.1

GENERAL

8.1.1

Scope of Work

1

This part deals with the transportation, placing and compaction of concrete.

2

Related Parts are as follows:

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8.1.2

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This Section Part 1 ............... General Part 7, .............. Concrete Plants Part 9, .............. Formwork Part 15, ............ Hot Weather Concreting Part 16, ............ Miscellaneous

Page 2

References

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ACI 304, ............. Guide for Measuring, Mixing, Transporting, and Placing Concrete ASTM C94, ......... Specification for ready-mixed concrete BS 8500,............. Concrete, Complementary British Standard to BS EN 206-1. BS EN 206-1, ..... Concrete. Specification, performance, production and conformity EN 1992-1-1 ....... Eurocode 2: Design of concrete structures. General rules and rules for buildings Submittals

1

Should the Contractor propose to use concrete pumps for the transportation and placing of concrete, he shall submit details of the equipment and operating techniques he proposes to use for the approval of the Engineer.

2

A method statement shall be submitted for approval for major concrete placements, which shall address

(b)

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8.1.3

(c)

number of trucks

(d)

number and positioning of pumps

(e)

pour sequence

(f)

quality control measures

(g)

spare equipment

(h)

any other factors that might affect the placing of concrete.

the planned rate of placing number of batching plants

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(a)

3

The method statement should be submitted at least three days in advance of the planned pour. If required by the Engineer or any other concerned party a prepour planning meeting may be arranged with representatives from the ready-mix supplier, Contractor and Engineer.

4

The Contractor shall submit to the Engineer for approval details of his proposed operations and standby equipment.

QCS 2014

Section 05: Concrete Part 08: Transportation and Placing of Concrete

Page 3

TRANSPORTATION

8.2.1

General

1

Transportation delivery and handling shall be in accordance with the requirements of BS 8500 and BS EN 206-1.

2

Concrete shall be conveyed from the mixer to its place in the Works as rapidly as possible by methods which will prevent segregation or drying out and ensure that the concrete is of the required workability at the point and time of placing.

3

Should segregation occur in the concrete then the materials shall be remixed to the satisfaction of the Engineer or discarded. Furthermore the cause of the segregation shall be determined and further occurrences prevented.

4

The Contractor shall ensure that the time between placing of different lifts or layers of concrete is short enough to prevent the formation of cold joints. The Contractor shall ensure that there is a back up plant that can be used in the event of a breakdown, and that adequate provision has been made for the number of delivery trucks.

5

The concrete shall be transported to the site in an approved type of truck mixer or agitator truck which apart from the cab and chassis shall be painted white and kept clean at all times. The discharge chute and other dirty areas shall be washed down after delivery to prevent spillage on the roads.

6

If a truck mixer or a truck body with an agitator is used for central-mixed concrete, limit the volume of concrete charged into the truck to 80% of the drum or truck volume as per ASTM C94 and NRMCA requirements. if shrink mixing is approved by the engineer limit the volume of concrete charged into the truck to 63% of the drum volume.

7

All trucks shall be rotated 30 revolutions at mixing speed before discharging concrete to assure uniformity.

8

The insides of concrete mix trucks shall be inspected periodically, and any build up of concrete removed that may impair the efficiency of the mixing action. All trucks shall be NRMCA certified or any equivalent certification

9

Discharge of the concrete shall be completed within 90 min, or before the drum has revolved 300 revolutions, whichever comes first, after the introduction of the mixing water to the cement and aggregates or the introduction of the cement to the aggregates. These limitations are permitted to be waived by the purchaser if the concrete is of such slump or slump flow after the 90 min time or 300-revolution limit has been reached that it can be placed, without the addition of water, to the batch. In hot weather, or under conditions contributing to quick stiffening of the concrete, a time less than 90 min is permitted to be specified by the Engineer

8.2.2

Pumped Concrete

1

Access for the pump shall be checked prior to the pour. If access cannot be assured, the Contractor shall not continue with concreting operations.

2

If approval is obtained for pumped concrete, the Contractor shall ensure that shock is not transferred from the pipeline to the formwork and previously laid concrete.

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QCS 2014

Section 05: Concrete Part 08: Transportation and Placing of Concrete

Page 4

During placing concrete by pumping the end hose must never reach into the concrete. All measures shall be taken to avoid blockage of the delivery hose system. The Compaction of concrete shall be carried out as per standard practice procedures.

4

Grout shall be pumped through the concrete pump to provide initial lubrication. The initial discharge of any pumped concrete shall not be incorporated in the permanent works.

5

Where concrete is conveyed by chuting or pumping the plant shall be of a size and design to ensure continuous flow in the chute or pipe. The slope of the chute or the pressure of the pump shall allow the concrete to flow without the use of any water additional to that approved by the Engineer to produce the required consistency and without segregation of the ingredients. The delivery end of the chute or pipe shall be thoroughly flushed with water before and after each working period and kept clean. The water used for this purpose shall be discharged outside and away from any permanent works.

8.2.3

Records

1

Within 24 h of delivery, the Contractor shall provide the Engineer with delivery notes giving the information required under Paragraph 7.4.1.5 of this Section.

8.3

PLACING CONCRETE

8.3.1

General

1

The Contractor shall obtain the approval of the Engineer to his proposed arrangements before beginning concreting.

2

All placing and compacting of concrete shall be carried out under the direct supervision of a competent member of the Contractor’s staff with a minimum of five years of experience in concreting works, and in a manner to produce a watertight concrete of maximum density and strength.

3

For night concreting operations, the Contractor shall arrange adequate suitable lighting.

4

The Contractor shall provide safe secure access for all personnel on concreting operations.

5

Where the thickness of the concrete section exceeds 600 mm the Contractor shall adopt

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special precautions, to be approved by the Engineer, to avoid thermal cracking due to external and core temperature differentials. 6

Concrete shall not be placed in adverse weather conditions such as dust storms or heavy rain.

8.3.2

Preparation

1

No concrete shall be placed until the Engineer has inspected and approved in writing the surfaces upon which the concrete is to be placed, the formwork, and reinforcing steel. The Contractor shall give the Engineer at least 24 hours notice to enable this inspection to be carried out. If concrete is not placed within 24 hours of approval being given, approval shall be obtained again before concreting. An inspection shall be made immediately prior to concreting to check the cleanliness of the forms.

QCS 2014

Section 05: Concrete Part 08: Transportation and Placing of Concrete

Page 5

Wood forms, unless lined, shall be oiled or wetted with water in advance of placing concrete so that joints will tighten and prevent seepage of cement grout from the mix.

3

The reinforcement shall be sprayed with a small amount of water prior to starting the pour. Reinforcement shall be secured in position, inspected, and accepted by the Engineer before placing the concrete.

4

All inserts, anchor bolts, sleeves and other embedded items shall be accurately located, using templates where appropriate, and held securely to prevent displacement during the placing of the concrete. Aluminium items shall be completely covered and protected when embedded in the concrete.

5

Except where shown on the drawings, no fixtures shall be attached to the concrete by shot fixing or drilling without acceptance by the Engineer. Notwithstanding any such authorisation, the Contractor shall be responsible for all damage so caused to the concrete and make good at his own expense.

6

Water shall be removed from excavations before concrete is deposited. Any flow of water shall be diverted through proper side drains and shall be removed without washing over freshly deposited concrete. All dewatering works shall be continued as long as required. Hardened concrete, debris, and foreign materials shall be removed from interior of forms and from inner surfaces of mixing and conveying equipment.

7

Runways or other means accepted by the Engineer shall be provided for wheeled equipment to convey the concrete to the points of deposit. Equipment used to deposit concrete shall not be wheeled over reinforcement nor shall runways be supported on reinforcement.

8

Before depositing new concrete on or against concrete that has set, existing surfaces shall be thoroughly roughened and cleaned of laitance, foreign matter and loose particles. Forms shall be re-tightened and existing surfaces slushed with a grout coat of mortar consisting of cement and fine aggregate in the same proportion in the mix, but not leaner than one (1) part cement to two (2) parts fine aggregate, after the existing surface has been moistened. New concrete shall be placed before the grout has attained initial set. Horizontal construction joints shall be given a brush coat of grout consisting of cement and fine aggregate in the same proportion as concrete to be placed, followed by approximately 75mm of concrete of regular mix, except that the proportion of coarse aggregate shall be reduced 50%.

9

High strength grout for precision support of machine base and soleplates, including equipment subject to thermal movement, tanks, column baseplates, bridge seats, anchor bolts and dowels, etc., shall be a non-shrink, ready-to-use, fluid precision grout material, proportioned, premixed and packaged at the factory, delivered to the job site to be placed with only the addition of water, formwork, and curing shall be as specified.

8.3.3

Placing

1

Concrete shall be placed in its final position before initial set has commenced and shall not be subsequently disturbed. All concrete shall be placed within 15 min of mixing unless carried in purpose made agitators.

2

Concrete shall be carefully placed in horizontal layers which shall be kept at an even height throughout the work. The depth of layers and time between placement of layers shall be such that each layer can be properly merged into the preceding layer before initial set takes place, the depth of layer shall be determined from the type of plant the Contractor proposes to use.

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QCS 2014

Section 05: Concrete Part 08: Transportation and Placing of Concrete

Page 6

3

Concrete shall be allowed to slide or flow down sloping surfaces directly into its final position from skips, down pipes or other placing machines or devices or, if this is not practical, it should be shovelled into position, care being taken to avoid separation of the constituent materials.

4

Concrete placed in horizontal slabs from barrows or other tipping vehicles shall be tipped into the face of the previously placed concrete.

5

Concrete dropped into place shall be dropped vertically. It shall not strike the formwork between the point of its discharge and its final place in the Work, and except by approval of the Engineer it shall not be dropped freely through a height greater than 1.5 m. Chutes and

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conveyor belts shall be also designed so that there is no segregation or loss of mortar and shall be provided with a vertical tapered down pipe, or other device, to ensure that concrete is discharged vertically into place. Concrete shall not be placed in standing water in the formwork.

7

Concrete that has attained its initial set or has contained its water content for more than 1.5 hours or 300 drum revolutions, whichever comes first, shall not be deposited in the work.

8

Cold weather concreting shall be in accordance with EN 1992-1-1 or CIRIA Report 67 and ACI 306.

9

Hot weather concreting shall be in accordance with Part 15 of this section.

10

Special care shall be taken to protect new concrete from the harmful effects of drying winds.

11

During wet weather, the concrete shall be adequately protected as soon as it is in position.

12

No concreting shall be carried out during periods of continuous heavy rain unless it is completely covered during mixing, transporting and placing.

13

No concrete shall be carried out during dust storms.

14

Underwater placing of concrete is allowed only for unreinforced components, the placing being effected exclusively with stationary tremies or with a bottom-opening watertight boxes and shall be in accordance with the requirements of design or equivalent as accepted.

15

Underwater concrete is to be placed continuously without interruption. For water depths up to 1 m the concrete may be placed without tremie. In the case of water depths exceeding 1 m the concrete is to be placed in such a way that it does not fall freely through the water. The tremies must at all times dip sufficiently far into the freshly placed concrete to ensure that the concrete emerging from the tremie does not come into contact with the water.

16

All work connected with the placing of concrete under water shall be designed, directed and inspected with due regard to local circumstances and purposes. Work shall not proceed until all phases and methods to be used in the placing operations have been accepted by the Engineer.

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Section 05: Concrete Part 08: Transportation and Placing of Concrete

Page 7

Stops in concrete, at the end of a period of work, shall be made only at construction joint locations shown on the drawings and/or positions accepted. Where the positions of construction joints are not indicated on the drawings, these may be assumed, for estimating purposes, to occur at 5 metre intervals in foundations and retaining walls and at one-third to one-quarter of span in slabs and beams subject to a maximum spacing of approximately 9 metres.

18

At construction joint location the surface of the completed concrete shall be prepared by spraying, wire brushing or chipping so that it is free from all laitance, scum and loose material and shows a slightly roughened texture and tips of the coarse aggregate exposed. Before continuing concreting the exposed concrete face shall be thoroughly wetted.

19

In the ground floor slab (where ground bearing), construction joints, crack inducer joints, contraction joints and expansion joints shall be incorporated into the work as appropriate. The spacing of construction joints, crack induced joints, contraction joints and expansion joints in water retaining structures shall be shown on the design drawings

20

Where the positions or type of joints are not indicated on the drawings in the ground floor slab, the slab shall be cast in strips not more than 4.0 metres wide, in alternating sequence, across the width of the building. A minimum of 3 days shall elapse between the casting of adjacent strips. Within each strip, crack induced joints shall be provided at not more than 5.0 metre spacing, and contraction joints shall be provided at not more than 15.0m spacing. Across the width of the building, construction joint shall be provided between adjacent strips th with contraction joint at every 4 construction joint.

21

Wherever necessary and as required by the Engineer, waterstops of a type acceptable to the Engineer shall be embedded in the concrete. The waterstop should be made of a high quality material, which must retain its resilience through the service life of the structure for the double function of movement and sealing. The surface of waterstops should be carefully rounded to ensure tightness of the joint even under heavy water pressure. To ensure a good tightness with or without movement of the joints, the waterstop should be provided with anchor parts. The cross-section of the waterstops should be determined in accordance with the presumed maximum water pressure and joint movements. The complete works of fixed and welded connections must be carried out strictly in accordance with the manufacturer’s instructions.

22

Engineer’s acceptance shall be obtained by the Contractor, prior to start of work, on the casting sequence and the layout of joints.

23

Waterstops shall be carefully maintained in position prior to concreting on accurately profiled stop boards to create rigid conditions.

24

The type of waterbar to be used shall suit the joint and purpose according to water bar manufacturers recommendations

8.3.4

Compaction

1

Concrete shall be thoroughly compacted by vibration during the operation of placing and thoroughly worked around the reinforcement, around embedded fixtures and into corners or the formwork to form a solid mass free from voids.

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QCS 2014

Section 05: Concrete Part 08: Transportation and Placing of Concrete

Page 8

When vibrators are used to compact the concrete, vibration shall be applied continuously during the placing of each batch of concrete until the expulsion of air has practically ceased and in a manner that does not promote segregation of the constituents of the concrete.

3

Immersion type vibrators shall be capable of producing not less than 10000 cycles per minute, and external vibrators not less than 3000 cycles per minute.

4

A sufficient number of vibrators in serviceable condition shall be on site to ensure that spare equipment is always available in the event of breakdown.

5

Immersion type vibrators shall be inserted into the uncompacted concrete vertically and at regular intervals. Where the uncompacted concrete is in a layer above freshly compacted concrete the vibrator shall penetrate vertically for about 100 mm into the previous layer. Vibrators shall not come into contact with the reinforcement or the formwork. They shall be drawn back slowly from the mass concrete so as to leave no voids. Internal type vibrators shall not be placed in the concrete in a random or haphazard manner nor shall concrete be moved from one part of the work to another by means of the vibrators.

6

Operators shall be trained in the use of vibrators. Foremen shall have a minimum of five years of experience in the supervision of placing concrete

7

Vibration of the concrete shall not be applied by way of the reinforcement.

8

Compaction shall commence as soon as there is sufficient concrete to immerse the vibrator and continue during the placing operations so that at no time shall there be a large volume of uncompacted concrete in the formwork.

9

The duration of vibration shall be limited to that required to produce satisfactory compaction without causing segregation. Vibration shall on no account be continued after water or excess grout has appeared on the surface.

10

During the placing of all reinforced concrete, a competent steel fixer and a competent carpenter shall be in attendance on each concreting gang. They shall ensure the reinforcement embedded fittings and forms are kept in position as work proceeds.

8.3.5

Continuity of Concrete Work

1

Whenever instructed by the Engineer, the Contractor shall carry out the work in such a manner that the placing of the concrete in any particular section of the structure shall be executed without any interruption whatsoever from the beginning to the end of the operation.

2

Casting of concrete shall not begin until a sufficient quantity of approved material is at hand to ensure continuity of operation, nor shall work begin until there is sufficient equipment in reserve in case of breakdown.

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END OF PART

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FORMWORK ........................................................................................................... 2 GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 3 FORMWORK MATERIALS ...................................................................................... 5 General 5 CLASS OF FINISH AND MATERIALS: .................................................................... 5 Unformed surfaces 5 Surface Finish Classifications 7 Formwork Materials 7 Exposed Concrete Surface Finishes 7 Form Ties 8 Coating and Accessories 8 FORMWORK EXECUTION ..................................................................................... 9 General 9 Trial Panels 9 Formwork Face in Contact with Concrete 9 Sloping Surfaces 10 Temporary Openings 10 Form Windows 10 Co-ordination 10 Conduits 10 Ties and Bolts 11 Chamfers 11 Cambers 11 Exterior Angles 11 Surface Retarders 11 Detection of Movement During Concrete Placement 11 Building in Pipes 12 Working Platform 12 Safe Access 12 Kickers 12 Cover Spacers 12 Water Bars 12 REMOVAL OF FORMWORK................................................................................. 13 General 13 Stripping of Formwork 13 Holes to be Filled 14 Repair to Damaged Concrete Surfaces 14 DELIVERY AND STORAGE .................................................................................. 14 Delivery 14 Storage 14 TOLERANCES ...................................................................................................... 15 EARLY LOADING .................................................................................................. 15

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9 9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.2 9.2.1 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6 9.4.7 9.4.8 9.4.9 9.4.10 9.4.11 9.4.12 9.4.13 9.4.14 9.4.15 9.4.16 9.4.17 9.4.18 9.4.19 9.4.20 9.5 9.5.1 9.5.2 9.5.3 9.5.4 9.6 9.6.1 9.6.2 9.7 9.8

Section 05: Concrete Part 09: Formwork

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Section 05: Concrete Part 09: Formwork

Page 2

9

FORMWORK

9.1

GENERAL

9.1.1

Scope

1

This Part includes permanent forms, temporary formwork, and falsework for structural and architectural cast-in-place concrete including form liners, coatings, and accessories.

2

Related Sections and Parts are as follows:

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management/administration

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prevention

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Section 11: Health and Safety Part 1, ............. Regulatory document Part 2, ............. Safety and accident (SAMAS)

.

This Section Part 8, .............. Transportation and Placing of Concrete Part 10, ............ Curing Part 17, ............ Structural Precast Concrete.

References

1

The following standards and other document are referred to in this Part:

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ACI Committee 117 ....“Standard Tolerances for Concrete Construction and Materials” (ACI 117-90), American Concrete Institute, Detroit, 22 pp.

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ACI Manual of Concrete Practice, Parts 2 and 5. BS 8500......................Concrete

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BS 5975......................Code of practice for false work

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BS EN 12812..............Falsework. Performance requirements and general design CP3 chapter V-2: 1972

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EN 1992-1-1 ...............Eurocode 2: Design of concrete structures. General rules and rules for buildings GSO EN 206-1 ...........Concrete. Specification, performance, production and conformity Concrete Society Technical Report No. 13 9.1.3

Submittals

1

Shop drawings shall include plans and sections, giving the following minimum information for each level: (a)

details of individual panels

(b)

position, size and spacing of adjustable steel shores

(c)

position, size and spacing of joists, soldiers, ties

(d)

details of formwork for columns, beams, parapets, slab and kickers

QCS 2014

Page 3

details of construction joints and movement joints

(f)

details of retaining walls and deep beams showing the position and size of ties, joints, soldiers and sheeting, together with detailed information on erection and casting sequences and construction joints

(g)

general assembly details

(h)

full calculation sheets

(i)

proposals at all penetrations through the concrete

(j)

proposed sequence of shoring and reshoring beams and slabs for different spans and floor heights and number of floors shored, and the stripping time for supported and suspended structural elements, clearly identifying the supported element and suspended element.

.

(e)

details: 1:1, 1:5, 1:10, 1:20

(b)

construction: 1:50, 1:100

(c)

layout and Site Plan: 1:100 or 1:200

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(a)

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Scales of shop drawings shall be as follows:

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Section 05: Concrete Part 09: Formwork

The Contractor shall submit samples of all proposed formwork materials and samples of ties proposed for use in general situations above the water table and for fair faced concrete.

4

The Contractor shall allow 14 days for Engineer’s review of submittals or samples.

5

Supply and delivery of built-in pipework should be clearly shown on the detailed construction program to be submitted by the Contractor.

6

Method Statements for erection and removal of formwork shall be submitted by the Contractor before the start of the works for the Engineer’s review and approval. The Method Statement shall include the Risk Assessments related to the activity.

7

When the formwork is to be carried out by a sub-contractor, then the pre-qualification documents shall be submitted for the Engineer’s review and approval.

9.1.4

Quality Assurance

1

Formwork shall comply with the requirements of BS 5975 and EN 1992-1-1

2

The erection of formwork and associated falsework shall be executed and supervised by fully qualified personnel having a minimum of five years experience.

3

The Contractor shall obtain approval to load any particular section of the works from the Engineer.

4

Formwork design shall be carried out in accordance with the Concrete Society Technical Report No. 13.

5

The erected formwork shall be watertight from the ingress of external liquids and the egress of internal liquids. Adjustable steel supports and shores shall allow formboards and framework to be accurately adjusted to line and level. The Contractor shall ensure that adequate ground support for falsework is available, and if not shall take measures to make them suitable.

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Section 05: Concrete Part 09: Formwork

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Formwork shall be designed to be sufficiently rigid to maintain the correct position, shape and profile so that the final concrete structure is within the dimensional tolerances specified Subpart 9.7 of this Part.

7

Formwork shall be designed to be demountable without causing shock, disturbance or damage to the concrete.

8

Soffit formwork, properly supported on shores only, shall be capable of being retained in position during the concrete maturing period.

9

The design shall allow free movement and accessibility under the formwork.

10

Shores for abnormal ceiling heights shall be specially designed.

11

The forms shall be designed to incorporate 20 mm chamfers on exposed corners of columns, walls and beams.

12

The design of formwork shall take into account the following:

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height and rate of pour

(b)

thickness of the member

(c)

concrete slump and density

(d)

placing temperature

(e)

texture of finish

(f)

construction joints

(g)

wind load

(h)

on soffit forms (in addition to concrete weight)

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(ii)

if a motorised cart is used, an additional live load of 3.75 kPa

minimum design load for combined dead and live load

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(i)

(ii)

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an additional live load of 2.5 kPa, or

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(a)

6.50 kPa if a motorised cart is used, 7.75 kPa

the worst combination of: (i)

self-weight

(ii)

formwork forces

(iii)

reinforcement weight

(iv)

wet concrete weight

(v)

construction loads

(vi)

wind loads,

(vii)

incidental dynamic effects caused by placing, vibrating and compacting concrete

(viii)

the use of externally applied vibrators

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Section 05: Concrete Part 09: Formwork

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(k)

method of concrete discharge

(l)

access for concrete placement and vibration.

Before beginning related formwork operations the Contractor shall erect a job mock-up, to a reasonable size including all items such as sheeting, stiffeners, soldiers, ties etc. (and including release agents, where used) for the following types of formwork, and shall obtain the approval the Engineer before proceeding: (a)

columns

(b)

slabs and beams

(c)

staircases

(d)

fair-faced concrete (show method used to conceal tie holes) cove ties not required.

Upon prior consultation, agreement of location and approval, the job mock-ups may remain as part of the finished work.

9.2

FORMWORK MATERIALS

9.2.1

General

1

Forms shall be of wood; metal or other material acceptable to the Engineer.

2

The design of formwork shall be the responsibility of the Contractor.

3

Formwork shall conform to the requirements of EN 1992-1-1

4

Form oil and form sealer shall be of quality as acceptable to the Engineer.

9.3

CLASS OF FINISH AND MATERIALS:

9.3.1

Unformed surfaces

1

Unformed surfaces shall be classified as either: U4, timber trowel finish

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14

(b)

U3, steel trowel finish

(c)

U2, brush finished

(d)

U1 other finish designated by the Engineer, such as: (i)

Screeded Finish - Where the floor slab is to receive a screeded finish, the slab shall be laid to the slopes and levels shown on the drawings and the top surface shall be tamped whilst unset, to produce a suitable keyed surface for the receipt of the appropriate finishing materials.

(ii)

Floated Finish - Where a floated finish is required to the floor slabs the top surface shall be leveled and floated whilst unset to an uniform finish to the slopes and levels shown on the drawings. The floating shall be done in such a manner as not to bring an excess of mortar to the surface.

Section 05: Concrete Part 09: Formwork

Page 6

Dustproof Finish - Where concrete surfaces are required to provide a dustproof finish these shall be treated with two coats of accepted material. Each coat shall be applied with a soft brush on a clean and dry surface in accordance with the manufacturer's printed instructions.

(iv)

Non-slip Finish - Concrete surfaces described on the drawings as having a nonslip finish shall be treated with carborundum dust, evenly sprinkled on whilst the concrete is still green, at a rate of 1½ kg/m² and lightly trowelled in before final finishing. Alternatively, the carborundum dust may be incorporated into the finish by means of a mechanical power float.

(v)

Hardened Finish - Where a hardened finish is required to the floor slabs these shall be treated with three coats of accepted material. Each coat shall be applied with a soft brush on a clean and dry surface in accordance with the manufacturer's printed instructions.

(vi)

Finishing Unformed Surfaces - Finishing unformed surfaces shall be tamped, floated, trowelled or brushed as defined below and shown on the drawings.

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(iii)

1.

Type T - Tamped surfaces shall be formed by levelling and tamping the concrete to produce a uniform plain or ridged surface, surplus concrete being struck off by a straight edge immediately after compaction. It is also the first stage of the following finish.

2.

Type F - Floated surfaces shall be uniform surface which has been worked no more than is necessary to remove screed marks by hand with a wood float or by power float of a type acceptable to the Engineer. The surface shall not be floated until the concrete has hardened sufficiently.

3.

Type ST - Steel trowelled shall be a hard, smooth finish, free from trowel marks and formed with a steel trowel under firm pressure. Trowelling shall not commence until the moisture film has disappeared and the concrete has hardened sufficiently to prevent excess laitance from being worked to the surface. If laitance is brought to the surface it shall be removed. Type BR - Brushed shall be formed before the concrete has hardened by drawing a wire broom over the concrete surface at right angles to the traffic flow to give an average texture depth of 1mm.

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QCS 2014

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5.

For ground slab concrete shall be treated with sodium silicate or a similar dust preventive coating. This must be applied in accordance with the manufacturer's instructions.

2

The type of finish will be specified on the drawings or as directed by the Engineer. Before beginning any concrete pour with unformed surfaces, the Contractor shall obtain confirmation of the type of finish required from the Engineer.

3

Initial finishing of unformed surfaces shall commence immediately after the placing and compaction have taken place.

4

Suitable access boards or platforms shall be provided to allow access to all parts of unformed surfaces to be finished.

5

Where a protective treatment or topping layer is to be applied to the concrete the manufacturers and suppliers recommendations shall be followed concerning the required finish.

QCS 2014

Section 05: Concrete Part 09: Formwork

Page 7

6

Brush to finish shall be obtained by carrying out a steel trial finish and then using a suitable stiff nylon brush dragged lightly across the surface.

7

The addition of small quantities of water to the finishing trowel will be permitted to aid finishing.

9.3.2

Surface Finish Classifications

1

Finishes to formed surfaces of concrete shall be classified as F1, F2 and F3, or such other special finish as may be designated.

2

Where the class of finish is not designated: all internal concrete shall be finished to Class F3

(b)

external concrete below ground shall be finished to Class F1

(c)

where surfaces are to be tanked by covering with paint or sheeting, the formwork shall be capable of achieving a finish suitable for the proposed tanking as directed by the Engineer.

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(a)

Formwork Materials

1

Formwork for Class F3 finish shall be lined with as large panels as possible of non-staining material with a smooth unblemished surface such as sanded plywood or hard compressed fibre board, arranged in a uniform approved pattern and fixed to back formwork by oval nails.

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9.3.3

the same type of lining shall be used throughout any one structure

(b)

unfaced wrought boarding or standard steel panels shall not be permitted.

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(a)

Formwork for Class F2 finish shall be faced with wrought tongued and grooved boards or plywood arranged in a uniform approved pattern free from defects likely to detract from the appearance of the surface.

3

Formwork for Class F1 finish shall be constructed of timber, or of any suitable materials which will prevent loss of grout when the concrete is vibrated.

9.3.4

Exposed Concrete Surface Finishes

1

Exposed concrete surfaces shall have a Class F3 finish.

2

Care shall be taken to ensure that the finish to the exposed concrete on the external and internal surfaces are of the highest quality to produce a smooth concrete surface of uniform texture and appearance without visible imprint of grains, steppings or ridges.

3

The resulting concreting shall be free from honeycombing, stains, fins, lipping, nail and screw marks, raised grain marks or any other imperfections and shall be of a uniform surface texture and colour. Only very minor surface blemishes caused by entrapped air or water will be accepted provided that they do not exceed 0.5% by area of each square metre considered separately and in addition they shall not be concentrated in a manner such that they are noticeable.

4

Formwork to the wetted surfaces of water retaining structures shall be Class F3

5

All exposed concrete corners and edges shall have 20 mm by 20 mm chamfers.

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6

Grooves in exposed concrete shall be formed by attaching tapered planed timber battens accurately aligned to the face of formwork.

9.3.5

Form Ties

1

Form ties shall conform to the following requirements: factory-fabricated

(b)

adjustable in length

(c)

use removable or snap-off metal form ties

(d)

designed to prevent formwork deflection and to prevent spalling concrete surfaces on removal

(e)

no metal shall be left closer than the applicable level of cover to the surface of the concrete

(f)

holes larger than 10 mm diameter in the concrete surface, when using snap ties shall not be permitted

(g)

form ties shall have a factor of safety not less than 1.5.

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(a)

Coating and Accessories

1

Form coatings shall be commercial formulation form-coating compounds that will not bond with, stain, nor adversely affect concrete surfaces requiring bond or adhesion, nor impede the wetting of surfaces to be cured, shall be used. The use of form coatings shall be strictly in accordance with the manufacturer instructions.

2

Formwork in contact with the concrete shall be treated with a suitable non-staining mould oil to prevent adherence of the concrete.

3

Forms for exposed surfaces shall be coated with oil before reinforcement is placed. Forms for unexposed surfaces may be thoroughly wetted with water in lieu of oiling, immediately before placing of concrete except during freezing weather.

4

Excessive oiling of the forms shall not be permitted in order to prevent discoloration of the cement plaster. Where concrete surface is to be painted, the form-oil must not affect the bond between concrete and paint.

5

Care shall be taken to prevent the oil from coming in contact with reinforcement or with concrete at construction joints. Any oil on reinforcing steel shall be removed.

6

Release agents shall not be used where concrete surfaces receive special finishes or applied coatings which may be affected by the agent, unless approved by the Engineer.

7

Fillet and chamfer strips shall be PVC or timber to the approval of the Engineer.

8

Tapes to be used to seal joints of formwork panels for smooth finish concrete shall be plastic faced adhesive tape to the approval of the Engineer.

9

Precast concrete moulds shall be rigid steel, wood or fibreglass moulds.

10

Flashing reglets shall be galvanised steel of the longest possible length.

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9.3.6

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Section 05: Concrete Part 09: Formwork

Page 9

FORMWORK EXECUTION

9.4.1

General

1

Where formwork to external faces will be permanently exposed, all horizontal and vertical formwork joints shall be so arranged that joint lines will form a uniform pattern on the face of the concrete.

2

Where the Contractor proposes to make up the formwork from standard sized manufactured formwork panels, the size of such panels shall be approved by the Engineer before they are used in the construction of the Works.

3

The finished appearance of the entire elevation of the structure and adjoining structures shall be considered when planning the pattern of joint lines caused by the formwork and by the construction joints to ensure continuity of horizontal and vertical lines.

4

Masonry nails or similar items shall not be used to fix formwork of the like to permanent concrete works.

9.4.2

Trial Panels

1

The trial panels shall comprise surfaces that have unformed surfaces and formed surfaces F1, F2 and F3.

2

The concrete cast from the job mock-up shall be used to assess the acceptability of the Contractor’s workmanship for finishing.

3

If the finishing is deemed unacceptable by the Engineer, the Contractor shall prepare a further mock-up with a particular class of finish.

4

The job mock-ups shall be retained during the course of the works to allow comparative inspection, with production concreting and finishing and for the purpose of colour comparison to ensure colour consistency.

9.4.3

Formwork Face in Contact with Concrete

1

Faces of formwork in contact with concrete shall be free from adhering foreign matter, projecting nails and the like, splits or other defects, and all formwork shall be clean and free from standing water, dirt, shavings, chippings or other deleterious matter.

2

Joints between forms and tie holes shall be watertight to prevent the escape of mortar or the formation of fins or other blemishes on the face of the concrete.

3

The Contractor shall verify lines, levels and measurement before proceeding with formwork erection.

4

The formwork surface shall be made clean and free from any foreign and deleterious matter, prior to start the concrete pour.

5

In hot weather, the surface of the formwork shall be sprayed with water in order to lower the temperature, prior to start the pour.

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9.4

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Sloping Surfaces

1

Formwork shall be provided for the top surfaces of sloping work where the slope exceeds 15  from the horizontal (except where any such top surface is specified as a spaded finish).

2

The formwork shall be anchored to enable the concrete to be properly compacted and to prevent flotation.

3

Care shall be taken to prevent air being trapped under the sloping formwork.

9.4.5

Temporary Openings

1

The Contractor shall provide temporary openings for inspection of the inside of the formwork and for the removal of water used for washing down. The openings shall be formed as to be easily closed before placing concrete.

2

Temporary opening shall be avoided in the case of fair faced concrete.

9.4.6

Form Windows

1

The Contractor shall provide windows in forms wherever directed by the Engineer or necessary for access for concrete placement and vibration.

2

The windows shall be of a size adequate for tremies and vibrators spaced at maximum 1.8 m centres horizontally.

3

Any windows shall be tightly closed and sealed before proceeding to place concrete at a higher level.

9.4.7

Co-ordination

1

The Contractor shall ensure that the work of other trades in forming and setting openings, slots recesses, chases, sleeves, bolts, anchors and other inserts is fully co-ordinated.

9.4.8

Conduits

1

Conduits or pipes shall be located so as not to reduce the strength of the construction.

2

In no case shall pipes other than conduits be placed in a slab 125 mm or less in thickness.

3

Conduits embedded in a concrete slab shall not have an outside diameter greater than one-third the thickness of the slab nor be placed below the bottom reinforcing steel or over the top reinforcing steel.

4

Conduits may be embedded in walls provided they are not larger in outside diameter than one-third the thickness of the wall, are not spaced closer than three diameters on centre, and do not impair the strength of the structure.

5

Embedded pipes and conduits shall be supported independently from reinforcing steel in a manner to prevent metallic contact and thereby prevent electrolytic deterioration.

6

Pipes and conduits where embedded shall be placed as nearly as possible to the centre line of the concrete section.

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9.4.4

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Conduits, piping, and other wall penetrations or reinforcements shall be subject to the Engineer’s review and approval.

8

Conduits shall be fixed properly to avoid any displacement during concreting and prevent coming in contact with the forms.

9.4.9

Ties and Bolts

1

The position of ties passing through concrete shall be subject to the approval of the Engineer.

2

Ties, bolts or other devices shall not be built into the concrete for the purpose of supporting formwork without the prior approval of the Engineer. The whole or part of any such supports shall be capable of removal so that no part remaining embedded in the concrete shall be nearer to the surface than the cover required for reinforcement.

9.4.10

Chamfers

1

Chamfer moulding strips shall be positioned on the exposed corners of columns and beams.

9.4.11

Cambers

1

If required, cambers shall be as shown on the Drawings.

2

The depth of beams at all points in the span, where cambers are used, shall be as shown on the Drawings.

3

Allowance shall be made for compression and settlement of the formwork on line and level.

9.4.12

Exterior Angles

1

All exterior angles to concrete exposed to view in the completed structure shall be cast to the true angles evenly throughout the length.

2

Care shall be taken to ensure that no waviness occurs along the angle and that no spalling occurs to the concrete on removal of the formwork.

9.4.13

Surface Retarders

1

Surface retarders shall not be used on any formwork surface in contact with concrete unless expressly authorised by the Engineer.

9.4.14

Detection of Movement During Concrete Placement

1

Devices of telltale type shall be installed on supported forms and elsewhere as required to detect formwork movements and deflection during concrete placement.

2

Where required slab and beam cambers shall be checked and correctly maintained as concrete loads are applied on forms.

3

Workmen shall be assigned to check forms during concrete placement and to promptly seal all mortar leaks.

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Section 05: Concrete Part 09: Formwork

Page 12

The forms shall be checked during concreting in order to identify any displacement and provide corrective actions immediately.

9.4.15

Building in Pipes

1

Pipes and pipe specials through concrete walls and floors shall as far as possible be positioned and built in during construction. They shall be located exactly in the positions shown on the Drawings and shall be true to line and level.

2

The Contractor shall take particular care to ensure that fully compacted concrete is in contact with the pipe at all points.

3

Where it is not practicable to cast pipes and specials in the concrete, boxholes shall be formed in the shuttering.

4

The box shall have six or eight sides, depending on the pipe diameter, and shall be no larger in size than will give adequate clearance for the subsequent positioning and grouting in of the pipe. The sides of the boxhole shall be provided with a tapered central annular recess to provide a positive key. The boxhole shall be provided with a grout hole and, at the top of the central annular recess, a vent hole. The boxhole shall be stripped with the main shuttering and the concrete surface thoroughly cleaned and roughened.

5

When the pipe is later fixed, the remaining hole shall be reshuttered and filled with non-shrink epoxy grout or non-shrink concrete. In the case of water retaining structures, the Contractor shall ensure that the measures adopted shall provide a finished joint which is resistant against and free from leakage.

9.4.16

Working Platform

1

Safe working platform shall be provided according to Section 11 (Health and Safety).

9.4.17

Safe Access

1

Safe access shall be provided for the workers, inspectors, and other users according to Section 11 (Health and Safety).

9.4.18

Kickers

1

Kickers shall be provided for walls and columns

2

The kickers shall be water tight in order to prevent any grout loss.

9.4.19

Cover Spacers

1

Cover spacers shall be used in order to maintain the required cover between the formwork and reinforcement.

9.4.20

Water Bars

1

In the case of watertight constructions water bars or equivalent, as approved by the Engineer, shall be used at joints.

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Section 05: Concrete Part 09: Formwork

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REMOVAL OF FORMWORK

9.5.1

General

1

The Engineer shall be notified in writing before the removal of any formwork.

2

The Contractor, under no circumstances, shall strike the formwork until the concrete has attained adequate strength to resist damage, in particular to arises and features.

3

Concrete shall be thoroughly wetted as soon as the forms are first loosened and shall be kept wet during the removal operations and until the curing media is applied.

4

A potable water supply with hoses having fine fog spray attachments shall be ready at each removal location before operations are commenced.

5

The forms after removal shall be cleaned and prepared for subsequent use.

9.5.2

Stripping of Formwork

1

The period of time elapsing between the placing of the concrete and the striking of the formwork shall be approved by the Engineer after consideration of the loads likely to be imposed on the concrete and shall in any case be not less than the periods shown in Table 9.1

2

Stripping of the formwork within the time limits listed above does not relieve the Contractor from successfully crushing test cubes and achieving the specified compressive strength results.

3

Notwithstanding the foregoing the Contractor shall be held responsible for any damage arising from removal of formwork before the structure is capable of carrying its own weight and any incidental loading.

4

Where finished surfaces have re-entrant angles, the formwork shall be removed as early as possible, within the time limits set above, to avoid shrinkage cracks.

5

The formwork shall be carefully stripped to avoid sudden shocks from the removal of wedges, or vibration which might cause damage to the concrete.

6

Reshoring to beams and slabs shall be placed immediately after stripping formwork.

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9.5

Table 9.1 Stripping Times of Formworks Type Of Formwork

Minimum Period Before Stripping (Times Are From Concrete Placement)

Beam sides, walls and column Soffits of slabs (props left under) Soffits of beams, joists and girders (props left under) Props to slabs Props to beams

1d 4d 10 d 11 d 15 d

QCS 2014

Section 05: Concrete Part 09: Formwork

Page 14

Holes to be Filled

1

Holes formed in concrete surfaces by formwork supports or the like shall be filled neatly with non-shrink grout.

2

The Contractor shall clean and scarify any hole that is to be filled with non-shrink grout.

9.5.4

Repair to Damaged Concrete Surfaces

1

Where the concrete surface has been damaged, the Contractor shall break out any loose, broken or cracked concrete or aggregate.

2

The concrete surrounding the hole shall be then be thoroughly soaked after which the surface shall be dried so as to leave a small amount of free water on the surface. The surface shall then be dusted with ordinary Portland cement by means of a small dry brush until the whole surface that will come into contact with the dry-pack mortar has been covered and darkened by absorption of the free water by the cement. Any dry cement in the hole shall be removed

3

Dry-pack material shall then be placed and packed in layers having a compacted thickness in accordance with the manufacturer’s instructions. Compaction shall be carried out by the use of a hardwood stick and a hammer and shall extend over the full area of the layer, particular care being taken to compact the dry-pack against the side of the hole. After compaction the surface of each layer shall be scratched before further loose material is added

4

The hole shall not be over-filled and the surface shall be finished by layering a hardwood block against the dry-pack fill and striking the block several times. Steel finishing tools shall not be used and water shall not be added to facilitate finishing.

5

The surface of the concrete shall be rubbed down smooth with carborundum and water in an approved manner within three days of removing the formwork. Holes left after removal of such supports shall be neatly filled with non-shrink grout of a suitable consistency and matching colour.

9.6

DELIVERY AND STORAGE

9.6.1

Delivery

1

The delivery of formwork materials shall be done in such a manner that damage can be prevented.

9.6.2

Storage

1

Formwork should be stored, after cleaning and preparing for reuse if used before, in such a manner that access to all different materials is available.

2

Materials which can be affected by weathering shall be stored in appropriate buildings or under cover.

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9.5.3

QCS 2014

Section 05: Concrete Part 09: Formwork

Page 15

9.7

TOLERANCES

1

The concrete work shall be constructed to an accuracy which shall permit the proper assembly of components and installations and shall be compatible with the finish. The accuracy of the work shall be within the tolerances shown on the Drawings or specified elsewhere and, in the absence of any other requirements, shall comply with the following: 5 mm 5 mm

All laying out dimensions Sections of concrete members

10 mm

Top surfaces of foundations, bases and piers

20 mm

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5 mm 10 mm 5 mm

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Surface level of floor slabs (5m straight edge) Surface level of floor slabs to datum Plumb of columns and walls in storey height

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5 mm

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Inside faces of elevator shafts in storey height

20 mm (1/1000) of height  150 mm

10 mm (0.5/1000) of height  75 mm

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Inside faces of elevator shafts in full building height (for each storey) above the top of foundation: 20m ≥ building height 150m ≥ building height ≥ 20 m building height ≥ 150 m

EARLY LOADING

1

The Contractor should note that the loading from the falsework and wet concrete, during the construction of a floor, will not exceed the permissible loading on the floor immediately below. Consequently two of the floors immediately below the one being constructed will need to be used, to share the loading.

2

While propping through two floors, the Contractor shall ensure, that the props beneath the floor last constructed are released over its full extent as soon as the concrete has achieved sufficient strength to support itself plus any superimposed loading, but not sooner than the periods given in Table 9.1. The props shall then be re-tightened so that these may be used to share the construction loading from the floor above.

3

Not withstanding the requirements of this Section for the removal times for formwork, the following provisions shall apply to early loading of concrete.

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QCS 2014

Section 05: Concrete Part 09: Formwork

Page 16

Concrete shall at no time be subject to loading including its own weight which will induce a compressive stress in excess of 0.33 of the actual compressive strength of the concrete at the time of loading or 0.33 of the specified 28 d characteristic strength whichever is the lower. For the purpose of this clause the assessment of the strength of the concrete and the stress produced by the loads shall be subject to the agreement of the Engineer.

5

If, due to his method of construction, the Contractor wishes to place an imposed load on the structure, he shall arrange for additional cubes to be cast at the point of the structure to be loaded and these cubes will be crushed to monitor the compressive strength in accordance with BS EN 12390-3 Compressive strength of test specimens. The Contractor shall submit calculations showing the stresses induced by any proposed temporary loads to be placed on the structure.

6

No superstructure load shall be placed upon finished piers or abutments until the Engineer has given his approval in writing and in no case shall any load be placed until the curing period is complete.

7

Deck slabs of bridges shall only be opened to traffic or construction equipment and plant when authorised by the Engineer and in no case until the curing period is complete.

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END OF PART

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Section 06: Road Works Part 01: General

Page 1

1

GENERAL ............................................................................................................... 2

1.1 1.2

RELATED DOCUMENTS & REGULATIONS ................................................ 2 BENCH MARKS AND MONUMENTS............................................................ 2

1.2.1 1.2.2 1.2.3

General Permanent Monuments Setting Out

1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11

EXISTING GROUND LEVELS....................................................................... 3 MATERIALS TESTING .................................................................................. 4 NUCLEAR DENSITY TESTING DEVICES .................................................... 5 TEMPORARY FENCING ............................................................................... 5 ROAD OPENING ........................................................................................... 5 CONCRETE WORKS .................................................................................... 5 STANDARDS AND CODES OF PRACTICE ................................................. 6 TRAFFIC MANAGEMENT ............................................................................. 6 ARMED FORCES .......................................................................................... 6

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QCS 2014

Section 06: Road Works Part 01: General

Page 2

GENERAL

1.1

RELATED DOCUMENTS & REGULATIONS

1

The information given in this Part is supplemental to QCS Section 1 - General. Reference should be made to Section 1 – General prior to referring to the clauses in this part of the specification which cover specific requirements for roadworks and are additional to Section 1 - General.

2

The Government specifications, regulations, notices and circulars mentioned in QCS Section 1 – General are amended and complemented by this Specification as detailed hereafter. In the case of any ambiguity or discrepancy the provisions of this Specification shall prevail over the provisions of the aforementioned Government published specifications.

1.2

BENCH MARKS AND MONUMENTS

1.2.1

General

1

The Contractor shall consult the Survey Section of the Ministry of Municipal Affairs and Agriculture prior to any earthworks or site clearance to determine if the work is likely to disturb survey marks.

2

If the survey section require a survey mark to be moved the Contractor will be responsible for recreating the survey mark to an approved design and specification, and for re surveying the point using survey companies approved by the Survey Section.

3

On the Practical Completion of the Works the Survey Section will issue a certificate stating that all survey marks, whether disturbed or otherwise, by the Contractor have been reinstated or protected to the satisfaction of the Survey Section.

4

In the event of failure to comply with the requirements of this Clause the Government, without prejudice to any other method of recovery, may deduct the costs of any remedial work after the Practical Completion date, carried out by Survey Section from any monies in its hands due to or which may become due to the Contractor.

5

All pertinent levels, lines and locations must be checked and verified by the Contractor before commencing the Works.

1.2.2

Permanent Monuments

1

At the time of substantial completion of the whole of the works, a schedule and plan drawings of all remaining Project related and supplementary bench marks and monuments shall be prepared and transmitted to the Engineer. All project related bench marks and monuments made permanent as above will be shown on the as-built plans, including the co-ordinates and level information for each.

2

Certain bench marks and monuments determined by the Engineer shall be made into permanent bench marks and monuments.

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QCS 2014

Section 06: Road Works Part 01: General

Page 3

Fabrication and installation of bench marks and monuments shall be as shown on the drawings or in the specifications and shall include attaching warning reflectors and painting if required. Each bench mark and monument shall be set accurately at the required location and elevation and in such manner as to ensure its being held firmly in place.

4

The Contractor may request the Engineer's approval for concrete monuments, markers and posts supplied by an established commercial manufacturer, whose capability of producing survey monuments has been well established by both testing and performance. Written approval shall be obtained prior to installation of the units on the project.

1.2.3

Setting Out

1

The level datum for the works shall be the Qatar Datum as defined by the PWA.

2

The works shall be set out to the Qatar national grid as defined by the PWA. The Contractor will be supplied with the details and grid reference of setting out monuments.

3

The works shall be set out in accordance with the standard specification of the PWA.

4

Before commencing the works the Contractor shall obtain from the Engineer all information pertaining to project related bench marks and monuments bearing local grid co-ordinates.

5

After the Contractor takes possession of the Contract Drawings and has noted all the existing bench marks, he shall carry out at his own expense the setting out of the works, definition of levels, centre lines and slopes, all in accordance with the Drawings.

6

The Contractor shall be responsible for the true and proper setting out of the work in relation to original points, lines and levels of references given in the Drawings and for the accuracy of the positions, levels, dimensions and alignment of all parts of the work, and for any delay or loss resulting from errors made in completing the setting out of the work.

7

The Contractor shall protect, preserve and be responsible for all existing bench narks, pegs and boundary marks and shall keep these in place or replace them when necessary either in their positions or in other approved positions.

8

Setting out shall be approved by the Engineer before commencing the Works, but such approval shall in no way relieve the Contractor of his responsibility for the correct execution of the works.

1.3

EXISTING GROUND LEVELS

1

The Contractor will survey cross-sections of the site prior to the commencement of works in any section.

2

The Contractor shall include in his critical path programme the date by which survey work should be completed in each section of the site. No works may commence in any section prior to the programme date without the written approval of the Engineer.

3

Sections will be prepared at such intervals as are necessary to give a representative record of existing conditions and in no case will the intervals exceed 50 metres.

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QCS 2014

Section 06: Road Works Part 01: General

Page 4

The Engineer may choose to carry out his own survey of the site and in such cases will give the Contractor 48 hours notice of his intention to carry out survey work in any particular section of the Site.

5

The Contractor may nominate a representative to be present to observe the survey. If, having been given such notice, the Contractor fails to appoint a representative or if the representative should fail to be present during the survey work, the Engineer shall proceed with the survey which shall be deemed to have been prepared in the presence of the Contractor.

6

The Contractor shall prepare drawings showing the various cross-sections obtained from the above survey.

7

The original of the drawings shall be signed by the Engineer and the Contractor as an agreed record of the existing ground levels.

8

A copy transparency of each original drawing will then be given to the Engineer. These drawings shall be deemed to be the Contract Drawings replacing the original.

1.4

MATERIALS TESTING

1

Reference should be made to the requirements for the provision of facilities and equipment for the testing of materials given in Section 1.

2

In addition to these requirements the Contractor shall provide a fully equipped site laboratory or shall arrange for materials and samples to be transported to the Ministry of Environment (MOE) for testing or otherwise specified by the Engineer or the Project Documentation.

3

In addition the Contractor shall provide suitable facilities at the asphalt batching plants to enable the Engineer to carry out all necessary tests on the raw materials and mixes. Such facilities will be subject to the Engineer's approval and the preparation of asphalt mixes shall not be allowed until the facilities have been approved by the Engineer.

4

Approved equipment shall be maintained on site at all times to: Determine the laying and rolling temperature of bituminous materials.

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(b)

Check surface tolerance by using a straightedge and wedges or rolling straightedge.

(c)

Carryout soil grading shape, classification, moisture content and compaction tests, as required.

(d)

Carryout in situ dry density tests.

(e)

Carryout bitumen extraction.

5

Equipment shall also be made available when required by the Engineer to take 150 mm diameter cores from the carriageway.

6

The Engineer may require samples of materials to be delivered to the MOE for additional tests.

QCS 2014

Section 06: Road Works Part 01: General

Page 5

1.5

NUCLEAR DENSITY TESTING DEVICES

1

No person or company will be permitted to determine in-situ density by mean of a nuclear density measuring device without complying with the following regulations: (a)

Each device shall have a valid Calibration Certificate issued by the MOE.

(b)

Persons operating the device shall hold a valid authorised user certificate issued by the MOE.

(c)

During the operation of the device the person operating it and any assistants shall wear a suitable film badge or a personal radiation warning alarm. Copies of radiation exposure report of the film badges should be submitted on monthly basis to the MOE.

TEMPORARY FENCING

1

Temporary fencing shall be appropriate to the usage of the adjoining land and unless otherwise described on the drawings may be of a type selected by the Contractor taking into account the usage of the adjoining land subject to the approval of the Engineer.

2

As soon as the Contractor is placed in possession of any part of the site he shall immediately erect fencing on the boundaries of the land as shown on the Drawings. In places where permanent fencing cannot be erected immediately or where none is required, the Contractor shall erect, and when and where required re-erect and maintain, temporary fencing and subsequently take down and remove as necessary.

3

The Contractor shall not use barbed wire in areas accessible to the general public. Access shall be made in temporary fencing as necessary for the use of the occupiers of adjacent lands.

4

If temporary fencing is removed temporarily for the execution of any part of the Works it shall be reinstated as soon as possible and in the meantime, subject and without prejudice to the Conditions of Contract, the gap in the fencing shall be patrolled so that no unauthorised entry onto adjoining land takes place.

5

Temporary fencing shall remain in position either until it is replaced by permanent fencing or until its removal on completion of the Works, unless otherwise described in the contract or directed by Engineer.

1.7

ROAD OPENING

1

Road openings shall be carried out in accordance with the procedures laid down in The Code of Practice and Specification for Road Openings in the Highway, prepared by the Ministry of Industry and Public Works, January 1992.

2

Newly compacted bituminous courses shall not be opened to traffic until they have cooled to ambient temperature. Longer periods may be applied during the summer months for heavily trafficked roads at the discretion of the supervising engineer

1.8

CONCRETE WORKS

1

All concrete works shall be carried out in accordance with the requirements of Section 5.

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1.6

QCS 2014

Section 06: Road Works Part 01: General

Page 6

Concrete works shall include; mass concrete, reinforced concrete, in-situ concrete, precast concrete and prestressed concrete.

3

Concrete works shall be deemed to include reinforcement, formwork and all the other materials procedures and requirements covered by Section 5 - Concrete.

1.9

STANDARDS AND CODES OF PRACTICE

1

The standards, codes of practice and other reference documents referred to in the roadworks section of the specification are listed in the first clause of each of the parts of the specification.

2

Unless otherwise agreed with the Engineer a full set of these documents shall be provided by the Contractor within 30 days of the commencement of the contract. These documents shall be kept at the site and shall be available at all times for the use of the Engineer and his staff.

1.10

TRAFFIC MANAGEMENT

1

The Contractor shall comply with all instructions given by the Qatar Traffic Police in relation to traffic management and road safety.

1.11

ARMED FORCES

1

The Contractor shall comply with all reasonable instructions given by the Qatar Armed Forces to allow them access to the Works and with the PWA.

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END OF PART

QCS 2014

Section 06: Road Works Part 10: Vehicle Crash Barriers

Page 1

10

VEHICLE CRASH BARRIERS ....................................................................... 2

10.1

GENERAL REQUIREMENTS ........................................................................ 2

10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6

Scope References Performance Requirements Submittals Quality Assurance Maintenance

10.2

STEEL WIRE ROPE BARRIERS .................................................................. 5

10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8

General Component Ropes Tail Rope Safety Check Rope Posts Anchorage Frames Other Components Installation

10.3

TENSIONED CORRUGATED BEAM SAFETY FENCE ................................ 9

10.4

UNTENSIONED CORRUGATED SAFETY FENCE .................................... 10

10.5

OPEN-BOX BEAM SAFETY FENCE ........................................................... 11

10.6

TENSIONED RECTANGULAR HOLLOW SECTION SAFETY FENCE ......................................................................................................... 12

10.7

MARKERS FOR BARRIERS ....................................................................... 12

10.8

CRASH CUSHIONS AND TERMINALS ...................................................... 12

10.9

VEHICLE BARRIER UNITS (VBU) .............................................................. 13

10.10

TEMPORARY CONCRETE BARRIERS ...................................................... 13

10.11

ALUMINIUM BRIDGE PARAPET ................................................................ 14

5 5 6 6 6 7 7 8

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2 2 3 3 4 5

QCS 2014

Section 06: Road Works Part 10: Vehicle Crash Barriers

Page 2

10

VEHICLE CRASH BARRIERS

10.1

GENERAL REQUIREMENTS

10.1.1

Scope

1

This section of the specification covers the supply, installation and foundation requirements of the following representative types of vehicle crash barriers. The definition of each type of barrier is given in the relevant section of the specification. steel wire rope barriers.

(b)

tensioned corrugated beam safety fence

(c)

untensioned corrugated beam safety fence

(d)

open box beam safety fence

(e)

tensioned rectangular hollow section safety fence

(f)

permanent concrete barriers

(g)

temporary concrete barriers

(h)

aluminium bridge parapet.

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This section of the specification does not cover the design criteria for deciding on the type of barrier to be applied in a particular situation.

3

Related Sections and Parts

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Fencing

Section 5

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This Section Part 12

References

1

The following standards and other documents are referred to in this Part:

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BS 4............................Structural steel sections BS 302........................ Wire ropes for cranes, excavators and general engineering purposes BS EN 13411-1 ..........Specification for Thimbles for wire ropes BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles BS 970........................Wrought steels for mechanical and allied engineering purposes BS 1449: Part 2 ..........Stainless and heat resistant steel plate sheet and strip BS 1474......................Wrought aluminium and aluminium alloys for engineering purposes BS 1490......................Aluminium and aluminium ingots for engineering purposes BS EN ISO 2081 & BS EN ISO 2082, Electroplated coatings of cadmium and zinc on iron and steel BS EN 10264..............Round carbon steel wire for wire ropes BS 3416......................Bitumen based coatings for cold application BS EN 1011................MIG Welding of aluminium and aluminium alloys BS 4320......................Metal washers for general engineering purpose BS 4464......................Spring washers for general engineering and automobile purposes BS EN ISO 3506 ........Corrosion-resistant stainless steel fasteners BS 6579......................Safety fences and barriers for highways

QCS 2014

Section 06: Road Works Part 10: Vehicle Crash Barriers

Page 3

BS EN 1317................"Highway parapets for bridges and other structures. Part 1. Specification for vehicle containment parapets of metal construction BS EN 10025..............Hot rolled products of non-alloy structural steels - Technical delivery conditions. DTP, Manual of contract documents for highway works - volume 1 specification series 400 DTP, Manual of contract documents for highway works - volume 3 standard details ASTM D 1248 .............Specification for Polyethylene Plastics Moulding and Extrusion Materials US, Department of Transportation Research Report NCHRP, No. 230. ISO 9002 ....................Quality assurance system for production and installation Performance Requirements

1

The vehicle crash barriers shall present a continuous smooth face to an impacting vehicle so that the vehicle is redirected without turning on its side or rolling over to a course that is nearly parallel to the barrier face and with a lateral deceleration which is tolerable to the vehicle occupant. The vehicle shall be redirected without rotation about either its horizontal axis (spinning out) or vertical axis (overturning) and the rate of lateral deceleration shall be such as to cause minimum risk of injury to the passengers.

2

The vehicle shall be directed so that no part of the vehicle crosses the line parallel with and 4 m from the original alignment of the traffic face of the fence or barrier within a distance of

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10 m from the last point of initial impact in the direction of the adjacent traffic flow. On impact the safety fence or barrier shall contain and redirect a vehicle of a certain mass travelling at a certain velocity at an angle of incidence of 20 degrees to the fence or barrier.

4

The level of vehicle containment shall be lower, normal or higher as designated, with the following value for vehicle mass and vehicle speed.

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Vehicle Mass, kg 1500 1500 5000

Vehicle Speed, km/h 113 80 80

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Containment Normal Lower Higher

The centre of gravity of the test vehicle prior to impact shall be 500 mm above the ground. 5

All the components of a vehicle crash barrier shall be designed to achieve a serviceable life of not less than 20 years except for the use of temporary concrete barriers where the nominal service life shall not be less than 10 years.

10.1.4

Submittals

1

The Contractor shall submit details of previous installations of the vehicle crash barrier over a 10-year period, indicating the system, its location and the type of highway.

QCS 2014

Section 06: Road Works Part 10: Vehicle Crash Barriers

Page 4

For the particular crash barrier system proposed, the Contractor shall submit a detailed report giving the results of vehicle impact tests, and may include photographs and video recordings. The report shall be from an internationally recognised laboratory approved by the Engineer. The report shall describe in detail the arrangements for the test including vehicle weight, speed, impact area, full details of the test vehicle guidance and measuring systems and speed measurements. The report shall include photographs showing the results of the test. The report shall give full details of the actual vehicle speed, approach angle, vehicle interaction and fence movement of vehicle and roll, yawl and pitch of the vehicle movement after exit from safety fence. The report shall include details of the safety fence damage and the vehicle damage.

3

Crash cushions and terminals. The Contractor shall make a detailed technical submission that will include drawings indicating the layout for the system at different locations. The Contractor shall also submit design calculations for the system for head on impact and side impact. These calculations shall indicate the reduction in G force or all vehicles of specified weight and speed. The submission shall contain the precise specification of the individual elements of the system, installation procedures, fixing details and fully dimensioned scale layout drawings. The Contractor shall submit reports from the highway authority where the particular barrier system has been used showing details of vehicle collisions and the results of such collisions.

4

The Contractor shall submit calculations to show that post foundations can withstand an overturning moment of 6.0 kNm.

5

The Contractor shall submit full technical details of the safety fence system proposed including post to beam connection details of beam joints and post to beam connection details of posts, and details of tensioning assembly.

6

The Contractor shall submit calculations showing the required size and details of the lifting eyes for permanent and temporary concrete barriers for the designated barrier details.

10.1.5

Quality Assurance

1

Vehicle crash barriers shall have been tested by an approved Testing establishment such as the UK Transport and Research Laboratory. The Engineer shall decide what is an approved Testing establishment.

2

The manufacturer shall operate an approved quality assurance system complying with ISO 9002 for the fabrication and supply of components used in the vehicle safety barriers. Only components complying with the manufacturer’s specifications may be used.

3

The supplier shall submit certification showing that tensioned rectangular hollow section safety fence systems have been tested in accordance with the requirements of the UK Transport and Research Laboratory.

4

Crash cushion and terminal systems shall have been satisfactory tested following the procedures set down in the US Department of Transportation Research Report NCHRP, No. 230. The installation of the system shall be supervised by a representative of the manufacturer with a minimum of five years of experience in the use of the system.

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10.1.6

Maintenance

1

For vehicle crash barriers, crash cushion and terminal systems the Contractor shall supply: (a)

four copies of the installation and maintenance manual

(b)

a relevant spare parts list for the system showing the recommended set of spare parts needed to restore one system to its original condition after a head on impact

(c)

if specified elsewhere in the Contract the Contractor shall supply spare parts for the system

(d)

current prices of spare parts

(e)

profile of a local agent

STEEL WIRE ROPE BARRIERS

10.2.1

General

1

Steel wire rope safety fence barriers shall be supplied and installed in accordance with the designated dimensions and details shown on the contract drawings. The post details, spacing, anchorage, size shapes and general layout shall be as per the details shown on the contract drawings.

2

Wire rope barriers shall consist of either two or four, tensioned, galvanised, steel-wire ropes. The type of system to be specified shall be as shown on the contract drawings.

3

Four wire rope barriers shall consist of two upper ropes located in a slot at the top of the steel posts and two lower ropes interwoven along the fence between each pair of ropes. The ropes shall be joined and tensioned by means of screws at the designated intervals.

4

The ends of the ropes shall be attached to anchor blocks and embedded in the ground. Steel posts may be located in the ground either as driven posts or in concrete footings. In the case of any obstruction, the Contractor shall propose an alternative steel post, surface mounted to the equivalent of strain. Steel posts shall be removable and replaceable.

5

The supply and installation of steel wire safety fence barriers is to be carried out in accordance with BS 6579, except as modified herein.

10.2.2

Component Ropes

1

Component ropes shall consist of steel wire ropes fitted with end terminals.

2

The rope shall be 19 mm diameter, 3 x 7 (fill) galvanised wire rope generally to BS 302: Part 1 with a minimum breaking force of 173.6 kN. All wire used in the rope shall be to BS EN 10264 galvanised normal duty. Various galvanised wire finishes may be used by agreement with the Engineer.

3

The rope shall be prestressed by applying a cyclic loading until all initial extension has been removed. After prestressing the rope will exhibit a minimum modulus of elasticity of 8300 kg/mm2 based on an area of 283 mm2.

4

The complete component rope shall have terminals, one end right-hand thread and the other left-hand thread.

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Section 06: Road Works Part 10: Vehicle Crash Barriers

Page 6

The fittings shall be attached to the rope whose length measured over the extreme ends of the threaded portion of the fittings shall be 153.35 m, -0/+25 mm. Other special lengths of rope with identical construction may be detailed as necessary for specific applications.

6

All threaded terminals shall be made from steel to BS 970: Part I Grade 65SM13 and either cadmium plated to BS EN ISO 2081 & BS EN ISO 2082 class B or alternatively galvanised to BS EN ISO 1461. A test will be carried out to destruction on a threaded terminal test piece consisting of a terminal and a length of rope such that the minimum test length is 600 mm. This assembly shall have a minimum breaking force of 164.6 kN.

10.2.3

Tail Rope

1

Tail ropes shall be short lengths of rope fitted with threaded terminals at both ends that are used to connect component ropes to anchors. Tail ropes shall be supplied to the site prefabricated.

2

Tail ropes are of identical construction and specification to the component ropes but of different overall length. These ropes must also be prestressed.

3

The length of the fitted rope measured over the extremities of the threaded portions of the screwed terminals shall be 6 m  10 mm.

4

Tail ropes shall be terminated in one of two ways using identical terminals to those specified for component ropes: with right-hand terminations on both ends, or with a right-hand at one end and a left-hand termination at the other.

10.2.4

Safety Check Rope

1

Safety Check Ropes are steel wire ropes fitted with end terminations. The rope itself shall be 8 mm diameter 6 x 19 (9/9/1) IWRC galvanised wire rope to BS 302 with a minimum breaking

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The rope shall have a galvanised heart-shaped thimble to BS EN 13411-1 capable of accepting a 38 mm diameter pin fitted by using a pressed ferrule on one end and a forked

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force of 40.3 kN. All wires used in the rope shall be to BS EN 10264 grade normal duty, galvanised to class 'A' finish.

terminal on the other end. 3

The length of the rope between the centre of the 38 mm pin hole and the 9 mm pin hole shall be 1.8 m –0/+20 mm.

10.2.5

Posts

1

There are three types of posts with variations for embedded style or surface mounting: line, deflection and surface.

2

All posts shall be manufactured from 6 mm section cold rolled mild steel plate to BS EN 10025 grade Fe 50A, having a minimum yield strength of 355 N/mm2. All posts shall be galvanised to BS EN ISO 1461. Dimensions and tolerances of the types of posts shall be as designated.

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Section 06: Road Works Part 10: Vehicle Crash Barriers

Page 7

Post foundations and anchor blocks shall be as per the dimensions and details designated by the supplier.

10.2.6

Anchorage Frames

1

A range of anchorage frames must be available for various locations and applications. These are: on the median, verge and for end/intermediate and embedded/surface mounted fixings. The anchorage frames shall comply with the requirements of clause 4.3 of BS 6579.

2

End anchorage frames shall be constructed from weldable structural steel as defined in BS EN 10025 Grade Fe 430A with steel plate to section 4, and steel bar to section 6. Rolled steel channel to BS 4. All materials shall be galvanised to BS EN ISO 1461.

3

Intermediate anchorage frames are double sided frames. All materials and finishes shall be as defined above.

4

The intermediate anchor frames may be surface mounted.

10.2.7

Other Components

1

Sockets for post foundation shall be constructed from 3 mm steel to BS EN 10025 Grade Fe 430A. Galvanised to BS EN ISO 1461.

2

Excluders shall be produced from high-density polyethylene type iii class C Cat 4, ASTM D 1248

3

Rigging screws shall be used to connect component ropes together and component to tail ropes. The rigging screws shall be the body of a rigging screw manufactured to BS 4429. Except for the threads which are to be right and left hand M24 x 3-7H. Each rigging screw shall be hot dipped galvanised to BS EN ISO 1461.

4

Steel pins used in the fork terminal on the safety check rope shall be made from BS 970 Grade 045M10.

5

Split cotter pins shall be in stainless steel 2.5 mm x 16 mm to BS 4320 and shall have a retaining pin.

6

Nuts used to secure the threaded rope terminal to an anchor frame shall be M24 thread in zinc electroplated condition. Steel washers shall be M 24 to BS 4320 and fitted over the threaded terminal and between the nut and anchor frame.

7

Locating hooks shall be made in stainless steel to BS 970 Part I. Nuts (for hooks) shall be M6

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to BS 3692 Grade A2. 8

Caps for posts shall be high-density polyethylene Type III class c cat 4, ASTM D 1248

9

Ordinary thimbles shall be size 9, fitted to safety check rope made to BS EN 13411-1.

10

The fork terminal shall be fitted to the safety check rope shall be made to BS 970 Grade 45 M10.

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11

All ropes, terminals, rigging screws, posts and anchor frames are to be clearly marked with the manufacturers identification and the date of manufacture and the standard of construction.

10.2.8

Installation

1

Steel wire ropes safety fences shall not be used where the length of fence at full height would be less than 37.5 m

(b)

on horizontal kerb at radius less than 600 m

(c)

on vertical sag curves of radius less than 300 m

(d)

on medians having a width of less than 3.14 m

(e)

where the height of any kerb at the edge of the adjacent surface exceeds 100 mm

(f)

where high mast lighting columns are situated within 10m of the edge of the paved surface

(g)

where the fence has to be connected to any other fence or building

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(a)

All components shall be suitably protected and supplied in packaging that prevents any permanent damage particularly to threaded components. Damage to metallic coating shall be prevented by appropriate means. Any damage found on inspection prior to installation shall be made good to the satisfaction of the Engineer.

3

Component ropes and tail ropes shall be supplied on reels with a bar of diameter not less than 450 mm.

4

Ropes shall not be twisted or kinked.

5

Driven line posts shall be installed to the alignment and level shown on the drawing without damage to the slot on the top of the post.

6

The top of the post shall be capped with a black polypropylene excluder.

7

The length of the line rope between any two adjacent anchors shall be not greater than 627m.

8

Tensioning between any two limits shall not proceed until the Engineer is satisfied that each limit is anchored sufficiently securely to resist the load effects due to tensioning.

9

The tension shall be measured using a device approved by the Engineer.

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Page 9

The ambient air temperature shall be noted at the time of tensioning and adjusted as follows;

AMBIENT TEMPERATURE C

14.00 16.75 19.50 22.25 25.00 27.75 30.50 33.25 36.00

45 40 35 30 25 20 15 10 5

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ROPE TENSION kN

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Section 06: Road Works Part 10: Vehicle Crash Barriers

TENSIONED CORRUGATED BEAM SAFETY FENCE

1

Except as modified herein, tension corrugated beam safety fences shall comply with the DTP Manual of Contract Documents for Highway Works Specification - Volume 1, specification series 400.

2

Tensioned corrugated beam safety fences are for use on high speed roads at the road edge or on the central median in one of the following forms:

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10.3

Single sided for road edges.

(b)

Double sided for medians.

(c)

Dual single sides for medians .

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(a)

In the event of an accident, the support post shall give away while the safety fence remains in tension absorbing the impact energy while protecting the traffic on the opposite carriageway. The angle of deflection shall be reduced and as the vehicle decelerates it shall be redirected towards the carriageway.

4

The barrier shall consist of a strong corrugated steel beam section mounted and tensioned on steel universal posts. End posts shall be set in concrete and intermediate posts can be driven or set in concrete.

5

Surface mounted posts may be used where there are obstructions. In all cases the end posts which are attached to barriers must be set in concrete.

6

The layout and the positioning of the barrier shall be as shown on the contract drawings. The details and sizes and spacing of the various components shall be as shown on the contract drawings.

7

The height of the centreline of the barrier shall be 610 mm above the edge of the carriageway unless shown otherwise on the contract drawings.

8

There is no maximum length for installation. Where the line of the barrier is interrupted for an obstacle or gap, additional end anchorages shall be provided.

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Where a barrier protects an individual short obstacle the barrier should extend from at least 30 m in front of the obstacle to at least 7.5 m or more beyond it. A minimum clearance of 1.2 m behind the barrier shall be allowed for deflection.

10

Circular installations shall be at a radius of not less than 120 m. Tighter radii than this shall not be used without the written approval of the Engineer. Tensioners shall consist of two longitudinal bulbs installed in brackets and shall be positioned in intervals along the barrier and bolted to the corrugated beam.

12

Beams shall be connected by lap joints using screws nuts and washers. Beams shall be spliced by lapping with the edge facing away from the direction of traffic. Longitudinal clearance between screws and slotted holes in the beams shall be removed by prising apart the beams. The nuts shall be tightened to a torque approved by the supplier.

13

Tensioning between any two limits shall not proceed until the Engineer is satisfied that each limit is anchored sufficiently securely to resist the load effects due to tensioning. Tensioning shall be carried out strictly in accordance with the system manufacturer’s recommendations. Adjustments to the tensioning shall be made for the ambient temperature at the time of tensioning strictly in accordance with the system manufacturer’s recommendations.

14

The beam shall be completely formed, punched with holes for mounting and splicing and ready for assembly when delivered. It shall be uniform corrugated section straight or curved sections, galvanising shall be carried out after fabrication and each element and end sections shall be marked at the point of fabrication with the manufacturer’s name or trade mark, gauge and heat ( steel batch ) number and with the coating lot referenced.

15

The barrier system shall be supplied with all required terminals and approach flares for the particular installation situation.

16

Safety barriers shall be erected to present a flowing alignment, with the alignment in plan not more than ± 30 mm from the prescribed alignment and no deviations in a 10 m length by

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more than ± 15 mm from the prescribed alignment. The height of the beam shall not depart from the prescribed height by more than ± 30 mm nor deviate in any 10 m length from the

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prescribed height by more than ± 10 mm.

10.4

UNTENSIONED CORRUGATED SAFETY FENCE

1

Untensioned corrugated safety fences shall meet the requirements of the tensioned corrugated safety fence except as modified herein and the fence shall not be tensioned.

2

Untensioned corrugated safety fences can be used in low-speed situations to prevent vehicles crossing median and for protection at the verge.

3

Beams shall be shaped so that there are no sharp edges protruding into traffic. Beams shall be connected by lap joints made in the direction of the traffic flow. The beams shall be formed from a 3 mm steel strip to give a corrugated cross-section. On curves less than 45 m radius, the beam shall be provided in preformed curves, internal or external, without any reduction in strength.

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Section 06: Road Works Part 10: Vehicle Crash Barriers

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At terminations, the end rails shall be sloped down at a slope of approximately 1 in 6 to terminate just above ground level. Anchorage shall be provided by an end post set in concrete. Unless otherwise designated the centreline of the beam shall be 610 mm above the edge of the carriageway or hard shoulder.

10.5

OPEN-BOX BEAM SAFETY FENCE

1

Open box beam safety fences shall meet the requirements of the DTP - Manual of contract documents for highway works - volume 1 specification series 400 except as modified herein.

2

The open-box beam barrier shall be used on high-speed roads where a stiffer barrier than the tensioned corrugated beam is required. The open-box barrier can be used for a double sided installation in a median.

3

The layout, positioning, post spacing and all dimensions of the system shall be as designated.

4

The systems shall comprise a main traffic section rail element with a traffic face 150 mm wide. This shall be ground mounted on relatively weak Z-section posts or with hexagonal energy absorbing brackets bolted to a reinforced concrete wall or bridge pier. The traffic face shall be set to a height of 610 mm at the centreline of the rail.

5

There is no limit to the length of the installation, but end rails shall be taken down to ground level and bolted to end posts to form anchors which are set in concrete.

6

Where the installed barrier exceeds 100 m in length, expansion joints are to be inserted in

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4

The standard section length shall be 4.8 m unless otherwise designated, and this value shall

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the main rail.

be used on curves of radii down to 335 m. For radii between 335 m and 107 m special fish plates shall be used.

9

For radii between 107 m and 50 m, 2.4 m rail lengths shall be used with special fish plates.

10

Z-section intermediate posts shall be connected to the main rail by shear bolts and clamp plates into the back of the rail section.

11

Rail sections shall be butt jointed together connected by fish plates and bolted in connection.

12

Where a non-standard situation arises in the use of the crash barrier, the supplier shall obtain recommendations from the UK Transport Research Laboratory.

13

In particularly hazardous locations where vehicles with a high centre of gravity are in use, the open box barrier may be installed to a double height with two protective rails. The horizontal centreline of the second rail shall be positioned 1 m above the adjacent carriageway. The

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two box section rails shall be connected together with vertical straps or a single shear bolt in the centre of each connection of the rails to longer intermediate posts.

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10.6

TENSIONED RECTANGULAR HOLLOW SECTION SAFETY FENCE

1

Tensioned rectangular hollow section safety fences shall be installed as designated. The position, layout dimensions and details shall be as designated.

2

The barriers shall be used where protection is required for bridge piers lighting columns and other obstructions.

3

The size of the rectangular hollow section shall be 100 mm wide x 100 mm high or 100 mm wide x 200 mm high.

4

The minimum recommended curve for the barrier shall be 120 m radius. Tensioners shall be fitted at a maximum spacing of 70.5 m and the first tensioner shall be within 50 m of the

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anchorage.

When supplied the system shall include a detailed packing list with each component referenced and clearly marked to the standard of manufacture and the manufacturer’s name and date of manufacture.

10.7

MARKERS FOR BARRIERS

1

To ensure that the vehicle crash barriers are clearly delineated, reflectorized markers shall be fixed to the barriers. The work shall consist of the fabrication supplied and fixing of reflectorized markers to vehicle crash barriers and other road side obstructions.

2

Reflectorized markers shall consist of two retro-reflective faces of minimum area 4000 mm2 on a weather proof durable backing capable of being fixed to the barrier. All metal fixings and fittings shall be galvanised or stainless steel and approved by the Engineer.

3

Reflectorized faces shall consist of a minimum of 210 glass beads set in a 3 mm thick tough durable plastic backing. The two faces of the marker shall be of the colour specified in the Qatar Traffic Manual unless shown otherwise in the drawing or instructed otherwise by the Engineer.

4

Reflectors shall be fixed to safety barriers and other structures where designated. Stainless steel fixings complying with BS EN ISO 3506 grade A4 shall be used to attach markers to concrete. Plastic isolation washers shall be used if the marker is galvanised.

10.8

CRASH CUSHIONS AND TERMINALS

1

Where designated, permanent or portable energy absorbing terminal systems shall be provided for protection of traffic as shown on the drawings.

2

Proposed systems shall have a proven record of satisfactory performance of at least five years in a number of locations.

3

The system shall be able to withstand head on and side impacts within the specified design criteria. The system shall have the performance characteristics of a conventional metal beam guard rail for strength durability and redirectional properties.

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All of the components and materials of the system shall be suitable for use in the climatic conditions of Qatar and shall not be liable to damage or deterioration in high temperatures or by prolonged exposure to direct sunlight.

5

The system shall be such that most major components can be reused after a typical impact.

6

All metal work used in the system shall be galvanised or stainless steel.

7

All concrete used in the system shall meet the requirements of Section 5.

8

No work or fabrication of the system or ordering of the materials shall be carried out until the Engineer has given formal approval in writing to the Contractor’s detailed submission.

10.9

VEHICLE BARRIER UNITS (VBU)

1

Vehicle barrier units and their foundations shall be as per the details and dimensions shown on the drawings.

2

Vehicle barrier units shall be mass concrete of grade C25

3

The barriers shall be cast in-situ in nominal 6 m length units unless designated otherwise.

4

All the concrete materials and procedures including any steel reinforcement for the barriers shall comply with Section 5.

5

Forms shall be smooth and tight-fitting which can be held rigidly to the line and grade during the placing of concrete.

6

At the option of the Contractor, the barriers may be precast in sections not exceeding 6 m in

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length. In such cases the barrier shall be reinforced to ensure that information technology can be safely handled and have 2 no. lifting eyes of galvanised steel cast in at the top. The method of casting, handling and placing of barrier sections shall be proposed by the Contractor for approval by the Engineer. The joints between the barriers shall be as per the details shown on the drawings.

8

Vehicle barrier units shall be cast onto blinding concrete laid onto compacted subgrade

10.10

TEMPORARY CONCRETE BARRIERS

1

Temporary concrete barriers shall be used for traffic management at road diversions or detours where there is slow moving traffic.

2

Temporary concrete barriers shall be as per the designated detailed dimensions. The barriers shall be either double or single sided.

3

The barriers shall be cast in nominal 6 m length units unless otherwise designated.

4

Each barrier shall have cast in at the top two lifting eyes of galvanised steel.

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Where adjacent barriers are put together two galvanised steel wire eyes shall be cast in to the ends to allow a steel pin to be placed through the eyes and into the road surface to secure the barrier laterally.

6

The Contractor shall propose the reinforcement in the precast barriers which shall be adequate to resist the forces and moments induced during lifting and handling.

7

All the concrete work including any steel reinforcement for the barriers shall comply with Section 5 of this specification.

8

The method of casting, handling and placing of barrier sections shall be proposed by the Contractor for approval by the Engineer.

10.11

ALUMINIUM BRIDGE PARAPET

1

The aluminium alloy parapets for installation on the bridges and retaining walls shall be designed to the requirements of BS EN 1317 "Highway parapets for bridges and other structures. Part 1. Specification for vehicle containment parapets of metal construction".

2

The parapet shall be designed for normal level of containment as defined by the standard i.e. that required to resist penetration from the following vehicle’s impact characteristics:

as

Saloon Car 1500 kg 600 mm 2 degrees 113 km/h

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Vehicle Mass Height of centre of gravity Angle of impact Speed

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5

The parapet proposed for use shall be a three rail system of an established design the prototypes of which have been subjected to full scale dynamic testing. The parapet design which shall therefore be considered exempt from further dynamic testing shall be taken from the list in Appendix G of BS EN 1317.

4

The parapets supplied to the project shall be certified by the supplier as a normal containment system complying with one of the following.

5

That it complies in all respects with the design of parapet that successfully met the requirements of Clause 26.1 or 26.5 (concerning dynamic testing) of BS EN 1317 as appropriate.

6

That any modifications that have been made to the tested design comply with Clause 26.6 or 26.7 of BS EN 1317 as appropriate.

7

The parapet construction materials shall be as follows:

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Extruded sections Castings

Aluminium alloy 6082-T6 to BS 1474 Aluminium alloy LM6M to BS 1490

8

The finish of the parapets shall be high quality defect free mill finish and as cast finish for extrusions and castings respectively.

9

All aluminium welds shall confirm to BS EN 1011 and the requirements of BS EN 1317.

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Section 06: Road Works Part 10: Vehicle Crash Barriers

Page 15

All setscrews and nuts are to be stainless steel to BS EN ISO 3506 material grade A4. Setscrews are to be strength class 80. Washer material is to be stainless steel to BS 1449: Part 2 conforming to grade A4 or A2 as defined in BS EN ISO 3506.

11

Rail attachment and rail joint screws are to be M12 x 30 long hexagon head each complete with one spring washer to BS 4464 type B, and one plain washer to BS 4320 form A.

12

Holding down bolts are to be M20 hexagon head bolts of sufficient length to give the engagement required in BS EN 1317.

13

Bottom mesh fixing screws if required, are to be to the M8 long hexagon head set screws each complete with one spring washer, two plain washers and one M8 nut where appropriate.

14

The holding down arrangement shall be in accordance with the requirements of BS EN 1317.

15

Loctite grade 270 (or similar approved) to be applied on erection to all rail joint and rail attachment setscrews. At the holding down bolts, contact between the stainless steel and aluminium baseplate shall be avoided by the use of a suitable "top-hat" insert manufactured from an inert material.

16

Underside of baseplates are to be given at least two coats of an alkali resistant bitumastic paint or pitch complying with BS 3416.

17

Mesh, if required, shall be 10 gauge welded steel wire in accordance with BS EN 1317, where appropriate. It may be galvanised, or any other finish as directed by the Engineer.

18

Rivets shall consist of Avdel drive rivets, code 5141 or 06 37 or similar approved. Where there is no substantial backing Avdel chrobert rivets, code 1125 06 13 with sealing pins code 1182 06 07 or similar approved, shall be used.

19

Full details of the proposed supplier with his technical specification in English covering materials, main dimensions and sizes shall be submitted to the Engineer for approval before the Contractor places an order.

20

Two copies of detailed shop drawings shall be submitted and the Engineer's approval obtained before manufacture is commenced.

21

During erection, parapets shall be securely held in their correct position until all connections and fastenings are complete and the post fixings have attained adequate strength to the Engineer's approval.

22

The finished parapets shall be true to line and level throughout their length.

23

Panels and members shall be free from twist, and posts shall be truly vertical.

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END OF PART

QCS 2014

Section 06: Road Works Part 11: Kerbs, Footways and Paved Areas

Page 1

KERBS, FOOTWAYS AND PAVED AREAS............................................................ 2

11.1 11.1.1 11.1.2 11.1.3 11.1.4

GENERAL ............................................................................................................... 2 Scope 2 References 2 Submittals 2 Quality Assurance 2

11.2 11.2.1 11.2.2 11.2.3

KERBS .................................................................................................................... 3 General 3 Materials and Manufacture 3 Laying 5

11.3

PRECAST CONCRETE PAVING BLOCKS ............................................................. 6

11.4

LAYING PRECAST CONCRETE PAVING BLOCKS ............................................... 7

11.5

PRECAST CONCRETE PAVING SLABS ................................................................ 8

11.6

CAST-IN-PLACE CONCRETE PAVED AREAS....................................................... 9

11.7

BITUMINOUS PAVED AREAS ................................................................................ 9

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Page 2

11

KERBS, FOOTWAYS AND PAVED AREAS

11.1

GENERAL

11.1.1

Scope

1

Highway kerbs, edging kerbs for footways and other paved areas. Precast concrete paving slabs and precast interlocking concrete block areas.

2

Related Sections and Parts:

.

Earthworks Unbound Pavement Materials Asphalt Works

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This Section Part 3 Part 4 Part 5

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Section 5, Concrete

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Section 13, Masonry References

1

The following standards and other documents are referred to in this Part:

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BS 812........................Testing Aggregates

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BS 1377......................Methods of test for soil for civil engineering purposes BS 7533......................Code of practice for laying precast concrete units

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BS 7533-3 ..................Laying precast concrete paving blocks and conformity criteria for

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BS EN 197-1 ..............Cement composition specifications comments cements BS EN 1338................Precast concrete paving blocks

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BS EN 1339................Concrete paving flags

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BS EN 1340................Concrete kerbs unit BS EN 12620..............Aggregates for concrete

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BS EN 12878..............Pigments for the colouring of building materials

11.1.3

Submittals

1

The Contractor shall submit samples of the various types of concrete kerbs and other pavement materials for approval by the Engineer before beginning the work.

11.1.4

Quality Assurance

1

Tests shall be carried out on the concrete mix before beginning manufacture of precast kerbs and other items to ascertain the strength and surface finish requirements can be met. If the required strength and surface finish are not obtained, the Engineer may order revisions to be made in order to achieve the designated requirements.

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Page 3

2

The Engineer shall, at all reasonable times, have access to the place where paving blocks and other items and their constituent materials are manufactured and stored, for the purpose of examining and sampling the materials and finished blocks, inspecting the process of manufacture and marking the blocks.

3

The laying of paving blocks shall comply with the requirements of the Code of Practice for Laying Precast Concrete Block Pavements and BS EN 1338 except where otherwise designated.

KERBS

11.2.1

General

1

The following are the types of precast kerbs to be constructed where designated together with associated channels, edgings and quadrants: Non-mountable.

(b)

Dropped.

(c)

Flush.

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11.2

The dimensions and shapes of the different kerb types shall be as per the details in BS EN 1340 unless otherwise shown on the drawings or designated in the contract.

3

The bedding and support for such units shall be as shown on the drawings.

4

Except as modified in this Part, all precast concrete kerbs, channels, edgings and quadrants shall be hydraulically pressed complying with BS EN 1340.

5

Kerbs shall be laid and bedded in accordance with BS 7533 on the concrete pavement slab, a mortar bed, the road base, or on a concrete foundation while it is still plastic or after it has set. All precast units shall be backed with concrete as per the designated details.

6

The use of cast-in-situ concrete for kerbs will not be permitted except with the express written approval of the Engineer.

11.2.2

Materials and Manufacture

1

Constituent concrete materials for kerbs shall conform to the requirements designated in Section 5. Kerbs shall be prepared with a concrete mixture containing not less than 400 kg/m3 of sulphate resisting Portland cement.

2

Testing of concrete kerbs shall be carried out in accordance with the requirements of BS EN 1340.

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2

QCS 2014

3

Section 06: Road Works Part 11: Kerbs, Footways and Paved Areas

Page 4

The aggregate shall meet the designated requirements and conform to the following gradation. Table 11.1 Aggregate Gradation for Kerb Concrete % Passing by Weight

19

100

13.2

76-100

9.50

60-80

4.75

40-60

2.36

22-42

1.18

12-32

0.6

7-23

0.3

4-15

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0.15

2-10 0-2

ta

0.075

The 28-day compressive strength of the concrete shall be not less than 30 N/mm2

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4

.

Sieve mm

determined on 150 mm cube specimens, and not less than 75 % of this figure after seven

as

days.

Non-mountable kerb, dropped kerb, flush kerb and heel kerb elements shall only be precast from concrete produced in a fully automatic batching plant.

6

Before approval of elements of commercial manufacture, cores shall be taken from a random sample to ascertain that the concrete strength is not less than 25 N/mm2 at 7 days.

7

Elements shall be manufactured to the designated dimensions as standard 900 mm lengths unless specified otherwise in the contract documents.

8

Non-mountable and dropped precast kerbs shall be formed by elements 500 mm long where required to be laid in straight lines but may be reduced to 250 mm long where required to be laid to curves, depending on the radii of the curves.

9

The finished product shall be of solid appearance with clean planar faces, be free of segregation, honeycombing, pits, broken corners or other defects and there shall be no evidence of external rendering.

10

Bull-nosed and curved faces shall be of constant radius with a smooth change from radius to straight.

11

Tolerances of manufacture shall be 3 mm in any one dimension and end faces shall be truly

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5

perpendicular to the base.

QCS 2014

12

Section 06: Road Works Part 11: Kerbs, Footways and Paved Areas

Page 5

Transverse strength requirements shall be assessed in accordance with BS EN 1338 appendix B. The loads at failure shall not be less than the appropriate value given in Table 11.1A. Table 11.1A Transverse strength of kerbs, channels and edgings Width as tested (mm)

Load at failure (kN)

150

305

22.2

125

150

8.0

125

255

13.3

50

255

50

205

50

150

Dropper kerbs 125

255 to 150

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5.1 4.5

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3.3

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10.3

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Water absorption requirements shall be assessed in accordance with BS EN 1338 appendix C. The water absorption shall not exceed the appropriate value given in Table 11.1B.

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13

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Depth as tested (mm)

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Table 11.1B Water absorption of kerbs, channels and edgings

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Water absorption in % by mass Edgings

3.0

3.6

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Kerbs, channels and quadrants

11.2.3

Laying

1

Elements shall be set on to the designated lines and grades. Under no circumstances shall it be permitted for levels to be set by direct measurement from pavement layers.

2

Unless otherwise indicated, elements shall be laid either directly onto a wet-concrete base or onto a sand/cement (3:1) mortar bedding, 25 mm thick, on a previously laid concrete base or approved subbase. The dimensions of the base and concrete class shall be as designated.

3

After kerb units have been laid, a contiguous backing of concrete shall be poured for the elements using steel forms, unless otherwise designated. Lateral resistance shall be provided to the kerbs by placing dowel bars in the backing concrete in not more than 500mm intervals.

QCS 2014

Section 06: Road Works Part 11: Kerbs, Footways and Paved Areas

Page 6

4

No pavement layers shall be laid against kerbing until such time as the backing is completed, backfilled and approved by the Engineer.

5

Joints between kerbs, shall have a width of 4 mm. These joints shall be filled completely with fluid sand cement mortar approved by the Engineer and the joints shall be formed again. Immediately after any concrete is in place, and for seven days thereafter, the kerbs, base, and backing shall be fully cured and protected from drying out and against the harmful effects of weather, including rain and rapid temperature changes. The method of protection shall be subject to the Engineer's approval. The use of coloured curing membranes will not be permitted. Concrete not properly cured and protected will be rejected and shall be removed from the site.

7

At every 10 m interval movement joint 20 mm thick shall be formed through the concrete bed and backing. The joint filler shall be bitumen impregnated cork board. The filler shall extend through the kerb, bed, backing and channel, and shall be trimmed to the finished shape of the kerb and channel.

8

At access points, the kerbs, including the bed backing shall be dropped to show a face of 25 mm or as otherwise designated.

9

At the termination of any kerb run, the end kerb section shall be sloped down to ground level, if applicable, and angled away from the road at 30 degrees in accordance with BS 7533.

10

All kerbs shall be thoroughly cleaned of all extraneous materials.

11

Kerbs shall be laid within a tolerance of  3 mm, at each end of an element, to the designated

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lines and grades.

PRECAST CONCRETE PAVING BLOCKS

1

Standard rectangular precast concrete paving blocks shall have a work size length of 200 mm and a work size width of 100 mm. Paving blocks of any other shape may be made provided they fit within a 295 mm square co-ordinating space. The preferred work size thicknesses are 60 mm, 80 mm and 100 mm for all types of paving blocks.

2

The actual sizes of the paving blocks as determined in accordance with BS EN 1338 shall not deviate from the work size dimensions by more than the following tolerances:

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11.3

Length

 2 mm

Width

 2 mm

Thickness

 3 mm

3

The binder used in making the paving blocks shall be Ordinary Portland Cement, Sulphate Resisting Portland Cement or Moderate Sulphate Resisting Portland Cement which complies with BS 4027 or ASTM C150; respectively.

4

The aggregates used in making the paving blocks shall be Gabbro, and they shall comply with section 5 of QCS.

QCS 2014

Section 06: Road Works Part 11: Kerbs, Footways and Paved Areas

Page 7

The water used in the manufacturing of the blocks shall be of drinking quality or shall be in conformance with section 5 of the QCS.

6

The pigments, which are used to give colour to the paving blocks, shall comply with BS EN 12878.

7

The average tensile splitting strength of 16 paving blocks tested in accordance with BS EN 1338 shall not be less than 3.6MPa and the strength of any individual block shall not be less than 2.9MPa and the failing load not lower than 250N/mm.

8

The average water absorption of three tested samples shall not exceed 5% and no individual block shall have a water absorption greater than 6%.

11.4

LAYING PRECAST CONCRETE PAVING BLOCKS

1

The paving blocks shall be laid generally in accordance with BS 7533-3 and to a pattern approved by the Engineer.

2

A laying course consisting of fine aggregates (sand), which complies with the corresponding grading requirement given in Table 11.2, shall be constructed. The fine aggregates shall be placed in a moist but not a saturated condition and shall be compacted so that a laying course thickness of 50 mm approximately is formed. This sand layer shall be placed on a compacted aggregate subbase or base as indicated in the project specifications/drawings.

3

The paving blocks shall be laid on the laying course and compacted using a plate compactor with a plate area of not less than 0.25 m2, transmitting an effective pressure of not less than 75 kN/m2 of plate at a frequency of vibration in the range of 75 Hz to 100 Hz.

4

A maximum deviation for the block paving from design levels of  6 mm shall be maintained.

5

The joints between the paving blocks shall be filled with dry jointing sand by spreading it over the surface and brushing it into the joints. The dry sand shall be natural and shall comply with the corresponding grading requirement given in Table 11.2. The block paving shall be vibrated to ensure that the joints have been completely filled.

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5

Table 11.2 Grading for laying course & jointing sand % Passing

Sieve Size Laying Course Sand

Jointing Sand

10 mm

100

5 mm

90-100

100

2.36 mm

75-100

95-100

1.18 mm

55-90

90-100

600 m

35-70

55-100

300 m

8-35

15-50

150 m

0-10

0-15

75 m

0-3

0-3

QCS 2014

11.5

Section 06: Road Works Part 11: Kerbs, Footways and Paved Areas

Page 8

PRECAST CONCRETE PAVING SLABS

1

Precast concrete paving slabs shall be hydraulically pressed, complying with BS EN 1339.

2

The dimensions of precast concrete paving slabs shall be as per Table 3 of BS EN 1339 unless shown otherwise on the contract drawings.

3

Where permitted by the Engineer as an alternative, slabs 450 mm x 450 mm and smaller may be bedded on a layer of clean sharp sand complying with BS EN 12620 Grading C or M, 25 mm  10 mm thick. On circular work where the radius is 12 m or less, all slabs shall be radially cut on both edges to the required line.

5

Transverse strength and water absorption requirements shall be assessed in accordance with BS EN 1339 - appendix B and appendix C; respectively. The loads at failure shall not be less than the appropriate value given in Table 11.3 and the water absorption shall not exceed the limit given in the aforementioned Table.

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ta

Table 11.3 Transverse strength and water absorption of flags Minimum load at failure for thickness (kN)

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65 mm

70 mm

12.7

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-

-

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Flag type

-

16.9

-

-

-

-

-

18.8

9.1

-

-

15.4

-

9.6

13.8

-

-

-

60 mm

A

8.3

-

B,C,D

11.1

E

9.6

F G

63 mm

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50 mm

Maximum water absorption in % by mass

The mortar bed shall be spread only after the base has been approved by the Engineer. The subbase shall be tested for density and the minimum density shall be greater than 95% of the maximum dry density.

7

Slabs shall be laid in accordance with BS 7533 to the designated cross-section and with joints at right angles to the kerb.

8

Slabs shall be bedded on a sand/cement (3:1) mortar bedding not less than 10 mm and not more than 40 mm thick.

9

Unless designated elsewhere paving slabs shall be laid with close joints of between 2 to 4 mm. After laying the joints shall be filled with sand complying with clause 8.3.3.

10

Where designated paving slabs shall be laid with open joints of between 5 to 10mm laid in accordance with BS 7533.

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QCS 2014

11.6

Section 06: Road Works Part 11: Kerbs, Footways and Paved Areas

Page 9

CAST-IN-PLACE CONCRETE PAVED AREAS Cast-in-place concrete for footways and paved areas shall only be permitted for small areas where it is awkward or impractical to use one of the alternative paving materials specified in this part of the specification.

2

The use of steel reinforcement bars or mesh in cast-in-place concrete slabs is not permitted.

3

Paving shall be cast in sizes to avoid the formation of shrinkage cracks. The actual maximum size of area to be cast at one time will be advised by the Engineer based on the mix design and layer thickness shown on the drawings. The Contractor may be permitted to cast larger areas at one time if non-metallic fibres are added to the concrete mix to eliminate cracking. In such cases the maximum pour size shall be proposed by the Contractor and approved by the Engineer.

4

Cast-in-place concrete for footways and paved areas shall be mixed, laid and cured as described in Section 5.

5

The grade of concrete, layout, thickness, position of joints and surface finish shall be as designated.

6

Cast-in-place concrete shall be laid on a designated sub-base in accordance with Part 4.

BITUMINOUS PAVED AREAS

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.

1

Flexible surfacing for footways and paved areas shall be made and laid in compliance with Part 5.

2

The type of mix and the surface treatment/finish to the paving will be as designated..

3

Surfacing shall be laid to true levels and crossfalls and be of the designated thickness.

4

Surfacing shall be laid on a designated sub-base in accordance with Part 4.

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END OF PART

QCS 2014

Section 06: Road Works Part 12: Fencing

Page 1

12

FENCING ....................................................................................................... 2

12.1

GENERAL ...................................................................................................... 2

12.1.1 Scope 12.1.2 References 12.1.3 Submittals

2 2 3

FENCING GENERALLY ................................................................................ 3

12.3

CHAIN LINK FENCING.................................................................................. 4

12.3.1 12.3.2 12.3.3 12.3.4 12.3.5

General Materials Gates Finish to Components Construction

12.4

STRAINED WIRE FENCING ......................................................................... 7

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12.4.1 General 12.4.2 Materials 12.4.3 Installation

4 4 5 6 6 7 8 10

PEDESTRIAN GUARD-RAIL ....................................................................... 11

12.5.1 12.5.2 12.5.3 12.5.4

Aluminium Guard Rails Galvanised Steel Rails Materials and Fabrication Installation

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12.5

11 12 12 13

QCS 2014

Section 06: Road Works Part 12: Fencing

Page 2

FENCING

12.1

GENERAL

12.1.1

Scope

1

This part of the specification covers the materials and installation requirements for the following permanent fence types. The definition of each type is given in the relevant section of the specification.

(b)

strained wire fencing.

(c)

pedestrian guard-rail.

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chainlink fencing.

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References

BS 4............................Structural steel sections

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BS 970........................Wrought steels for mechanical and allied engineering purposes BS 1449: Part 2 ..........Stainless and heat resistant steel plate sheet and strip

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BS 1474......................Wrought aluminium and aluminium alloys for engineering purposes

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BS 1490......................Aluminium and aluminium ingots for engineering purposes BS 1722-2 ..................Strained wire fences

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BS 1722, Part 1 ..........Chain link fences

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BS 1722, Part 2 ..........Rectangular wire mesh and hexagonal wire netting fences BS 4102......................Specifications for steel wire and wire products for fences BS 4320......................Metal washers for general engineering purpose

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This Section Part 1 General Part 10 Vehicle Crash Barriers Section 5, Concrete

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Related Sections and Parts:

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(a)

.

12

BS 4464......................Spring washers for general engineering and automobile purposes BS 4652......................Specifications for zinc rich priming paint BS EN 1011................Welding BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles BS EN ISO 3506 ........Corrosion-resistant stainless steel fasteners BS EN 10210-2 ..........Hot finished structural hollow sections of non alloy and fine grain steels BS EN 10244-2 ..........Steel wire and wire products ASTM A53 ..................Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless ASTM A193 ................Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature

QCS 2014

Section 06: Road Works Part 12: Fencing

Page 3

ASTM A240 ................Specification for Heat-Resisting Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels ASTM B108 ................Specification for Aluminium-Alloy Permanent Mould Castings ASTM B221 ................Specification for Aluminium-Alloy Extruded Bars, Rods, Wire, Shapes, and Tubes ASTM D4364 ..............Practice for Performing Accelerated Outdoor Weathering of Plastics Using Concentrated Natural Sunlight ASTM Dl499 ...............Standard practice for filtered open-frame carbon-arc exposure of plastic ASTM G152................Standard practice for operating open flame carbon-arc light apparatus for exposure of non-metallic materials

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ASTM G153................Standard practice for operating endorsed arc light apparatus for exposure of non-metallic materials.

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ASTM G23..................Practice for Operating Light-Exposure Apparatus (Carbon-Arc Type) With and Without Water for Exposure of Non-metallic Materials

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AASHTO M181...........Chain link fence

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USA Federal Salt Spray Test (Test Standard 141 Method 6061) Submittals

1

For all fencing systems, the Contractor shall submit the following for the Engineer’s approval, before an order is placed with the manufacturer:

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12.1.3

Name and address of the factories at which the required materials will be manufactured.

(b)

Technical submittals accompanied by a completed specification in the English language, catalogues and a tabulation showing the overall dimensions of each type and size of the required materials.

(c)

Programme of delivery certified by the manufacturer and supplier.

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Detailed drawings.

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(d)

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(a)

(e)

Material composition certificates.

(f)

Technical information for the materials and system.

2

The submittals shall clearly show the standard to which the material complies. All materials shall meet the requirements of the relevant BS. The Engineer may accept materials that comply to a comparable international standard if the contractor demonstrates that the standard is equivalent.

12.2

FENCING GENERALLY

1

All permanent fencing, unless otherwise designated shall be erected to present a flowing alignment both in plan and elevation following approximately the level of the finished ground along the line of the fence. The Contractor shall trim or fill the ground along the line of the fence when required. The fencing shall be neatly and effectively joined to existing fences and to other structures and parapets.

QCS 2014

Section 06: Road Works Part 12: Fencing

Page 4

Where designated, existing fences, gates and stiles, with posts shall be carefully taken down, laid aside, removed or later re-erected. Fences, gates, stiles and posts which are to be reerected shall be handled carefully to avoid any damage.

12.3

CHAIN LINK FENCING

12.3.1

General

1

This work consists of the supply and installation of all plastic coated chain link fencing complete with all necessary hardware and appurtenances as designated and in conformity with the lines and grades directed by the Engineer.

2

All materials to be furnished and installed shall conform to all requirements of BS1722: Part 2 except as otherwise designated.

12.3.2

Materials

1

The base metal for the manufacture of posts and braces shall conform to the requirements of BS1722: Part 1, except that the carbon content of steel posts shall not be more than 0.4 % if welding is required. Posts and braces shall be galvanised in accordance with BS EN ISO 1461.

2

Fence posts and braces and gate frames shall be pipe conforming to the requirements of Table 12.1 unless otherwise designated:

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Table 12.1 Fence posts and braces and gate frames requirements

End, Corner, Pull Posts

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Line Posts

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Location

Minimum Weight, kg/m

60.3

5.43

48.3

4.05

42.2

3.38

Posts for each side of gates shall be pipe conforming to the requirements of Table 12.2:

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Braces

Minimum O.D., mm

Table 12.2 Post dimensions for chain link fences

Gate Opening, m

Minimum O.D., mm

Minimum Weight, kg/m

1.5

60.3

5.43

4.0

73.0

8.62

4

All fence and gate posts (including all end and corner posts) shall be fitted with plastic or vinyl coated aluminium tops designed to fit securely over the posts and crowned to shed water.

5

Changes in line where the angle of deflection is 15° or more shall be considered as corners and corner posts shall be installed.

QCS 2014

Section 06: Road Works Part 12: Fencing

Page 5

6

Extension arms, stretcher bars, and other required fittings and hardware shall be steel, malleable iron or wrought iron and shall be hot dipped galvanised. All required fittings and hardware shall be fastened to the posts in the proper manner.

7

Chain link fence fabric shall be galvanised steel fabric conforming to the BS1722: Part 1. The base metal for the fabric shall be medium high carbon hot-dip galvanised steel wire. All chain link fence fabric shall be woven into approximately 50 mm mesh such that in a vertical dimension of 600 mm along the diagonals of the openings there shall be at least 7 meshes. Between posts, chain link fabric shall be fastened to a top and bottom tension cable. The tension cable shall be 10 gauge galvanised steel.

9

Tie wires and post clips shall be at least 9 gauge galvanised steel.

10

Turnbuckles and truss tighteners shall be fabricated of steel, malleable iron, or wrought iron and shall be hot dipped galvanised. The truss tighteners shall have a strap thickness of not less than 6 mm.

11

The class of concrete for post footings shall be as designated.

12.3.3

Gates

1

Gate frames shall be constructed of not less than 42.2 mm galvanised pipe weighing

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8

3.38 kg/m and conforming to ASTM A53. Gate frames shall be cross trussed with 9 mm

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adjustable truss rods. The corners of gate frames shall be fastened together and reinforced with a malleable iron fitting designed for the purpose or by welding. All welds shall be ground smooth. Chain link fence fabric designated for the fence shall be attached to the gate frame by the use of stretcher bars and the tie wires as designated for fence construction, and suitable tension connectors shall be spaced at approximately 300 mm intervals.

3

The gates shall be hung by at least two steel or malleable iron hinges not less than 80 mm in

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width, so designed as to securely clamp to the gate post and permit the gate to be swung back against the fence. The bottom hinge shall have a socket to take the bail end of the gate frame. 4

Gates shall be provided with a combination steel or malleable iron catch and locking attachment of approved design. Stops to hold gates open and a centre rest with catch shall be provided where required.

5

All gates shall be provided with standard hardware and heavy duty padlocks with four keys each, the type and details of which shall be to the approval of the Engineer.

QCS 2014

Section 06: Road Works Part 12: Fencing

Page 6

12.3.4

Finish to Components

1

All posts, gate frames, rails and similar materials shall have a coating thickness of 254 to 356 micron of a polyvinyl chloride (PVC) which has been chemically bonded to the metal surface with an appropriately cured primer. Final finish colour shall be as designated.

2

Chain link fence fabric shall have a vinyl coating of minimum wall thickness of 0.559 mm over the galvanised substrate. The vinyl coating shall be continuously extruded (not sprayed or dipped) over the galvanised steel wire by the thermal extrusion process under pressures to 352 kg/cm2 to ensure a dense and impervious covering free of voids, having a smooth and lustrous surface appearance. The wire shall be vinyl-clad before weaving and shall be free and flexible at all joints.

4

Colours shall be stabilised and have a light fastness that shall withstand a minimum WEATHER-O-METER exposure time of 4000 h without any deterioration in accordance with ASTM Dl499 and G23, Type E. Alternatively a sample of fencing may be subject to an

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3

ta

exposure time of 2000 h at 85 °C humidity in a humidity oven. The sample shall exhibit no

5

qa

colour loss, cracking, peeling, blistering or other deterioration. The vinyl-clad wire shall withstand an accelerated ageing test of 2000 hours at 62 °C without

as

cracking or peeling.

The vinyl covering shall, in addition, resist attack from prolonged exposure to dilute solutions of most common mineral acids, sea water and dilute solutions of most salts and alkali.

7

The pipe resin formulation shall meet the standard ASTM D4364, minimum 5000 h

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WEATHER-O-METER requirement without cracking, blistering, or loss of adhesion. The protective resin coating shall withstand an impact resistance test (Gardner Test Method) of a minimum of 1850 mm/kg. Certified abrasion resistance shall be in excess of a ten minute blast of 5.6 kg/cm2 at 305 mm at 25 °C with S230 shot at an impingement angle of 90 ° without exposing the steel substratum. It shall not support combustion and shall be self-extinguishing; and shall withstand a salt spray test (Federal Test Standard 141, Method 6061 of greater than 10,000 h with no

m

8

perceptive deterioration to coating or evidence of metal corrosion for unscored samples. For scored samples after exposure of 1000 h, under-cutting shall not exceed 5 mm. The protective resin coating shall exhibit a chemical resistance after prolonged exposure at 24 °C to fumes. 12.3.5

Construction

1

Line posts shall be spaced at not more than 3.0 m intervals, measured from centre to centre of posts, in general, in determining the post spacing, measurement will be made parallel to the slope of the natural ground, and all posts shall be placed in a vertical position, except in unusual locations where the posts shall be set perpendicular to the ground surface if so directed by the Engineer.

2

All posts shall be set in concrete footings conforming to the designated details.

QCS 2014

3

Section 06: Road Works Part 12: Fencing

Page 7

End, corner, pull and gate posts shall be braced to the nearest line post with galvanised diagonal or horizontal braces used as compression members and galvanised 9 mm steel truss rods with turnbuckles or truss tighteners used as tension members.

4

Pull posts shall be placed at locations agreed by the Engineer. They shall be placed at 200 m intervals between posts to which the ends of the fabric are clamped or midway between such posts when the distance is greater than 40 m but less than 200 m. Chain link fabric shall be fastened on the side of the posts designated by the Engineer.

6

The fabric shall be stretched and securely fastened to the posts, and between posts the top and bottom edges of the fabric shall be fastened to the tension wires. Tension wires shall be stretched tight, the bottom tension wire shall be installed on a straight grade between posts by excavating at the high points of ground and in no case will filling of depressions be permitted.

7

The fabric shall be fastened to end, corner and gate posts tall with minimum 10 mm diameter steel stretcher bars and not less our than 3 mm by 18 mm stretcher bar bands spaced at maximum or 300 mm intervals. The fabric shall be fastened to line posts ends and tension

ta

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.

5

qa

wires with tie wires or post clips. The fasteners shall be spaced at maximum intervals of 500 mm.

STRAINED WIRE FENCING

12.4.1

General

1

Strained wire general and dropper fences shall be as designated and they shall comply with BS 1722-2 with the following amendments.

2

This part of the specification covers the requirements for materials and workmanship for strained wire fences of the general pattern and of the dropper pattern. Droppers are defined as intermediate and vertical stiffeners between some or all of the wires that are used to maintain the spacing of the wires. The droppers are not connected to the ground.

3

Strained wire fences comprise of tensioned horizontal steel wires fixed between vertical straining posts with support angle struts and connected to intermediate posts. Posts shall be constructed of either steel or precast reinforced concrete and anchored in concrete foundations.

4

Wire dropper fencing shall be provided at locations where it is necessary to restrict the access of vehicles, and camels and wandering animals.

5

Strained wire general and dropper fences shall be of one of the types shown in Table 12.3

6

The strained wire fences shall be coded according to the type dependant on the number of line wires, whether droppers are used, material used for the posts, these type references are given in Table 12.3. The first letter indicates that it is either a general pattern or a dropper pattern strained wire fence, the second letter indicates the type of posts that are used, the numbers give an indication of the height of the fence e.g. DC90 indicates a 0.9m high fence with concrete posts and droppers.

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12.4

QCS 2014

7

Section 06: Road Works Part 12: Fencing

Page 8

For the sake of uniformity quoted heights of those to the top wire and exclude any variation in ground clearance to the base, the third letter where present indicates the number of line wires. Table 12.3 General Characteristics of Strained Fences - Fence Types With Concrete Posts Dropper Pattern

General Pattern

Dropper Pattern

General pattern

Dropper Pattern

SC105A

DC 90 DC105A

SS90 SS105A

DS90 DS105A

SW90 SW105A

DW90 DW105A

m 0.90 1.05

No. 3 5

SC105B

SS105B

SS105B

DS105B

SW105B

DW105B

1.05

6

SC120

DC120

SS120

DS120

SW120

DW120

1.20

6

SC135A

DC135A

SS135A

DS135A

SW135A

DW135A

1.35

7

SC135B

DC135B

SS135B

DS135B

SW135B

DW135B

1.35

8

SC135C

DC135C

SS135C

DS135C

SW135C

DW135 C

1.35

9

DW180

1.80

11

DW210

2.10

16

DC210

er

Spacing between horizontal wires, from the top wires mm 330,330 250,250,230,150 250,250,230,150, 100 250,250,230,150, 150 250,250,230,150, 150,150 250,250,230,150, 150,150,100 250,225,225,150, 125,125,100,75 225,225,200,175, 175,175,150,150, 125,100 100,100,100,100, 100

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DS210

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DS180

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DC180

With Wooden Posts

.

General Pattern

Height of Top Wire & Number of Wires

With Steel Posts

Materials

1

The sizes stated for components are the minimum requirements and it is permissible to use larger sizes except where this would adversely affect the fit of the components or where replacement parts need to match those already present.

2

Line wire shall comply with BS 4102 and shall be one of the following:

3

Zinc coated low carbon steel with a nominal wire diameter of either 4.5 or 5mm

4

Zinc coated high tensile wire with a nominal wire diameter of 3.15mm

5

Plastic coated high tensile wire having a tensile strength of 1050 N/mm2 with a Zinc coated core of 3.15mm nominal core diameter and a 4 .0mm overall diameter.

6

Stirrup wire shall comply with BS4102 and shall be of zinc coated low carbon steel with grade A plastic coated low carbon steel and should have a nominal wire core diameter of 2.5 mm.

7

Barbed wire shall comply with BS 4102, shall be zinc coated and made from either low carbon steel or high tensile steel wire.

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12.4.2

QCS 2014

Section 06: Road Works Part 12: Fencing

Page 9

The materials, protective treatment, tolerances on size and general construction details of steel posts and struts, for strained wire fences shall comply with the requirements for chain link fences, except that components shall not be plastic coated unless specifically required under the contract documentation.

9

The materials and tolerances on precasting of all concrete components shall comply with the relevant parts of section 5.

10

The minimum concrete grade for posts shall be C25 and the minimum cement content should be 350 kg.

11

The mixing, placing and compaction of the concrete shall be as per Section 5.

12

All inserts and holes cast into precast concrete components with posts shall be adequate for the bolts or appurtenances to be fitted.

13

All holes shall be free from obstructions and accurately positioned.

14

The minimum grade of concrete to be used for posts shall be C25 and the minimum cover to embedded steel in posts shall be 50mm.

15

The dimensions of concrete fence posts and struts shall be as given in Table 12.4.

16

Posts shall be reinforced with 4 steel reinforcing bars of the size given in Table 12.4.

17

Straining posts and struts shall not be tapered.

18

The dimensions and details of the foundations shall be as shown in the contract drawings. Concrete for foundations for the bases of posts and struts shall comply with the requirement of section 5 of the specification and shall be grade C15.

19

Straining posts shall be provided with a firm bearing struts at a point within the top of the length of the string posts, measured above the ground level.

20

Straining posts shall be provided with holes for the attachment of straining fittings.

21

Where line wires are to be passed through them, struts shall be provided with either holes or slots.

22

Intermediate posts shall be tapered to 75mm x 75mm at the top and shall be holed to allow the attachment of line wires.

23

High bolt strain shall consist of bolts of 250mm overall length, not less than 9.5mm diameter with an eye at one end. They should be threaded and fitted with nuts and washers.

24

2 way eye bolt strainers shall be fitted with ring nuts. They shall be hopped and galvanised to BS EN ISO 1461. Widening brackets intended for attachment to the post shall be manufactured from mild steel flat not less than 25mm x 3mm and shall be fitted with a widening bolt 12mm minimum diameter with a friction type ferrule or ratchet winder.

25

Hair pin staples shall be of not less than 3mm diameter round wire or sectional wire of the same cross sectional area and shall have a zinc coating complying with BS EN 10244-2.

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QCS 2014

26

Section 06: Road Works Part 12: Fencing

Page 10

Droppers shall be at least 65 mm longer than the distance between the top and bottom wires covered by them and shall be made of steel of the section not less than 0.0066 kg/m or steel wire or galvanised in accordance with BS EN ISO 1461. Table 12.4 Concrete Fence Posts and Struts Strain Posts

Reinf. Dia.

Length

m

m

mm x mm

mm

m

0.90

1.57

100 x 100

1.57

1.05

1.72

100 x 100

1.87

1.20 1.35a and b 1.35c 1.80 2.10

1.87

125 x 125

2.02

mm x mm 100 x 100 or 125 x 125 100 x 100 or 125 x 125 125 x 125

2.02

125 x 125

2.17

125 x 125

2.17 2.62 2.92

125 x 125 125 x 125 125 x 125

2.32 2.77 3.07

150 x 150 200 x 200 200 x 200

Reinf. Dia.

Length

mm

m

qa

as

Section

Reinf. Dia.

1.98

mm x mm 75 x 75 or 100 x 75 75 x 75 or 100 x 75 100 x 75

8

2.13

100 x 75

6

10 12 12

2.13 2.73 3.03

100 x 75 100 x 100 100 x 100

6 8 8

5 or 8 5 or 8 8

ta

Section

1.50

mm

6

.

Section

.l. l

Length

Struts

1.83

rw

Intermediate Posts Height

6 6

Installation

1

Droppers shall be securely fixed to all the line wires covered by them and be of sufficient strength to maintain the spacing of the line wires and spread the load between them in use.

2

The post shall be adequately braced in both directions after insertion into the wet concrete and support shall be maintained till the concrete is fully hardened.

3

Excavation for foundations for post and struts shall be of the minimum stipulated dimensions at the base of the hole.

4

When erecting fence posts the concrete shall be placed in position before the commencement of the initial set.

5

The entire foundation hole shall be filled with concrete, the use of partly backfilled holes shall not be permitted. Straining posts shall be provided at the ends and corners of changes of direction or acute variations in level and at intervals not exceeding 150m for mild steel line wire or 300m for high tensile line wire in straight lengths of fence.

6

Struts shall be provided at each straining post.

7

Where there is a change in plan direction of the fence two struts shall be provided.

8

Intermediate posts shall be provided at intervals measured centre to centre of posts not exceeding 3.5m.

9

The number of line wires shall be as given in Table 12.3.

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12.4.3

QCS 2014

Section 06: Road Works Part 12: Fencing

Page 11

The top wire shall be secured with approximately 75mm below the top of the posts, each line wire shall be strained tightly and secured to each straining posts by either widening brackets attached to the post with fixing bolts or high bolt strainers passing through a hole in the post and secure with a nut and washer.

11

If barbed wire is specified it shall be attached to the straining posts and intermediate posts by the same method as the line wire.

12

Attachment to intermediate posts with the exception of the high tensile line wire for which stirrups are not permitted each line wire shall be secured to each intermediate posts by one of the following means;

13

A wire stirrup pass through a hole in the posts secured to the

14

a hairpin stapled post through a hole in the post and the ends twice bent over

15

A line wire pass through a hole in the post

16

Small areas of hot dipped galvanised coating damaged by welding cutting or by excessively rough treatment during the transit and erection shall be renovated either by the use of melting point zinc alloy repair rods or powders made specifically for this purpose or by the use of at least 3 coats of good quality zinc paint as per BS 4652. Sufficient material shall be applied to provide a zinc coating at least equal in thickness.

17

Droppers shall be attached after all wires have been strained and secured in position.

18

The interval between dropper and the posts or between adjacent droppers shall not exceed the following:

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10

For full length droppers 2m.

(b)

For sectional droppers, bottom wires 2m.

(c)

Top wires 2.5m.

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(a)

Where sectional droppers are used the ends of all droppers or adjacent levels of wire shall be fixed to at least one wire common to both levels.

20

When measured within 14 days of erection the settled tension in the line wire between straining posts at 100 m apart shall be at least 1.6 kN

21

The method of approximately measuring the tension shall be as described in appendix F to BS 1722-2.

12.5

PEDESTRIAN GUARD-RAIL

12.5.1

Aluminium Guard Rails

1

This Sub-section covers the requirements for the supply and installation of aluminium pedestrian guard-rails and accessories.

2

Guard-rails shall be constructed to the designated line and grade and shall not reflect any unevenness in the founding construction. Unless otherwise designated, railing posts shall be vertical. For bridges, railing shall not be placed on a span until centring or falsework has been removed, rendering the span self-supporting.

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QCS 2014

Section 06: Road Works Part 12: Fencing

Page 12

The foundation details for the fence shall be as per the designated details and dimensions.

12.5.2

Galvanised Steel Rails

1

Galvanised steel pedestrian guard rails shall comply with the strength requirements of BS 3049 Clause ‘A’ and shall be fabricated to the dimensions shown on the drawings from hot rolled steel section and bars to BS EN 10210-2 and BS 4360, Grade 43C.

2

The following Minimum steel section thickness shall be used: : :

2.5 mm 4.0 mm

Posts - Sealed hollow sections Other sections

: :

3.0 mm 5.0 mm

.l. l

Rails - Sealed hollow section Other sections

.

3

Joints shall be welded by metal arc welding to BS EN 1011 except where shown otherwise on the drawings.

4

The guard rails and components shall be fabricated such that no burrs or sharp edges occur, that the finished work is free from distortion and cracks and that welded joints are fully bonded, form accurate fit and are finished smooth and flush with adjacent surfaces.

5

The guard rail components shall be fixed to the posts at the lower joints by 12 mm diameter, 80 mm long galvanised steel bolts with one galvanised steel washer through 40 x 40 x 6 mm cleats. End units shall be purpose made to project over the posts with a rounded end.

6

Posts shall be closed at the top with a 6 mm plate having two 12.5 mm, 25 mm long dowels welded thereto. The holding down plate at the bottom of the post shall be a minimum of 20 x 100 x 6 mm thick.

7

All steel posts shall be hot dip galvanized both inside and outside to BS EN ISO 1461. “-end of specification addition.

12.5.3

Materials and Fabrication

1

Material for cast aluminium guard-rail posts shall conform to the requirements of AASHTO M193 and ASTM B108, alloy S7A - T4 (A444 - T4).

2

Aluminium alloy extruded rail shall conform to the requirements of ASTM B221 alloy, 6061-T6 or 6351-T5 with a minimum yield strength of 2466 kg/cm2, a minimum tensile strength of 2677 kg/cm2 and an elongation of 10 % in 50 mm.

3

Stainless steel hardware for aluminium railings shall be machine bolts or cap screws conforming to ASTM A193, grade B8, Class 2.

4

Stainless steel flat washers and lock washers shall conform to the requirements of ASTM A240, Type 302.

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QCS 2014

5

Section 06: Road Works Part 12: Fencing

Page 13

Material 12.7 mm thick or less may be cut by shearing, sawing or milling. Material over 12.7 mm thick shall be sawed or milled. Cut edges shall be true and smooth and free from excessive burrs or ragged breaks. Re-entrant cuts shall be filleted by drilling before cutting. Flame cutting will not be permitted. Material may be heated to a temperature not exceeding 240 °C for a period not exceeding 30 minutes to facilitate bending unless cold bending is required to retain the original mechanical properties of the material furnished.

6

Rivet and bolt holes shall be drilled to finished size or stub punched smaller than the nominal diameter of the fastener and reamed to size. The amount by which the diameter of a stub punched hole is smaller than that of the finished hole shall be at least one-quarter the thickness of the piece. The finished diameter of circular holes shall be not more than 7 % greater than the nominal diameter of the fastener. Slotted bolt holes to take care of expansion shall be provided as designated. Anchor-bolt holes may be up to 25 % greater

rw

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than the nominal bolt diameter with a maximum of 12.7 mm greater than the nominal bolt diameter. Installation

1

The Contractor shall co-ordinate and space the rail posts to miss any items which may be furnished and installed under this Contract. The Contractor shall also co-ordinate and space the rail posts to miss lighting poles and any other existing obstructions.

2

Where aluminium alloys come in contact with other metals, except stainless steel, the contacting surfaces shall be thoroughly coated with an aluminium-impregnated caulking compound, or a synthetic rubber gasket may be placed between the two surfaces. Aluminium alloys shall not be placed between the two surfaces. Aluminium alloys shall not be placed in contact with copper, copper base alloys, lead or nickel.

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12.5.4

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END OF PART

QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 1

13

TRAFFIC SIGNS, MARKINGS AND STUDS ................................................. 2

13.1

GENERAL ...................................................................................................... 2

13.1.1 13.1.2 13.1.3 13.1.4

Scope References Definitions for Reflective Traffic Studs Submittals

13.2

TRAFFIC SIGNS ........................................................................................... 3

13.2.1 13.2.2 13.2.3 13.2.4 13.2.5

Scope of Work Sign Foundations Traffic Sign Materials Installation Requirements for Traffic Signs Advance and far Advance Directional Signs

13.3

PAVEMENT MARKINGS ............................................................................. 10

13.3.1 13.3.2 13.3.3 13.3.4 13.3.5

Scope of Work Materials for Pavement Markings Application of Thermoplastic Performance Requirements and Testing Protection of Pavement Markings

13.4

TEMPORARY ROAD MARKING ................................................................. 14

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13.4.1 ROAD MARKING PAINT 13.4.2 ADHESIVE ROAD MARKING STRIP 13.4.3 REMOVAL OF ROAD MARKINGS

.

2 2 2 3 3 4 5 7 8 10 10 12 13 14 14 15 15

REFLECTIVE STUDS ................................................................................. 15

13.5.1 13.5.2 13.5.3 13.5.4

General Reflectors Reflectivity Installation of Reflective Studs

13.6

NON-REFLECTIVE STUDS ........................................................................ 19

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13.5

13.6.1 General 13.6.2 Materials and Manufacture 13.6.3 Installation

15 16 17 18 19 20 21

QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 2

13

TRAFFIC SIGNS, MARKINGS AND STUDS

13.1

GENERAL

13.1.1

Scope

1

This Part covers the supply and installation of traffic signs (complete with posts and foundations), thermoplastic road marking, road marking paint for temporary roads and diversions, reflectorised studs and non-reflective studs.

2

Related Sections and Parts: Traffic Signals

Section 5,

Concrete

rw

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This Section Part 16,

References

1

The following manuals and standards are referred to in this Part:

ta

13.1.2

qa

Qatar Traffic Control Manual

BS 381C .....................Colours for identification purposes

as

BS 873........................Road traffic signs

se

BS 1470......................Wrought aluminium for general engineering purposes; plate sheet and strip

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BS 1474......................Wrought aluminium for general engineering purposes; bar, extruded round tubes and sections

ov

BS 1490......................Aluminium and aluminium alloy ingots for general casting purposes BS 2000, Part 58 ........Determination of softening point of bitumen (ring and ball)

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BS 3262,(Part 1) l989 .Hot applied thermoplastic road marking materials

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BS 6088 1981.............Solid glass beads for Road Marking BS EN ISO 591-1 .......Titanium dioxide pigments

m

BS EN ISO 1461 ........Hot dipped galvanising ASTM A307 ................Steel anchor bolts ASTM C373 ................Standard test methods for water absorption ASTM C424 ................Test methods for crazing resistance CML 14-97..................Standard Method of test for determination of appearance, shape, dimensions and compressive strength of ceramic non-reflecting road studs. TRL Road Note 27 .....Skid resistance portable tester. 13.1.3

Definitions for Reflective Traffic Studs

1

Entrance Angle: The angle in the horizontal plane between the direction of incident light and the normal (perpendicular) to the leading edge of the stud.

QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 3

Observation Angle: The angle at the reflector between observer's line of sight and the direction of the light incident on the reflector.

3

Specific Intensity (S.I.): The candle-power of the returned light at the chosen observation and entrance angles for each foot candle of illumination at the reflector on a plan perpendicular to the incident light.

13.1.4

Submittals

1

Within three weeks of acceptance of the manufacturer's tender, the Contractor shall submit for approval working drawings for signs posts and base plates. Fabrication shall not begin until approval has been given.

2

The Contractor shall submit detailed drawings of the foundations proposed for traffic signs.

3

The Contractor shall submit samples of the proposed materials for approval on request by the Engineer before delivery to Site, at his own cost.

4

The Contractor shall submit to the Engineer for approval three copies of his working drawings for all traffic sign faces both in Arabic and English. Size and style of lettering shall be as designated. No order shall be placed without written agreement of the Engineer and the Concerned Authorities.

5

Before proceeding with drilling holes for sign foundations, the Contractor shall submit to the Engineer for approval; the type of plant proposed for drilling holes, details of any temporary metal casings, proposed method of concreting and the proposed method of conduit installation.

13.2

TRAFFIC SIGNS

13.2.1

Scope of Work

1

This work shall consist of furnishing and installing road signs and posts assemblies as designated. All sign faces and lettering shall be in accordance with the Qatar Traffic Control Manual. The required post sizes for different sign sizes shall be as tabulated in the Qatar Traffic Control Manual. Where in this section of the specification the term “designated” is used, this refers to the contract drawings and the Qatar Traffic Control Manual.

2

The minimum depths and sizes for sign foundations shall be as per the requirements of the Qatar Traffic Control Manual. For each of the signs the Contractor shall submit design calculations for the proposed foundations.

3

The following documents should be specifically referred to for this work;

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2

4

(a)

BS 873

(b)

Qatar Traffic Control Manual

Permanent traffic signs shall be reflectorised or non reflectorised illuminated and shall, in respect of quality, comply with the requirements of the latest editions of; (a)

BS 873

(b)

Qatar Traffic Control Manual

QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 4

In the case of conflict with these specifications and the above documents, the matter shall be referred to the Engineer.

6

All foundations, framing and fixings for information signs shall be suitable for local conditions. The design calculations shall be submitted to the Engineer for approval. The wind loads shall be calculated based on the wind speed provided in Section 1 part 1 clause 1.5.2.

7

A positive system of identification of signs, posts and all fittings shall be adopted. The reference number of the sign together with the date of manufacture shall be indicated by selfadhesive numbers on the reverse side of the sign in the bottom left hand corner and in a consistent and readily visible position on all posts and fittings. The manufacturer's name of trademark will not be permitted on the face of the sign. It may be affixed on the back of the sign, provided approval to the size and colour of the mark has been obtained from the Engineer. Any previously marked reference number should be transferred to new signs on replacement.

8

All road signs shall be guaranteed by the Contractor against any defect in material and workmanship for a period of five years from the date of completion of the Works under the Contract. If any defect should arise due to poor material or workmanship, it shall be rectified by the Contractor.

13.2.2

Sign Foundations

1

Sign foundations shall either be reinforced concrete columns in drilled holes or shallow reinforced concrete spread footings. The dimensions and details of the foundations shall be as designated.

2

The number of anchor bolts and bolt locations and anchor bolt dimensions shall be as designated. All anchor bolts nuts and washers shall be hot dipped galvanised to BS EN ISO 1461. Any protruding parts to the bolt thread or nut shall be further protected by the application of a wax or grease impregnated tape. Any conduit cast into the foundation for cable access shall be mild steel, hot dipped galvanised after fabrication to BS EN ISO 1461. The minimum bend of conduit shall be 600 mm radius.

3

All concrete and reinforcing steel used in the sign foundations shall be of the designated grade and type and shall comply with the requirements of Section 5. Anchor bolts shall 2 comply with the requirements of ASTM A307 with a minimum tensile strength of 414 N/mm .

4

Each bolt shall be supplied with two hexagonal nuts for levelling purposes complete with washers.

5

If an obstruction is encountered whilst drilling the foundation hole the Contractor shall inform the Engineer. The Contractor may elect to bore or drill through the obstruction depending on its nature or may propose to reallocate the signs slightly to avoid the obstruction subject to the approval of the Engineer. In either case the work is deemed to be included in the scope covered by this Part.

6

The sides of excavation shall be vertical and any additional excavations carried out beyond that designated, for the particular post and sign being erected, shall be filled with concrete or granular material as directed by the Engineer.

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QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 5

7

The reinforcement cage shall be securely fixed centrally about the axis of the foundation, any electrical conduit shall be securely fixed in position as designated before replacement of concrete.

8

The top of the concrete foundation shall be finished with a steel trowel to a smooth finish.

9

The top of the concrete foundation shall not extend more than 100 mm nor less than 50 mm above the finish grade level unless otherwise designated. All backfilling and compaction shall be completed before the erection of any sign on the structure.

11

All excavations shall be approved by the Engineer before the sign is erected and before backfilling with fill or concrete as designated.

13.2.3

Traffic Sign Materials

1

Sign plates shall be manufactured either from sheet aluminium to BS 1470, SIC - 1/2H, NS33/4N, NS-1/2H or HS 30-WP with a minimum thickness of 3 mm (11 swg) or from extruded aluminium plank sections to BS 1470, HE 9-WP, HE 9P or HE 30-WP or extruded aluminium alloy plank sections to BS 1474, HE 9 TE and HE 30 TF. However information signs shall be constructed in extruded aluminium planks, which will either be self-locking or rear fixing, and the aluminium shall be BS 1470, BS 1474 or BS 1490 or other approved equivalent International standard.

2

All sign plates shall have clean, smooth edges cut to the required shape of the sign, and shall be etched and degreased to the sign sheeting manufacturer's specifications before application of the sheeting.

3

Illuminated signs shall be covered with "Super Engineering Grade" reflective sheeting.

4

Reflective signs shall be covered over the whole front face with "High Intensity" reflective sheeting. The sheeting shall be of the designated colour and shall have a manufacturer's guarantee of not less than five years. The rear faces shall be non-reflective grey and should give a similar life span to the sign face.

5

The reflective sheeting shall be fixed to the sign plate either with a heat activated adhesive using vacuum applicator or with a pressure sensitive adhesive using a pressure roller in accordance with the sheeting manufacturer's instructions.

6

Sign faces shall be formed from a single piece of reflective sheeting, but if for any reason the sign face must be fabricated from more than one piece of material all joints in the material shall be overlapped by not less than 6 mm and where sheeting is applied to extruded

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10

sections it shall extend over the top and bottom edges of the sections by not less than 3 mm. No butt joints shall be permitted and in horizontal joints the overlap shall be from the top. 7

The corners of all direction signs shall be rounded to a radius of 75 mm.

8

Signs constructed of aluminium sheet shall, when recommended by the Traffic Signs Manual, be framed on all edges using hot dipped galvanised steel angle or angle-channel of equivalent section.

QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 6

Signs constructed from extruded aluminium plank sections are to present the same flanged appearance on all edges of the sign by fitting an aluminium end capping to the exposed ends of the plank section on both sides of the sign.

10

Where the designated sign width requires the use of more than one length of plank section, support beams shall be provided and positioned as approved by the Engineer.

11

For plank type signs supported on two posts the plank rails and support beams shall be manufactured from one length of extruded aluminium section. One tie bar shall be fitted between the bottom two plank rails (or the plank rail and support beam) at the centre of the span between the mounting posts.

12

Where plank type signs are supported on more than two posts, and the designated sign width is wider than the plank rail and support beams, the plank rail and support beam may comprise two or three lengths provided butt joints occur at an inner post. One tie bar shall be fitted between the bottom plank rail and support beam at the centre of the span between the mounting posts.

13

All stiffening and framing shall be continuous and shall prevent the sign from twisting.

14

All rivets or other devices fixing sign plates to their framework shall be of non-staining steel or other material approved by the Engineer and shall have a sufficient cross-sectional area to prevent failure from thermal stresses or wind pressure or such other stresses as may be designated.

15

All rivet and bolt holes shall be edge-sealed with clear lacquer after the application of the plastics sheeting.

16

Rivets shall be spaced at not more than l50 mm apart, around the outside edge of the sign plate and on cross braces the spacing shall be not more than 300 mm.

17

Any rivet brought through the sign face shall be coloured to match the sign face. Any rivet or other device fixing sign plates to their frame work shall have a protective washer of nylon or other approved insulating material inserted where they would be in contact.

18

All brackets, clips, screws, bolts, nuts and washers used for mounting sign plates to support posts shall be manufactured from stainless steel. For plank type signs, brackets and clips shall be extruded aluminium alloy section.

19

Saddles shall be aluminium alloy or other material approved by the Engineer and shall be provided with a nylon strip or other approved insulating material.

20

There shall be full adhesion of all sheeting material including letters, symbols and borders and there shall be no air bubbles, creases or other blemishes.

21

All panels, cut-out letters, numbers, borders, symbols and back grounds on reflective sheeting shall be carefully matched for colour at the time of sign fabrication to provide uniform appearance both by day and night. The sheeting manufacturer's recommendations on colour matching methods shall be observed. Non-uniform shading or undesirable contrast between reflective sheeting on any one sign will not be accepted.

22

The edges of all applied sheeting materials including edges of all plates which make up a sign, letters, symbols and borders shall be sealed as designated by the manufacturer.

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QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 7

Where required by the sheeting manufacturer the face of the sign plate shall have a coat of clear lacquer of a type designated by him.

24

The top of sign support posts shall be capped with a plastic cap.

13.2.4

Installation Requirements for Traffic Signs

1

All sign faces shall be of the designated type, colour and size.

2

Signs delivered for use in the project shall be in new and unused condition, except where otherwise designated; and shall be stored off the ground and under cover in a manner approved by the Engineer. Any sign damaged, discoloured or defaced during transportation, storage or erection shall be rejected.

3

The position and mounting height of each sign shall be as designated.

4

Designated post lengths are approximate only. When progress of the work is at the appropriate stage the Engineer will authorise the location of each sign, with the chainage and offset distance from the edge of the road pavement. The Contractor shall be responsible for determination of the exact post lengths to provide the designated vertical clearance. Field cutting of posts shall be performed by sawing. Welded posts will not be permitted.

5

All posts shall be erected vertically and where two or more posts are provided for any sign the faces of these posts shall be lined up and their deflection angle checked for compliance with this Part before concreting in.

6

For a period of 14 days after concreting in position, all posts shall be suitably braced to prevent movement. Sign faces should not be fixed to posts until after the bracing has been removed and the Engineer has inspected and approved the post stability and foundations.

7

All posts shall be of the designated type and shall be protected against corrosion by hot dip galvanising to BS EN ISO 1461.

8

Unless otherwise designated, all signs shall be erected so that the edge and face of the sign are truly vertical and the face is at an angle of 95  to the centreline; that is, facing slightly

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23

m

away from the centreline of the lane which the sign serves. Where lanes divide or are on sharp curves, the Contractor shall refer the orientation of the sign face to the Engineer for his instruction. 9

All sign supports shall be plumbed vertical.

10

The distance between the lower edge of the signs and the road surface shall be as designated.

11

Signs shall be fastened to sign supports in accordance with the designated requirements and the recommendations of the sign manufacturer to the satisfaction of the Engineer.

12

The Contractor shall at his own expense, immediately after erection and approval by the Engineer cover the sign in order to prevent misleading information being displayed. The covering shall be close weave hessian securely fixed over the face of the sign using a lacing of nylon cord so as not to damage the sign. The Contractor shall maintain such coverings in good order until receipt of the Engineer's instruction for their removal.

QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

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13

Signs shall be thoroughly cleaned immediately before being handed over. The type of detergent used shall be approved by the Engineer.

13.2.5

Advance and far Advance Directional Signs

1

The face of the sign shall be completely covered with 3M Diamond Grade or similar approved reflective material complying with the following Table 13.1A for retro-reflectivity. Table 13.1A Minimum Coefficients of Retro-Reflection 2

(b)

30° Entrance Angle

2

0.33°

0.5°

1.0°

430 350 110 45 20

300 250 75 33 15

250 200 60 25 10

80 65 20 10 4.0

0.33°

0.5°

1.0°

150 130 30 18 7

170 140 40 19 7

50 40 13 5 2.5

0.5° 35 30 10 3.5 1.5

1.0° 20 17 6 2.0 0.7

se

qa

Observation Angle

er

0.2°

235 190 60 24 11

1

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White Yellow Red Green Blue

.

0.2°

as

White Yellow Red Green Blue

1

.l. l

Observation Angle

rw

4° Entrance Angle

ta

(a)

(c)

90° Orientation, 40° Entrance Angle

2

Observation Angle

White Yellow Red Green Blue 1

0.2° 150 125 40 15 6

0.33° 85 75 25 8 4

1

Observation (Divergence) Angle – the angle between the illumination axis and the observation axis 2 Entrance (Incidence) Angle – The angle from the illumination axis to the retroreflector axis the retroreflector axis is perpendicular to the retroreflective surface.

QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 9

3

Values for screened red colour on white sheeting may be significantly lower.

2

The material also shall satisfy the requirements of the following Tables 13.1B & 13.1C with regard to colourimetric and photometric performance. Table 13.1B Chromacity factors 1

3

4

Limit Y (%)

Y

X

Y

X

Y

X

Y

Min

Max

White

.035

.305

.355

.355

.335

.375

.285

.325

40

-

Yellow

.487

.423

.545

.454

.465

.534

.427

.483

24

45

Red

.690

.310

.595

.315

.569

.341

.655

.345

3

15

Green

.030

.398

.166

.364

.286

.446

.201

.794

3

9

Blue

.078

.171

.150

.220

.210

.160

.137

.038

1

10

rw

.l. l

.

X

qa

ta

Colour

2

Table 13.1C Minimum Luminance Factors Factor 0.03 0.24 0.01 0.40 0.01

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Red Yellow Blue White Green

as

Colour

All plastic sheeting shall be fixed in accordance with the sheeting manufacturer’s instructions.

4

Unless otherwise agreed by the Engineer, sign faces shall be formed from a single piece of plastic sheeting.

5

Where, with the agreement of the Engineer, more than one sheet is used the number of sheets shall be kept to a minimum.

6

Only vertical and horizontal joints shall be permitted and all joints in plastics sheeting shall be overlapped by not less than 6 mm. The overlap on the horizontal joints shall be from the top; but joints in plastics sheeting shall not be permitted. The number of joints shall be kept to minimum.

7

Where sheeting is applied to extruded sections by pressure roller, it shall extend over the top and bottom edges of these sections by not less than 3mm.

8

All materials comprising the sign face, including the background, border and legends shall be carefully matched for colour at the time of sign fabrication to provide uniform appearance both by day and night. The sheeting manufacturer’s recommendations on colour matching methods shall be observed.

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QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

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Letter, numerals, symbols and borders shall be of material compatible with the sheeting to which they are applied. They shall be applied in accordance with the sheeting manufacturer’s instructions.

10

Sheeting materials including letters, numerals, symbols and borders shall be fully adhered with a pre-coated heat activated adhesive using a vacuum applicator equipped with a temperature controller and there shall be no air bubbles, creases, cracks or other blemishes. Application of the material shall be made using equipment specifically designed and manufactured for the purpose by the sheeting manufacturer and maintained according to his instructions. Where the sheeting manufacturer requires the assembly materials to be provided with a coat of clear lacquer, it shall be uniform and continuous. All lacquer shall be applied at the time of fabrication of the sign face and shall be of a type specified or supplied by the sheeting manufacturer.

11

Details of the graphic designs, Arabic and English legends to be used on directional and certain informatory signs are given on the Contract Drawings. The Contractor shall submit design drawings detailing the proposed layout of all such signs for the approval of the Engineer prior to their manufacturer. Otherwise, the signs shall be in accordance with the specified regulatory, warning and informatory signs detailed in the Qatar Traffic Manual, Volume 1.

13.3

PAVEMENT MARKINGS

13.3.1

Scope of Work

1

This Work shall consist of the supply and application of thermoplastic road marking paint for marking of the pavement as outlined herein. It shall include the marking of the centreline, the shoulder strip or edge, the barrier lines, the cross walks and any other markings required on the pavement for the control and direction of the traffic.

2

Where designated, thermoplastic road marking paint shall be used in the construction of rumble strips and jiggle bars. In such cases the requirements of this Part will apply except that the thickness and profile of the thermoplastic will be as per the designated details.

3

The pavement markings shall be painted on the road to the dimensions and in the locations designated on the drawings as per Qatar Traffic Control Manual.

4

The Contractor shall set out the markings and obtain the Engineer's approval before beginning the work.

13.3.2

Materials for Pavement Markings

1

The material used shall conform to the superimposed type British Standard Specification for Road Marking Materials BS 3262: Part 1. Where the materials do not conform to the BS the deviations shall be clearly given in reference to the relevant tables and paragraphs of BS 3262: Part 1.

2

Ballotini shall comply with the requirements of BS 6088.

3

The material shall consist of light coloured aggregate, pigment and extender, bound together with hard wearing resins, plasticised with oil as necessary in approximately the proportions by weight as Table 13.1.

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QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 11

Table 13.1 Composition of Thermoplastic Material

Composition

Aggregate

40 %

Ballotini

10 - 20 %

Pigment and Extender

20%

Binder

20 %

The Contractor shall be responsible for blending the material to ensure that the performance requirements of this part of the specification are met. This approximate composition of the material as indicated above shall include the sprayed on ballotini.

5

The grading of various ingredients shall be such that the final product, when in a molten state, can be sprayed on the surface at a nominal 1.5 mm thickness.

6

The aggregate shall consist of white silica sand, crushed calcite, calcined flint or quartz, or other approved aggregate, and the colour shall comply, with the requirements laid down in paragraph 4b of BS 3262: Part 1.

7

Ballotini incorporated in the mixture shall be reasonably spherical, and free from flaws and not less than 80 % shall be transparent glass. The grading of the ballotini shall be as stated in

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4

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BS 6088.

The pigment shall be titanium dioxide in accordance with paragraph 6a (I) of BS 3262: Part 1 and shall be not less than l0 % by weight of the mix.

9

The extender shall be whiting in accordance with paragraph 6b of Part 1 of BS 3262.

10

For yellow material sufficient suitable yellow pigment in accordance with BS 3262 shall be substituted for all or part of the titanium dioxide to comply with the performance requirements of this specification.

11

The binder shall not contain more than 5 % of resin or other acidic material. It shall consist

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8

mainly of hydrocarbon resins plasticised with mineral oil. 12

The resins used shall be of a colour at least as pale as Grade WG resin. It shall have an acid value not greater than 2, and must pass the heat stability test described below.

13

The oil used as plasticiser shall be a mineral oil with colour and viscosity as defined in paragraph 7a (ii) of BS 3262: Part 1; i.e., at least as pale as grade 4 on the P-R-S- Shellac and Varnish "A" Disc, and 1/2 to 3 1/2 poises at 25 C viscosity. In addition, when heated for 16 hours at 150 C it shall not darken excessively.

14

The softening point of the binder shall be used only as a guide to quality control, and the behaviour of the thermoplastic shall be judged from the performance tests described below.

15

The viscosity of the melted binder at the spraying temperature must be such as to produce a thermoplastic mix of the required spraying properties.

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Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

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The temperature limits imposed by BS 3262: Part 1 for materials based on resin shall not apply. Temperatures up to 220 C may be used; at these temperatures the material shall not discolour in the time required for its use. Containers shall be made of a material which does not contaminate the contents and will protect the contents from contamination.

18

The capacity of each container shall be not less than 25 kg or more than 100 kg.

19

Each container shall be clearly marked with the manufacturer's name, batch number and date of manufacture.

20

Testing for the composition of the material and the grading of the aggregate shall be carried out in accordance with the methods in BS 3262 except as modified by this part of the specification. The composition of the laid material as found on analysis shall comply with Table 13.2 & Table 13.3; Table 13.2 Proportion of Constituents

rw

.l. l

.

17

ta

Percent by Weight

qa

Constituent

as

Binder

Maximum

18

22

78

82

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Aggregate, pigment and extender and ballotini

Minimum

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Table 13.3 Grading of Combined Aggregate Pigment and Extender

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Sieve (mm)

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BS

Percent by Weight Minimum

Maximum

0.850

100

-

0.600

75

95

0.300

35

65

0.075

25

35

13.3.3

Application of Thermoplastic

1

Application shall be by mobile sprayer, either hand-propelled or self-propelled.

2

The road surface shall be dry, and free of loose, detritus mud, or other extraneous matter.

3

All existing markings of more than 1 mm thick shall be removed completely before new markings are applied.

4

A tack coat should not be necessary when the thermoplastic is applied to carriageways. Where it is considered necessary to use a tack coat, this shall be rubberised type recommended by the manufacturers of the thermoplastic material.

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Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 13

In addition to the ballotini included in the mix, an additional quantity of glass beads shall be sprayed on to the hot thermoplastic line at the time of application. The rate of application 2 shall be at the rate of about 0.5 kg/m .

6

The thermoplastic material shall be applied in intermittent or continuous lines of thickness 1.5 mm  0.3 mm.

7

For special lettering, arrows or symbols the material shall be applied by hand methods.

8

The finished lines shall be free from raggedness at all edges and be true in place with the road surface.

9

The upper surface shall be level, uniform and free from streaks, blisters, lumps and other defects.

13.3.4

Performance Requirements and Testing

1

The thermoplastic material shall meet the requirements of Table 13.4:

ta

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.

5

Property 3

qa

Table 13.4 Properties of Thermoplastic Material Maximum

2.0 approx. 230 95 65 45 No Slump 45

105 25 0.3 -

Testing of thermoplastic material shall be as described below. All specimens shall be prepared by carefully heating a representative sample to a temperature of (softening point + 50 C) whilst stirring thoroughly to avoid segregation. The molten material shall be used

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as

Density, g/cm Open flashpoint °C Softening point (ring and ball BS 2000 Part 58), °C Luminance Luminance (Yellow) Flow resistance Flow resistance after 48 h at 40 °C Abrasive wear 9/100 revs Skid resistance

Minimum

without delay. 3

Heat Stability Luminance Test: The material shall be cast on to a suitable flat, glossy surface coated with a colourless release agent to give a slab 100 mm square by 3 mm thick. The luminance of the cast face, with reference to that of a block of magnesium oxide (luminance factor l00) shall be measured with the sample illuminated by a tungsten light source at an angle of 45  viewed at right angles by a selenium barrier layer photoelectric cell.

4

Flow Resistance Test: The material shall be cast into a conical mould having an apex angle of 60  and a vertical height of 100 mm. After cooling and setting for 24 h the cone shall be removed from the mould, placed on a flat level surface and maintained at a temperature of 23 C ± 2 C for 48 h.

QCS 2014

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Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

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Impact Test: A 3 mm thick coating of material shall be prepared as a screed on a Monel alloy panel 1.25 mm thick, previously coated with rubberised bitumen emulsion. The impact instrument, a 4.7 kg weight, shall be dropped vertically through 250 mm on to the surface of the panel, striking the surface with a hemispherical indentor of radius of 6 mm. The panel shall be retained by a metal block drilled to allow the indentor to strike the panel, with the depth of indentation limited to 2 mm. Five panels shall be tested and no fracture shall result from impact. A crack not longer than 2 mm will be accepted provided there is a smooth indentation in the material.

6

Abrasive Test: A 3 mm thick coating of material shall be screeded on to a Monel alloy panel and subject to wet (water lubricated) abrasion at 23 C on a Taber Model 503 standard

7

rw

.l. l

.

abrasion tester using H-22 Calibrade wheels, refaced between tests. The loss in weight after two successive tests of 100 revolutions shall be recorded and the average taken as the abrasive wear. The abrasive wear shall be less than the figure in Table 13.4. Skid Resistance: A 100 mm wide line of material 1.5 mm thick shall be screeded on to a flat,

ta

level base for a minimum length of 800 mm. After cooling to ambient temperature the skid

as

qa

resistance shall be measured using the TRRL Portable Tester as described in Road Note 27. Measurements shall be made on different parts of the specimen, corrected for temperature effects, and the average recorded. Protection of Pavement Markings

1

The Contractor shall control the traffic in such a manner as to protect the freshly marked surface from damage. The traffic control shall be so arranged as to give minimum interference to the travelling public. Signs, barricades, flagmen and control devices shall be supplied by the Contractor and a system of spaced warning flags or blocks shall be used to protect the fresh marking until it has dried as required. Any lines, stripes or markings which become blurred or smeared by the traffic shall be corrected by the Contractor.

13.4

TEMPORARY ROAD MARKING

13.4.1

ROAD MARKING PAINT

1

The use of road marking paint shall be restricted to traffic diversions or for other uses as directed by the Engineer.

2

Road marking paint shall be by an approved manufacturer. It shall be suitable for applying by brush or mechanical means to cement, concrete or bituminous pavement to give a chemically stable film of uniform thickness and shall be chlorinated rubber, one pack epoxy or alkyd based.

3

White paint shall contain not less than 6 % by mass of titanium dioxide as a pigment,

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13.3.5

conforming to type A (anatase) or type R (rutile) specified in BS EN ISO 591-1 4

Yellow paint shall be standard colour BS 381C No. 355, except where an alternative shade has been designated, and contain not less than 6 % by mass of a suitable yellow pigment.

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Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 15

The paint shall be supplied fresh and ready for use in sealed containers and stored in accordance with the manufacturer's instructions. The paint shall be applied without the use of thinners or other additives.

6

Paint shall be applied at a covering rate recommended by the manufacturer and approved by the Engineer.

7

Where markings are to be reflectorised with ballotini it shall be sprayed uniformly on to the 2 wet paint film at the rate of 400-500 g/m . Ballotini shall be graded to comply with the requirements of BS 6088.

8

Road marking materials shall only be applied to surfaces which are clean and dry. Markings shall not be ragged at their edges and shall be uniform and free from streaks. Carriageway lane and edge lines shall be laid by approved mechanical means to a regular alignment.

13.4.2

ADHESIVE ROAD MARKING STRIP

1

For temporary diversions the use of self adhesive proprietary marking strips will be permitted.

2

Self adhesive proprietary road marking strips shall be of the details and dimensions shown on the drawings.

3

The strips shall have a metallic backing that peels of and shall have reflective properties by the incorporation of ballotini.

13.4.3

REMOVAL OF ROAD MARKINGS

1

Where it is necessary to remove existing thermoplastic road markings the material shall be completely removed by sand blasting or other abrasive methods.

2

Care shall be taken to avoid damaging the wearing course surface during this operation.

3

Any damage caused to the wearing course shall be made good to the satisfaction of the engineer.

4

The painting over of old road markings with black paint shall not be permitted.

13.5

REFLECTIVE STUDS

13.5.1

General

1

Reflective road markers shall be smooth, pressure moulded aluminium alloy, complying with BS 1490 with lenses to meet the performance requirements of this specification. They shall be capable of withstanding the climatic conditions of Qatar and be maintained free. A performance guarantee of five years is required.

2

The Road stud shall measure 130 mm x 115 mm x 25 mm when seated on the road surface.

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5

Exact size of the road stud shall be as designated. 3

The shaft shall be "Anti-Twist/Hot-Tite", 76 mm long.

4

The slope of the reflecting face shall be 20.

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Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 16

5

The enveloping profile of the head of road studs shall be smooth and the studs shall not present any sharp edges to traffic.

6

The body of the stud shall be constructed in one integral part.

7

The anchorage part of the stud shall consist of a circumferential ribbed shank with parallel flats, the flats on the alternative ribs being at 90  to each other to prevent rotation of the stud when located in the road surface.

8

The studs shall be constructed in aluminium alloy to BS 1490 to provide a robust and durable location for the lenses. The alloy shall have the characteristics listed in Table 13.5.

.l. l

-

0.1 13.0 0.6 0.5 0.1 0.1 0.1 0.1 0.5 Remainder

rw

Maximum (%)

se

as

qa

Copper Silicon Iron Manganese Nickel Zinc Lead Tin Titanium Aluminium

Minimum (%)

ta

Composition

.

Table 13.5 Composition of Alloy for Road Studs

Reflective studs mechanical and physical properties shall comply with the Table 13.6 requirements:

ov

9

er

The Contractor shall submit mill certificates for the material showing the actual composition.

et it

o

Table 13.6 Mechanical and Physical Properties of Reflective Studs

m

Mechanical Properties

0.2 proof stress test, N/m 2 Tensile Strength, N/mm . Elongation, mm

2

Physical Properties Specific gravity

Minimum 120 280 2-5 Minimum 2.65

Method of Casting

Injection

Corrosion rating

Excellent

Brinell hardness number

55 - 60

13.5.2

Reflectors

1

The reflectors shall be rectangular in shape. The rectangular reflective unit shall be firmly located into a recess within the body of the stud such that the reflective face is established at the correct orientation. A sample of the proposed reflective studs shall be submitted for the Engineer’s approval.

QCS 2014

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Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 17

The Optical Performance (specific intensity) of each crystal reflecting surface shall not be less than the values listed in Table 13.7. Table 13.7 Optical Performance of Reflectors Observation Angle, °

0.3

0.5

1.0

2.0

Entrance Angle, °

5

10

10

15

Specific Intensity

160

100

27

3

Specific Intensity

120

72

20

2

For yellow reflectors the specific intensity shall be 50% of the value for crystal. For red and green reflectors the specific intensity shall be 20% of the value for crystal.

4

The colour limits of the reflector(s) when illuminated by CIE standard illumination A, with an entrance angle V= 0 , H= 5  L or R, and an observation angle of 0.3  shall comply with the

rw

.l. l

.

3

ta

requirements given in the following paragraphs.

White (uncoloured) reflectors shall not produce a selective reflection; that is to say, the trichromatic co-ordinates X and Y of the standard illuminant A used to illuminate the reflector shall undergo a change of more than 0.91 after reflection by the reflector.

6

Red reflectors shall have chromaticity co-ordinates which lie within the area formed by the straight lines defined by the following pairs of points, 1 and 2, 2 and 3, the spectrum locus, and the line joint the ends of the spectrum locus:

er

Point 2 0.657 0.335

Point 3 0.730 0.262

Amber reflector shall have chromaticity co-ordinates which lie within the area formed by the straight lines defined by the following pairs of points, 1 and 2, 2 and 3, 3 and 4, and the spectrum locus:-

et it

o

7

Point 1 0.665 0.335

ov

Co-ordinate X Y

se

as

qa

5

m

Co-ordinates X Y

Point 1 0.330 0.385

Point 2 0.228 0.351

Point 3 0.321 0.493

Point 4 0.302 0.692

8

Compliance with the colorimetric requirements shall normally be verified by means of a visual comparison test. If any doubt remains after this test, compliance shall be verified by the determination of the trichromatic co-ordinates as defined in the proceedings of the 1951 meeting of the International Commission (CIE).

13.5.3

Reflectivity

1

A sample of the road stud shall be submitted by the Contractor and relevant technical information, catalogues supplied by the manufacturers shall accompany the sample.

2

The reflectivity of the stud when new shall well exceed minimum standard as laid down in BS 873 and meet typical values as shown below:

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Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 18

Table 13.8 White Reflectors Tested to BS 873

Orientation

CIL Value (mod/1x)

CIL Value (mod/1x)

Typical

Minimum

5-7.5 26.5-30 59-93 100-190

2 10 15 20

.l. l

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Table 13.9 Amber Reflectors Tested to BS 873

.

Observation angle 2  Entrance Angle 15  L and 15  R. Observation Angle 2  Entrance Angle 10  L and 10  R Observation Angle 0.5  Entrance Angle 10  L and 10  R Observation Angle 0.3 Entrance Angle 5  L and 5  R

Orientation

CIL Value (mod/1x)

Typical

Minimum

3-4 10-20 20-50 30-90

1.0 5.0 7.0 10.0

se

as

qa

ta

Observation angle 2  Entrance Angle 15  L and 15  R. Observation Angle 1  Entrance Angle 10  L and 10  R. Observation Angle 0.5  Entrance Angle 10  L and 10  R. Observation Angle 0.3  Entrance Angle 5  L and 5  R.

CIL Value (mod/1x)

ov

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Table 13.10 Red Reflectors Tested to BS 873

o

Orientation

m

et it

Observation angle 2  Entrance Angle 15  L and 15  R Observation Angle 1  Entrance Angle 10  L and 10  R Observation Angle 0.5  Entrance Angle 10  L and 10  R Observation Angle 0.3  Entrance Angle 5  L and 5  R.

CIL Value (mod/1x)

CIL Value (mod/1x)

Typical

Minimum

1.5-2.0 4.5-7 10-20 16-35

2.0 10.0 15.0 20.0

13.5.4

Installation of Reflective Studs

1

Reflective studs shall be installed and anchored to the pavement as follows: (a)

Drill a hole into the asphalt pavement to the dimensions recommended by the manufacturer. Ensure that the hole is free of dust and also the pavement surface within a radius of 200 mm of the hole is free from debris and dust.

(b)

Fill the hole to overflow with the two part epoxy adhesive of the type specified in clause 10.6.2.

QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 19

(c)

Immediately after pouring the grout, the road stud shall be inserted into the hole and the reflective face aligned to the oncoming traffic. The road stud shall be firmly embedded into the ground ensuring a good bed of grouting compound under the road stud and solid fixing. Protect the installed marker until the epoxy adhesive has completely set.

(d)

Clean off any surplus grouting and protect the road stud from traffic for approximately 60 minutes.

NON-REFLECTIVE STUDS

13.6.1

General

1

Non-reflective road studs shall be ceramic and of approximately 100 mm diameter at the base, the studs shall consist of a heat-fired, vitreous ceramic base and a heat fired opaque smooth matte surface.

2

The colour of the studs shall be white unless otherwise designated. The base of the stud shall have a rough surface to ensure a good bond to the road.

3

The adhesive used for the installation of non-reflective ceramic studs shall be a two part epoxy or other material recommended by the manufacturers and tested under the climatic and traffic conditions prevalent in Qatar.

4

The non-reflective ceramic studs shall conform to the dimensions and shapes shown on the drawings and shall be installed at the location indicated on the drawings or where designated by the Engineer.

5

The studs shall be ceramic manufactured and shall consist of a heat-fired, opaque, glazed surface. The glazed surface shall not be present on the bottom of the studs which will be cemented to the road surface. The outer surface of the studs shall be smooth except for purpose of identification, and all edges exposed to traffic must be convex and the radius nearest the edge may be less. Any change in curvature shall be gradual. The bottom surface of the marker shall be of a roughness comparable to at least that of a fine grade of sandpaper, and shall be substantially free form gloss or substance that may reduce its bond to the adhesive.

6

The body of the marker shall be white.

7

Brightness will be measured with equipment conforming ASTM E97 using a Brightness Standard of 75%. The minimum weight of the marker shall be 125 grams.

8

A random sample of 5 buttons shall be subjected to the compressive load test. The average compressive strength of the 5 buttons shall not be less than 680 kg and no individual button shall have a compressive strength less than 544 kg. The button shall be centered base down, over the open end of a vertically positioned hollow metal cylinder. The cylinder shall be 25.4 mm high, with an internal diameter of 76.2 mm and a wall thickness of 6.4mm. A load necessary to break the button shall be at speed of 2.5 mm per minute to the top of the button. In the event that the bottom of the marker is dimpled, a 2 mm layer of wood shall insert between the base of the maker and the hollow cylinder. Should any of the samples tested for strength fail to comply with this specification, 10 additional samples will be tested. The failure of any one of the additional samples shall be cause for rejection of the entire lot or shipment represented by the samples.’

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13.6

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Page 20

Materials and Manufacture

1

The studs shall be produced from a combination of intimately mixed clays, shales, flints, feldspars or other inorganic material which will ensure the required properties are met. All studs shall be thoroughly and evenly matured and free from defects which affect appearance or serviceability.

2

The studs shall be of uniform composition and free from surface irregularities cracks, chipping, peeling spoiling, crazing and any other physical damage. The studs shall be precast in the form of a single based spheroidal segment terminating in a rounded or squared shoulder.

3

The height of the studs above road level shall be between 18 mm and 20 mm.

4

Compliance of the studs with respect to appearance, shape, dimensions and compressive strength shall be determined in accordance with CML Method 14-97. In particular, they shall exhibit an average compressive load at failure for each sample of 5 studs of not less than 680 kg and no individual value shall be less than 544 kg. Furthermore, the water absorption shall not exceed 1.0% when tested in accordance with ASTM C373. And the glazed surface of the stud shall not craze, spell, or peel when subjected to one cycle of the Autoclave test at 250 psi when tested in accordance with ASTM C424.

5

The adhesive for reflective studs and non-reflective studs shall be a two component epoxy. Each component shall be supplied in separate clearly marked containers and the time of use the contents of the two parts shall be thoroughly redispersed by mixing. Only complete containers of each part shall be used and these shall be mixed thoroughly until a uniform colour is achieved with no streaks of individual colours. The blend of the two components of epoxy thoroughly mixed together shall meet Table 13.11.

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13.6.2

Property

Value

Gel time

5 to 30 minutes

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Table 13.11 Specification for Epoxy Adhesive

Minimum Tensile strength of 1.6 mm film between steel blocks cured 24 h at 21 °C tested at 21 °C

7 N/mm

Shore hardness on 24 h sample at 21°C

70 to 80

Shore hardness on 24 h sample at 49 °C

30 minimum

Deformation temperature, °C

49 minimum

2

6

The Contractor shall submit recent test results that confirm the above properties of the supplied adhesive are met.

7

The epoxy shall be used strictly in accordance with the manufacturer’s recommendation for storage preparation, mixing and application. Any differences from the manufacturer’s recommendations and this specification shall be referred to the Engineer.

QCS 2014

Section 06: Road Works Part 13: Traffic Signs, Markings and Studs

Page 21

The final colour of the epoxy adhesive shall be uniform grey unless designated otherwise.

13.6.3

Installation

1

All sand, dirt and extraneous material shall be removed from the mark location and the surface cleaned and abraded. Cleaning shall be by compressed air. In the case of adhering material the application of heat or sand blasting will be required.

2

The surface shall be completely dry for the application of the adhesive.

3

The base of the supplied stud shall be free of any wax or grease from the manufacturing process. Any such wax or grease shall be sanded off the bottom of the marker.

4

The adhesive components shall be stored at the temperature recommended by the manufacturer both before use and during application. The two components of the adhesive shall be added to each other just before use, any unused mixed adhesive shall be discarded when catallic actions cause stiffening and reduction of workability or balls of gelled resin formed in the container.

5

The mixed adhesive shall be applied to the prepared pavement area to be covered by the marker and the stud pressed onto the adhesive so as to squeeze out a small bead of adhesive around the periphery of the stud.

6

The Contractor shall carry out a trial outside of the permanent works to establish the approximate amount of adhesive required per marker and application on the works shall be carried out to this quantity.

7

The studs shall not be fixed to the pavement where asphalt has been laid within the last 14 days unless otherwise directed by the Engineer. The studs shall be spaced and aligned as designated or as per the Qatar Traffic Control Manual. The tolerance for placing shall be not more than  10 mm.

8

Where studs are to be applied to pavement where the road is to be opened to public traffic shortly after placing, the preheating of the roadway surface to permit a rapid set is permitted. In such cases, the procedure followed shall be as recommended by the supplier of the epoxy adhesive and as approved by the Engineer.

9

On roadway sections that are not opened to public traffic no preheating of the studs or road 2 surface is required as long as the required bond strength of 12 kg/cm can be achieved in

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less than 3 h.

END OF PART

QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 1

14

WORKS IN RELATION TO SERVICES ........................................................ 2

14.1

GENERAL ...................................................................................................... 2

14.1.1 14.1.2 14.1.3 14.1.4

Scope References Submittals Notification to Service Authorities & Statutory Bodies

14.2

SERVICES GENERALLY .............................................................................. 3

14.2.1 14.2.2 14.2.3 14.2.4 14.2.5 14.2.6 14.2.7 14.2.8 14.2.9

General Safety Marking Services Location of Existing Services Protection of Services Relocation of Services Services Ducts Excavation for Ducts Bedding and Laying of Ducts

14.3

PARTICULAR REQUIREMENTS .................................................................. 8

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2 2 2 3

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14.3.1 Qatar General Electricity and Water Corporation, Electricity Networks Affairs, QGEWC (ENA) 14.3.2 Qatar General Electricity and Water Corporation, Water Networks Affairs, QGEWC (WNA) 14.3.3 Telecom Provider 14.3.4 Qatar Petroleum (QP) and Qatar Gas 14.3.5 PWA, Storm water and Groundwater

3 4 4 5 5 6 7 7 8

8 10 10 12 13

QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 2

WORKS IN RELATION TO SERVICES

14.1

GENERAL

14.1.1

Scope

1

This Part includes the provision of new services and the seeking, protection, diversion and relocation of the existing services for the following service authorities:

General Earthworks Road Drainage

Section 1 Section 5 Section 20

General Concrete Drainage Works For Buildings

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Part 1 Part 3 Part 17

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This Section

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Related Sections and Parts:

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Qatar General Electricity & Water Corporation (QGEWC) Telecom Provider Qatar Petroleum (QP) and Qatar Gas Public Works Authority (PWA) Urban Planning and Development Authority (UPDA) Local Municipality

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14

References

1

The following standards and reference documents are referred to in this Part:

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BS 1377......................Methods of tests for soils for civil engineering purposes BS 2484......................Straight concrete clayware cable covers

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BS 2782......................Methods of testing plastics.

Submittals

1

The Contractor shall prepare and submit records and sketches showing position, levels and types of each existing service including manholes, joint boxes, inspection chambers and connections. These records shall be maintained in the form of a daily diary.

2

The Contractor shall prepare and submit shop drawings for utility protection work and obtain the approval of the appropriate Authority before beginning construction.

3

Samples of proposed ducts shall be submitted to the Engineer for his approval beforehand.

4

The Contractor shall prepare and maintain up-to-date drawings for each service authority giving details of each duct laid including precise location, level, number and type, and these drawings are to be submitted to the Engineer.

5

The Contractor shall keep accurate records of the arrangement, positions and details of all works constructed by him as Record Drawings. The details, format, extent and procedures for the preparation and submission of the record drawings shall be in accordance with Section 1.

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14.1.3

QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 3

Notification to Service Authorities & Statutory Bodies

1

All works in relation to services shall be carried out by a contractor or subcontractor prequalified and approved by the concerned service authority. Proof of such approval shall be required in writing before the start of Works on the Site. The name of any subcontractor to be used shall be as designated.

2

No work concerning services will be started without having first informed and obtained approval of the concerned service authorities. Before opening the ground for any purpose, the Contractor must notify all concerned parties by issue of formal "Notice of Intent" and must obtain information by formal notice regarding the location of all services. The complete responsibility for obtaining this information rests with the Contractor. "Notices of Intent" shall be circulated to all concerned parties including those listed in Clause 11.1.1:

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Qatar General Electricity & Water Corporation (QGEWC) Telecom Provider Qatar Petroleum (QP) and Qatar Gas Public Works Authority (PWA) Urban Planning and Development Authority (UPDA) Local Municipality

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14.1.4

Prior to commencing any work on excavation in a roadway the Contractor shall obtain the approval of the Traffic Police. All excavations in a roadway shall be carried out in accordance with PWA road opening procedures.

4

Drawings and notices shall be sent in duplicate one of which shall be retained by the addressee and the other returned to the sender duly marked to show underground services. "Notice of Intent" will be given 14 days in advance of starting the proposed Works. In the event that the work is not started within eight weeks of the date of the "Notice of Intent", it will be deemed to have lapsed. A further Notice of Intent will then be submitted. The Contractor shall furnish copies of the above Notices of Intent to the Engineer.

5

The Contractor's attention is particularly drawn to the procedures to be followed concerning existing services and service diversions laid down in all current administrative orders of the service authorities.

14.2

SERVICES GENERALLY

14.2.1

General

1

The Contractor shall acquaint himself with the position of all existing services and shall obtain clearance from the concerned service authority before commencing any work in a particular area. Written evidence of such clearance shall be provided to the Engineer by the Contractor.

2

The position, types of ducts, pipes, cables, manholes and related structures are designated, but the final location will be determined on site by the Contractor and submitted to the Engineer for approval after having consulted with the concerned service authorities.

3

All concrete works shall conform to the requirements of Section 5.

4

The Contractor will be fully responsible for ensuring observance of the requirements of this clause by his subcontractors.

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QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 4

Where any utility or service works are to be constructed under a separate contract by the Engineer within the Site and concurrent with the execution of the Works, the Contractor shall co-operate with the other contractor and shall co-ordinate his construction operations to avoid interference with the other contractor's operations.

6

Any public or private service for water, electricity, drainage, or other utility, affected by the Works shall not be interrupted without the written permission of the Engineer. Such permission will be withheld until suitable approved permanent or temporary alternative services have been provided by the Contractor or by the owner of the utility or his agents.

7

For temporary traffic diversions as may be required for the construction of road crossings, full liaison with the Municipality and Police shall be required as well as compliance with the requirements of the PWA road opening procedures.

8

The Contractor shall be responsible for following each service authorities inspection and testing procedures.

9

The Contractor shall be responsible for liaison with each service authority to obtain their approval for the completion of the works.

14.2.2

Safety

1

The Contractor shall be responsible for public safety during execution of work. He shall take all measures, including, where necessary, the provision of ropes, picket fences, and other temporary barriers on the sides of trenches and excavations with warning lights.

2

The Contractor shall arrange for night watchman and any other measures required to ensure the safety of the public.

3

The Contractor will be held responsible for any damage to property or injury to persons due to his negligence. Any instruction from the Engineer concerning the safety aspects of the work must be carried out immediately, but the Contractor shall remain responsible for the adequacy of the safety measures.

4

The Contractor shall take into account the current laws regarding the safety of service lines, together with any amendment or additions thereto. The Contractor shall be responsible for locating or verifying the location of existing services, liaison with the various service authorities and complying with the above.

14.2.3

Marking Services

1

All services shall be provided with continuous warning tapes with the requirements of the following paragraphs.

2

The Contractor shall install approved warning tapes during backfilling work over buried pipes, cables, conduits and ducts, as required. Warning tapes shall be coloured and inscribed for identification according to the requirements of the concerned service authority.

3

Warning tape shall be approved high quality, acid and alkali-resistant polyethylene film 250 mm wide, and with a minimum thickness of 150 microns. Tape shall have a minimum

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tensile strength of 125 kg/cm2 longitudinally and 105 kg/cm2 laterally with an elongation factor of 350 %.

QCS 2014

4

Section 06: Road Works Part 14: Works in Relation to Services

Page 5

Tape shall be printed with 50 mm high black lettering, alternatively in Arabic and English. The complete wordings shall be repeated every 2 m along the tape. The colours shall be vivid, glossy and permanent with a life expectancy of 40 years. Warning tapes shall be placed with the inscriptions facing upwards. The level of the tape relating to the top of service shall be in accordance with the requirements of the concerned service authority.

6

Warning tapes over non-metallic services shall be backed with aluminium foil to facilitate detection.

14.2.4

Location of Existing Services

1

The positions of all designated public and privately owned services have been based on the records of various service authorities and must be regarded as approximate.

2

The positions designated for existing services are for informational purposes only and do not necessarily show exact locations, depths, spacings, or the presence and location of smaller services such as house connections which are not normally designated.

3

The Contractor shall verify this information and satisfy himself as to the exact nature and position of all such apparatus. The Engineer does not guarantee the accuracy of the designated information, and no warranty is given or implied.

4

The Contractor shall verify the position of services by digging trial trenches and pits. If ducts, pipes, cables and manholes which are not designated are found, the Engineer and the concerned service authority shall be informed as soon as possible. The concerned service authority will then instruct on the action to be taken, if any.

5

The Contractor shall excavate by hand, take trial pits at regular distances and also at all road intersections to locate existing services, their number, depth and route direction. As these services are located the Contractor shall prepare record drawings indicating the aforementioned information which shall be submitted to the Engineer.

14.2.5

Protection of Services

1

The Contractor shall take any and all measures reasonably required by any public or concerned service authority for the support and full protection of all mains, pipes, cables and other apparatus during the progress of the Works, and shall construct and provide to the satisfaction of the concerned service authority, all works necessary for the prevention of damage or interruption of services.

2

The protection of the existing services shall be carried out before the earth work starts in the vicinity of the services to be protected.

3

If some services have already been protected by the various Departments, no protection will be carried out under this Contract, but such protection can be extended or upgraded as instructed by the Engineer on Site after having consulted with the concerned service authority.

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QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 6

If in the execution of the Works, by reason of any subsidence caused by, or any act of neglect or default of the Contractor, any damage to any apparatus or any interruption of, or delay to, the provision of any service is caused, the Contractor shall report it to the Engineer immediately and bear and pay the cost reasonably incurred by the service authority concerned in making good such damage and shall make full compensation to the authority for any loss, sustained by reason of such interruption or delay.

5

All protected services, existing ducts found or newly laid ducts shall be marked with markers of approved of size and type as designated. The location of markers shall be as designated. No asphalt course will be laid unless the ends of the ducts or protected services have been exposed and marked with markers.

6

The Contractor shall, at all times during the progress of the works, afford facilities to properly accredited agents of any concerned service authority for access to all or any of their apparatus situated in or under the site, as may be necessary for inspecting, reporting, maintaining, removing, renewing or altering such apparatus in connection with the construction of the Works or any other purpose whatsoever.

14.2.6

Relocation of Services

1

The Contractor shall relocate certain utilities to service reservation areas as designated. This work may only include constructing necessary protective housing such as box culverts, slabs, and concrete encased sleeves in the service reservation areas for utility lines to be relocated. Or this work may include necessary protective housing as described above and, in addition, the relocation of specific utility lines to the service reservation areas.

2

In both cases the Contractor shall complete the necessary survey to establish the lines and levels, prepare shop drawings and submit them to the Engineer for his review. The Contractor shall obtain approval from the concerned service authority before commencing this work.

3

After existing services, according to the Engineer's instruction, have been exposed and if according to the opinion of the Engineer and after approval of the concerned service authorities it is found necessary to proceed with the lowering or diversion thereof, the Contractor shall proceed with the relevant excavation in co-ordination with the said authorities.

4

The Contractor shall maintain records of such excavation in a form acceptable to the Engineer. Two copies of such records shall be submitted to the Engineer on a weekly basis or as agreed with by the Engineer.

5

All materials removed shall be disposed of by the Contractor as designated.

6

When directed by the Engineer, all such excavations shall be backfilled with suitable material, placed and compacted as designated.

7

The Contractor shall place fill material and compact with care to avoid damage to the existing services. The Contractor shall be responsible for any and all damages caused by his construction operations.

8

The works relevant to the lowering of existing services will be started as soon as, according to the Engineer, all the necessary precautions have been taken to prevent any injury to person or damage to property or services.

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QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 7

The excavation for lowering existing services shall be performed by hand down to the elevation indicated by the Engineer and the concerned service authority.

10

At all times the Contractor shall provide and maintain access to the adjoining properties to the satisfaction of the Engineer.

14.2.7

Services Ducts

1

Service ducts shall be provided as designated so that future services can pass through them without disturbing road construction.

2

The Contractor shall supply, unless otherwise designated, and install all the necessary service ducts required for the project. The duct material shall be as designated.

3

Road crossing ducts shall extend beyond the road or shoulder line at each side of the road as designated.

4

To prevent earth blocking the ducts, the openings at both ends are to be protected with appropriate blanking caps.

5

In general, all duct laying work is subject to the approval of the Engineer and any particular requirements of the concerned service authority.

6

The Contractor shall after completing each duct, make the necessary arrangements with the service authority for testing and acceptance of the work. As a minimum this shall involve the verification of the duct by rodding or pulling through a mandrel.

14.2.8

Excavation for Ducts

1

The trench shall be excavated to the designated width and depth.

2

When appropriate, the excavation for the road crossing and laying of ducts, concreting and related work shall only be carried out on half the width of the road at one time, the other half being left available for traffic. In this case the necessary traffic warning signs on selfsupporting tripods or cones shall be provided well ahead of the duct crossing work and all care and attention exercised to avoid risk of traffic accidents during preparation and execution of the work.

3

All trenches and other excavation shall be maintained in a dry condition and the Contractor shall arrange a suitable dewatering system for any dewatering involved, in agreement with the Engineer, to keep the working place clean and dry.

4

The sides of pits and trenches shall be vertical and adequately supported at all times. Excavations may if considered necessary be battered with a safe slope, but only with the Engineer's written permission.

5

Where ducts are laid under any area of the road construction, the bottom of the excavation shall be completed to a density of 95 % of the maximum dry density, as determined by BS

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1377 Test 13 or as otherwise approved by the Engineer. 6

Excavated material shall, if found unsuitable as defined in Part 3 of this Section, be disposed of to an approved tip and replaced with suitable material. All surplus suitable excavated material shall be used in road construction or disposed of in an approved manner.

QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 8

7

Where split ducts are required for existing services crossing the Works, hand excavation shall be carefully undertaken until the position of the service to be protected is fully exposed.

14.2.9

Bedding and Laying of Ducts

1

As soon as possible after trench excavation, ducts of the required diameter shall be laid and jointed as designated and in accordance with the manufacturer's instructions.

2

Ducts shall be laid to the designated lines and levels with the required depth of cover. Where the designated minimum cover cannot be achieved, or as otherwise directed by the Engineer, they shall be bedded and surrounded with 150 mm of grade 20 concrete.

3

Unless surrounded in concrete, ducts shall be bedded on a 150 mm thick layer of well graded

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above the duct barrel, well packed and tamped. Filling with suitable material above this level shall be free from large stones. For multiple ducts, the spaces between ducts are to be filled with compacted sand and the ducts surrounded to a depth of l50 mm above the uppermost

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layer. Trench backfill shall be compacted to the designated requirements. Ducts shall be cut by the Contractor as necessary only at right angles to their length using a saw in a simple cutting guide. The inside cut edges Shall be thoroughly rounded off or dressed before installation to prevent damage to cables drawn through the ducts.

5

In kerbed areas of new roadway duct markers shall be used. Duct marker shall be of concrete construction, in-situ or precast depending on the location, as per the designated details complete with approved abbreviation cast thereon. The finished product shall be solid in appearance, free of segregation, honeycombing broken edges and other defects.

14.3

PARTICULAR REQUIREMENTS

14.3.1

Qatar General Electricity and Water Corporation, Electricity Networks Affairs, QGEWC (ENA)

1

All of the works associated with electricity supply shall be carried out in accordance with the latest specifications for materials, excavation and backfill, cable laying and jointing, as issued by the QGEWC (ENA). Contractors are deemed to be in possession of the latest QGEWC (ENA) specifications.

2

All QGEWC (ENA) MV, HV and EHV works shall be carried out by a Contractor or subcontractor prequalified and approved by the QGEWC (ENA). Proof of such approval shall be required in writing before the start of Works on the Site, and the name of any subcontractor to be used shall be as designated. All cable jointers to be used on the Contract shall be required to undertake and pass a trade test conducted by QGEWC (ENA).

3

The Contractor shall comply with all requirements of the Police Department for marking, lighting and protecting excavation. It is the responsibility of the Contractor to ascertain the requirements of the Police Department and to comply fully with these requirements.

4

Where carriageway works and road crossings are performed the Contractor shall provide steel plates of sufficient size and quality to permit the safe passage of traffic and the plates shall be so placed (and if necessary fixed) to permit reasonable traffic flow.

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QCS 2014

5

Section 06: Road Works Part 14: Works in Relation to Services

Page 9

All doorways, gates and entrances shall be kept clear with full access. Where excavations impede pedestrian access crossing boards shall be provided. Crossing boards shall be 1250 mm wide with a handrail on both sides 1 m in height and guard-rails on both sides at vehicular and pedestrian access to premises. Ducts will not be installed at entrances to premises except on the express instruction of the Engineer.

6

Materials excavated shall be placed so as to prevent nuisance or damage. Where this is not possible, the material shall be removed from site and returned for backfilling on completion of cable laying. In cases where the excavated material is not to be used for backfilling trenches it must be removed from site on the same day as it is excavated.

7

QGEWC (ENA) will require to carry out inspections at the following stages: Completion of excavations.

(b)

Completion of bedding of trench before cable installation.

(c)

Cable installation.

(d)

Completion of surround over cables and installation of cable tiles.

(e)

Upon completion of reinstatement.

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(a)

The Contractor must not progress from one stage to the next of the above without the approval of QGEWC (ENA) and the Engineer. The Contractor shall be responsible for arranging inspections by QGEWC (ENA) to suit his programme of works.

9

Where materials are to be supplied by the Contractor, the requirements described in the following paragraphs shall apply.

10

Materials shall be ordered in accordance with the specifications issued by QGEWC (ENA).

11

For works involving the use of high voltage overhead cables Contractors shall comply with the requirements of QGEWC circular no 6.

12

Specifications and the details of the proposed supplier shall be submitted to QGEWC (ENA) for approval before a firm order being placed.

13

On delivery of materials to Qatar, QGEWC (ENA) inspectors shall be given the opportunity to inspect the materials before their use.

14

The Contractor shall supply all cables and jointing materials for the works unless expressed stated to the contrary in the contract documentation. Cleaning materials, protection tiles, warning tape, and other materials shall be supplied by the Contractor.

15

The Contractor is responsible for all liaison with QGEWC (ENA) in respect of programming the installation and commissioning of the complete electrical system. He shall ensure that QGEWC (ENA) are at all times kept informed of the current progress of the civil works on the Site and that his approved electricity supply subcontractor programs the cable laying works in the designated sequence in accordance with the approved programme.

16

The Contractor shall provide and install concrete cable tiles over all 66 kV cables. The cable tiles shall be of the designated size and form. Samples must be provided for approval by QGEWC (ENA) and the Engineer, and satisfy a test of impact strength in accordance with BS 2484.

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QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 10

17

For cables of 132KV and above the measures for protection of the cable shall be as per the requirements of QGEWC.

18

Cable tiles shall be installed over all 11,000 volt cables. Cable tiles shall be manufactured from recycled polyethylene or similar with a minimum thickness of 12 mm, length 1 m, width (minimum) 24 mm, tensile strength 8.40 N/mm2 as per BS 2782, Method 320 C. The tiles shall be marked as designated. The cable tiles must be supplied complete with any pins, pegs or other devices for jointing tiles together. Samples must be supplied to QGEWC (ENA) and the Engineer for approval before use.

20

The Contractor shall liaise directly with QGEWC (ENA) regarding the removal of existing cables and shall not, under any circumstance, commence removal of cables until QGEWC (ENA) have verified such apparatus as being redundant.

21

Removal of cable shall only be carried out in the presence of a QGEWC (ENA) engineer.

22

The Contractor shall arrange uplift of empty cable drums from QGEWC (ENA) Stores and shall return all recovered cables neatly coiled on the drums provided.

23

Ducts are to be supplied by the Contractor. They shall be of high impact resistant PVC of internal diameter 150 mm or 100 mm as designated, minimum wall thickness 3.6 mm (for

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150 mm) or 2.4 mm (for 100 mm). Samples must be provided for approval by the Engineer

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before use.

Qatar General Electricity and Water Corporation, Water Networks Affairs, QGEWC (WNA)

1

All of the works associated with water supply shall be carried out in accordance with the latest General Specifications for Main Laying Contracts and Main Laying Materials, as issued by the QGEWC (WNA) except as modified in this Part. Contractors are deemed to be in possession of the latest specifications.

2

All QGEWC (WNA) Works shall be carried out by a Contractor or subcontractor prequalified and approved by the QGEWC (WNA). Proof of such approval shall be required in writing before the start of Works on the Site and the name of any subcontractor to be used shall be as designated.

3

The supply of the materials required to carry out the Works shall be as designated in the contract documents. The Contractor will be responsible for the conveyance of all materials to the site of the works.

14.3.3

Telecom Provider

1

All Telecom Provider works shall be carried out strictly in accordance with the Telecom Provider Standard Specifications Telecom Provider WRK 4001 Underground Duct Laying And Associated Works. Contractors are deemed to be in possession of the latest version of the specifications.

2

All Telecom Provider works shall be carried out by a Contractor or subcontractor approved by Telecom Provider. Proof of such approval shall be required in writing before the start of Works on the Site and the name of any subcontractor to be used shall be as designated.

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14.3.2

QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 11

Telecom Provider will supply as 'free issue" all ducts for Road Crossings projects only. Other projects will be charged for the ducts. All other materials required for any type of project shall be supplied by the Contractor.

4

Trenches for Telecom Provider ducts through rock fill shall be lined with geotextile, complying with the requirements of Part 16, Geosynthetics.

5

The Telecom Provider specification S. 006 shall be modified as described in the following paragraphs.

6

The Supervising Officer shall mean the Civil/Cable Engineer from Telecom Provider, for the purpose of superintending the work, or, where the context permits, the representative of such officers.

7

The concrete quality classes specified in Clause 202 of the Telecom Provider specifications shall be of the comparable classes in Section 5 as designated by the Engineer.

8

Clause 105 of Telecom Provider Standard Specifications Telecom Provider WRK 4001 ‘Underground Duct Laying And Associated Works’ should be read as:

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“Backfill materials” means earth free from stone or loose earth, compacted in two equal layers above the protection dune sand, and shall not leave voids to form a water course.

105 (b)

“Sand bed and surround” means dune sand, 75 mm below, above and around the duct.

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105 (a)

The Contractor shall consult Telecom Provider not less than one month before it is proposed to commence work to ascertain whether any underground installations will be affected by the proposed works, in which event the Contractor shall make all necessary arrangements with Telecom Provider to safeguard the installations.

10

The Contractor shall give at least one week's notice in writing to Telecom Provider of the dates upon which it is intended to operate plant or equipment or carry out any work for which permission has been given in writing by Telecom Provider. Such operations of work shall only be carried out in the presence at Telecom Provider unless notice shall be obtained in writing from Telecom Provider that they do not require to be present.

11

Telecom Provider may require work to be executed on their installations during the period of the Contract. The Contractor shall allow access to Telecom Provider’s Contractor or workmen until their diversion work is complete. The Contractor shall co-ordinate the work of Telecom Provider and his own activities and when necessary shall amend his programme of working to suit all requirements of Telecom Provider in connection with their diversion work and shall keep the Engineer informed in writing of all arrangements made.

12

The Contractor shall locate and mark with suitable posts all Telecom Provider underground installations that are within the area of the Works and shall ensure that such markers are maintained in their correct positions at all times. The Contractor shall advise Telecom Provider’s agent of any installation not found where designated, or found but not shown or found damaged or subsequently damaged.

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QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 12

Qatar Petroleum (QP) and Qatar Gas

1

All of the works associated with Qatar Petroleum and Qatar Gas shall be carried out in accordance with their latest specifications except as modified in this Part. Contractors are deemed to be in possession of the latest specifications. Before beginning any work the Contractor shall approach Qatar Petroleum and Qatar Gas and obtain a copy of their latest specification relating to the Works.

2

All Qatar Petroleum and Qatar Gas Works shall be carried out by a Contractor or subcontractor prequalified and approved by Qatar Petroleum and Qatar Gas. Proof of such approval shall be required in writing before the start of Works on the Site and the name of any subcontractor to be used shall be as designated.

3

When working near existing QP Gas/Oil facilities the following conditions shall be adhered to. All notices to be given to the Contractor shall be in writing and delivered by hand.

4

A permit to work must be obtained for all work within fifteen (15) meters distance from all boundaries of existing facilities. These permits can be obtained from QP and twenty four (24) hours notice should be given to prevent delays.

5

Mechanical or hydraulic rock breakers shall not be used adjacent to gas, oil or NGL pipelines.

6

Should jackhammers be required within two (2) meters of any buried pipelines and between any pipelines running in the same easement all round pipe protection must be provided before commencement

7

Pilot holes to locate existing lines shall be dug by hand tools only, before allowing mechanical equipment to operate within five (5) meters of a QP live gas, oil or NGL pipelines.

8

Prior to exposure of any live pipeline the Contractor shall erect a suitable and substantial barrier to prevent any damage to QP pipelines. This is particularly important where there are heavy vehicles in the vicinity and the possibility that removal of the bond for trenching operations opens up an illegal vehicle crossing.

9

When backfilling an exposed section of pipeline, naturally occurring soft dune sand shall be used and the pipeline shall be covered and re-bedded all round with 150 mm minimum of sand. The remaining height of the bund will be made up of selected desert fill with particle size not exceeding 150mm from organic material. QP engineer shall witness the backfill work, particularly the soft sand bedding operations.

10

When trenching between pipelines in the same easement, vehicle access between the pipelines must be maintained.

11

The maximum length of exposed unsupported pipeline must not exceed seven (7) meters. When it exceeds five (5) meters, a central substantial wooden support shall be installed within a minimum 10 mm thick rubber “shoe” contacting the pipe.

12

When the bund is removed from any existing line its buried route shall be clearly indicated by pegs and warnings.

13

Any damage to the pipe external protecting wrapping caused by the Contractor will be repaired in strict accordance with QP procedures at the Contractor’s cost.

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14.3.4

QCS 2014

Section 06: Road Works Part 14: Works in Relation to Services

Page 13

Provision of a permit-to-work by QP does not release the Contractor from obligation of obtaining relevant permits to expose or work near utilities/facilities not under QP area of responsibility. Examples – QGEWC, Telecom Provider etc.

14.3.5

PWA, Storm water and Groundwater

1

This subclause of the specification covers; stormwater and groundwater drainage, foul water drainage and treated sewage effluent systems.

2

All of the material submission, inspection & testing, preparation of record sheets, preparation of record drawings for works associated with PWA shall be carried out in accordance with the requirements of this part of the specification.

3

Where it is necessary to make a connection to an existing water service this shall be in accordance with Part 14 of this Section.

4

Works shall be in accordance with the latest PWA standard details except as modified in this Part. Contractors are deemed to be in possession of the latest standard details. Before beginning any work, the Contractor shall approach PWA and obtain a copy of their latest specification & standard details relating to the Works.

5

All work shall be carried out by a contractor or subcontractor prequalified and approved by PWA. Proof of such approval shall be required in writing before the start of Works on the Site and the name of any subcontractor to be used shall be as designated.

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14

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END OF PART

QCS 2014

Section 06: Roadworks Part 15: Road Lighting

Page 1

ROAD LIGHTING .................................................................................................... 4

15.1 15.1.1 15.1.2 15.1.3 15.1.4 15.1.5 15.1.6

GENERAL ............................................................................................................... 4 Scope of Works 4 References 5 Approved Contractors 6 Supply of Materials 6 Programme of Work 7 Technical Requirements 7

15.2 15.2.1

APPROVAL OF EQUIPMENT ................................................................................. 7 General 7

15.3

STORAGE OF PLANT AND EQUIPMENT .............................................................. 9

15.4

SPECIAL REQUIREMENTS .................................................................................... 9

15.5 15.5.1 15.5.2 15.5.3 15.5.4 15.5.5 15.5.6 15.5.7 15.5.8 15.5.9 15.5.10 15.5.11 15.5.12 15.5.13 15.5.14 15.5.15 15.5.16 15.5.17 15.5.18

HIGH MAST LIGHTING ......................................................................................... 10 General 10 High Mast Column 10 High Mast Head Frame 11 High Mast Luminaire Ring 11 Multi Core Mast Rising Cable 12 Raising and Lowering Equipment 12 Raising and Lowering Winch System 13 Finish 14 High Mast Luminaires 14 High Mast Distribution Equipment 15 Aircraft Obstruction Light 15 Earthing and Lightning Protection 16 High Mast Foundations Construction Requirements 16 High Mast General Requirements 16 High Mast Approval 17 Maintenance Requirements 17 High Mast Portable Cage for Maintenance 17 High Mast Lighting Performance 18

15.6 15.6.1 15.6.2 15.6.3 15.6.4 15.6.5 15.6.6 15.6.7 15.6.8 15.6.9

LIGHTING COLUMNS ........................................................................................... 18 General 18 Design Criteria for Columns 18 Details of Column 18 Details of Bracket 19 Doors and Base Compartments for Columns 20 Details of Base Flange Plate 20 Details of Column Foundation 21 Passively Safe Lighting Columns 21 Decorative Lighting Columns 23

15.7 15.7.1

LIGHTING UNITS .................................................................................................. 24 General 24

15.8 15.8.1

CONTROL GEAR .................................................................................................. 25 General 25

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15

QCS 2014

Section 06: Roadworks Part 15: Road Lighting

Page 2

LAMPS .................................................................................................................. 25 General 25

15.10 15.10.1 15.10.2 15.10.3 15.10.4 15.10.5 15.10.6 15.10.7 15.10.8

LIGHTING SYSTEM FOR UNDERPASSES .......................................................... 26 General 26 Vehicular Underpass 26 Pedestrian Underpass 26 Animal Underpass 26 Lantern Construction for use in Vehicular, Pedestrian and Animal Underpasses 27 Underbridge or Undercrossing Lantern and Installation 28 Underpass, Underbridge and Undercrossing Lantern Control Gear and Lamps 29 Underpass, Underbridge or Undercrossing Isolating Box 30

15.11 15.11.1 15.11.2 15.11.3 15.11.4 15.11.5 15.11.6 15.11.7 15.11.8 15.11.9

LED LIGHTING UNITS .......................................................................................... 30 Lighting Units 30 Lighting Performance 31 Thermal Management 32 Testing 33 In Situ Temperature Measurement Test (ISTMT) 34 Control Gear 34 LED Lamps 36 Quality Criteria for LED Lighting 37 LED manufacturers data 38

15.12 15.12.1 15.12.2 15.12.3 15.12.4

OVERHEAD SIGN GANTRY LANTERN AND INSTALLATION ............................. 38 General 38 Sign Gantry Lantern 39 Sign Gantry Lantern Control Gear and Lamps 40 Sign Gantry Isolating (Safety) Switch, Conduit and Associated Cables 41

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15.9 15.9.1

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15.13 PHOTO ELECTRIC CONTROL CELL ................................................................... 41 15.13.1 General 41

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15.14 ROAD LIGHTING COLUMN CUTOUT / ISOLATORS ........................................... 42 15.14.1 General 42 FEEDER PILLAR ................................................................................................... 43 General 43 Cabinet 43 Components of Feeder Pillars 44

15.16 15.16.1 15.16.2 15.16.3

ROAD LIGHTING CABLES ................................................................................... 45 Underground Cables 45 Packing of Cables 45 Insulated PVC Sheathed Circular High Temperature (85°C) 46

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15.15 15.15.1 15.15.2 15.15.3

15.17 MARKER TAPE FOR UNDERGROUND POWER CABLES .................................. 46 15.17.1 General 46 15.17.2 Material & Quality 46 15.18 MARKER POSTS .................................................................................................. 46 15.18.1 General 46

QCS 2014

Section 06: Roadworks Part 15: Road Lighting

Page 3

15.19 EARTHING ............................................................................................................ 46 15.19.1 General 46

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TESTING AND COMMISSIONING ON SITE ......................................................... 53 General 53 Electrical Tests 53 Photometric Performance Testing 54

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15.21 15.21.1 15.21.2 15.21.3

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15.20 INSTALLATION ..................................................................................................... 47 15.20.1 General Requirements 47 15.20.2 Temporary Lighting 48 15.20.3 Removal of Existing Columns 48 15.20.4 Detailed Drawing for RCC foundation 49 15.20.5 Road lighting Column/Lantern Installation 49 15.20.6 Road lighting Feeder Pillar Installation 50 15.20.7 Road lighting Cable Installation 50 15.20.8 Road Crossing Ducts 51 15.20.9 Backfilling and Re-instatement 52 15.20.10 Road lighting Cable Terminations and Testing 52 15.20.11 Electrical Power Supply 53

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15.22 RECORD DRAWINGS .......................................................................................... 55 15.22.1 General 55

QCS 2014

Section 06: Roadworks Part 15: Road Lighting

Page 4

15

ROAD LIGHTING

15.1

GENERAL

15.1.1

Scope of Works

1

Work related to the road lighting installation provided for in this specification shall include the supply, installation, testing, commissioning and putting into satisfactory operation any or all of the following systems as required by the project drawings. Road lighting (L.V) cables and terminations.

(b)

Road lighting Feeder Pillar and internal associated control equipment including photocell control.

(c)

Road lighting column/lantern assemblies.

(d)

High mast lighting mast/lantern assemblies.

(e)

Roadway Lighting System control, adaptive, smart or remotely managed

(f)

Lighting network earthing, including electrical grounding.

(g)

Installation testing including lighting performance verification.

(h)

Provision of equipment technical and maintenance data.

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(a)

The Contractor shall provide the shop drawings and supporting calculations required by the specification, as well as the provision of all required supporting technical literature and samples in connection with the approval of proposed equipment.

3

The equipment supplied shall include all necessary items for a complete installation according to the specification requirements in order to provide for satisfactory operation, not withstanding errors and omission. The equipment listed in the Contract documents are, therefore, indicative and not limitative.

4

On satisfactory completion and commissioning of the lighting installation the Contractor shall be responsible for the maintenance of the whole system for a period of 400 days. This will include for the free replacement of any component or lamp that fails during that period of time. In addition, the Contractor shall be responsible for the rectification of any fault that occurs within the cabling network. As part of this rectification work no cable joints will be permitted.

5

All of the works associated with the road lighting installation shall be carried out in accordance with the "Regulations for the Lighting of Roads for Motorised Traffic" and the latest specifications issued by the PWA including The Qatar General Electricity & Water Corporation “KAHRAMAA” Regulations for the Installation of Electrical Wiring, Electrical Equipment.

6

The Contractor is deemed to be in possession of these regulations and the latest specifications.

7

The luminaire shall be suitable for connection to the low voltage single phase supply of the main network grid in The State of Qatar.

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QCS 2014

Section 06: Roadworks Part 15: Road Lighting

Page 5

15.1.2

References

1

The following standards and other documents are referred to in this Part: ANSI/IESNA RP-008 ..Roadway Lighting BS HD 60269-2 ..........Low Voltage Fuses. Supplementary requirements for fuses by authorized persons (fuses mainly for for industrial application) BS 302........................Specification for higher breaking load ropes BS 791........................Solid-stem calorimeter thermometers BS 1011......................Process of arc welding of carbon and carbon manganese steels BS 2484......................Straight concrete clayware cable covers BS 4343......................Plugs, socket-outlets and couplers for industrial purposes

.

BS 4360......................Weldable structural steels

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BS 4533......................Luminaires

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BS 4800...................Colour chart

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BS 5467......................Cables with thermosetting insulation for electricity supply for rated voltages of up to and including 600/1000 V and up to and including 1900/3300 V BS 5489......................Road lighting

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BS 5649......................Lighting columns

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BS 5486......................Low voltage switch gear and control gear assemblies

BS 5972......................Photoelectric Control Units for Road Lighting

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BS 6121......................Mechanical Cable Glands for Elastomer and Plastic Insulated Cables BS 6141......................PVC insulated PVC sheathed circular flexible cables

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BS 6346......................PVC-insulated Cables for electricity Supply

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BS 6360......................High conductivity stranded copper shaped conductor with XLPE insulation

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BS 6622......................Cables with extruded cross-linked polyethylene or ethylene propylene rubber insulation for rated voltages from 3800 / 6600 V up to 19 000 / 33 000 V BS 6746......................Extruded black PVC over sheath

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BS 6977......................Specification for insulated flexible cables for lifts and other flexible connections BS 7430......................Code of practice for earthing BS 7671......................Requirements for electrical installations BS EN 40.................Lighting Columns BS EN 295..................Vitrified clay pipes, fittings and pipe joints for drains and sewers BS EN 1011................Welding BS EN ISO 1461 ........Hot dip galvanized coatings on iron and steel articles BS EN1559-1 ............Founding. Technical conditions of delivery. General. BS EN1559-4 ............Founding. Technical conditions of delivery. Additional requirements for aluminium alloy castings. BS EN1676.................Aluminium and aluminium alloys. Alloyed ingots for remelting BS EN 10137..............Plates and wide flats made of high yield strength structural steels

QCS 2014

Section 06: Roadworks Part 15: Road Lighting

Page 6

BS EN 10210..............Hot-finished hollow sections BS EN 12767...........Passive Safety of Support Structures BS EN 60529..............Degrees of protection provided by enclosures BS EN 60898..............Miniature and moulded case circuit breakers BS EN 60947-3 ..........Air-break switches, air-break disconnectors, air-break switch disconnectors and fuse combination units for voltages up to and including 1000 V ac and 1200 V dc. BS EN 62305..............Protection against the lighting IEC 60598 ..................Luminaires for roadway lighting CIE 126-1997 ............Guidelines for minimizing sky glow.

.

EN62262:2002 ..........(IEC62262:2002) Degrees of protection provided by enclosures for electrical equipment against external mechanical impacts.

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The Qatar General Electricity & Water Corporation “KAHRAMAA” Regulations for the Installation of Electrical Wiring, Electrical Equipment and Air Conditioning Equipment.

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The Qatar Highway Design Manual (QHDM). Current edition.

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WEEE Directive (2002/96/EC). RoHS Directive (2002/95/EC).

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Institution of Lighting Engineers (ILE), Code of Practice for Electrical Safety

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Institution of Lighting Engineers (ILE), Technical Report No 7 ‘High Masts for Lighting and CCTV’

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ISO 9001, Quality Management Systems

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Institution of Electrical Engineers (IEE), Wiring Regulations

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State of Qatar, Qatar Wiring Regulations

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Approved Contractors

1

All road lighting works shall be carried out by a contractor or sub-contractor approved by the PWA. Proof of such approval shall be required in writing prior to the works commencing on site and the name of any sub-contractor to be engaged shall be entered in appropriate forms during tender submittal.

15.1.4

Supply of Materials

1

The Contractor shall supply all the materials required to carry out the Works as specified in the Contract Documents and Drawings. No materials will be supplied by the Owner or the PWA.

QCS 2014

Section 06: Roadworks Part 15: Road Lighting

Page 7

Programme of Work

1

The Contractor is responsible, with the agreement of the Engineer, for all liaisons with the respective department within PWA, in respect of programming the installation and commissioning of the complete road lighting system. In addition to the Engineer, he shall also ensure that relevant departments within the PWA are at all times kept informed of the current progress of the road lighting works on site and that his approved sub-contractor programme works are in the specified sequence in accordance with the overall approved Works programme.

15.1.6

Technical Requirements

1

All works carried out on the installation shall be in accordance with the requirements of these specifications so that their true meaning and intent are fulfilled. Minor deviations from the drawings may be made to accomplish this but no change shall be made without written approval of the Engineer and in consultation with the relevant departments within the PWA.

2

In addition to all the regulations, codes of practice and standards referred to within this specification, all the lighting and associated electrical works shall comply with the current Qatar wiring regulations and the requirements of PWA.

3

Where applicable, any associated work involving other authorities in the State of Qatar their relevant standards and specifications, as issued by them, shall be complied with.

4

All equipment and materials supplied for the project shall be manufactured in strict compliance with the latest standard of BS, IEC, EN their equivalent AASHTO or other standards and regulations specifically referred to in this specification. Here in after they are referred to as the “Standards”.

5

Acceptance tests shall conform to those referred to in the above mentioned “Standards”.

15.2

APPROVAL OF EQUIPMENT

15.2.1

General

1

All materials shall be approved by the Engineer. The Contractor shall be responsible to ensure that, where applicable, for nominated items of equipment only the type and manufacturer approved by the PWA, as detailed in their List of Approved Manufacturers are submitted for incorporation into the works. In addition, written approval must be obtained from the PWA, prior to ordering. Contractors shall note that only products with a proven record of performance, efficiency and long life will be considered for approval.

2

The Contractor shall not order any equipment for the incorporation into the Works before receipt of formal approval in writing. The approval procedure shall be as follows:

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15.1.5

(a)

The Contractor shall submit four copies of his equipment proposals to the Engineer. This submission shall be comprehensive and clearly state any manufacturer’s deviations from the specification. Manufacturer’s literature associated with the submission shall be originals and not photocopies. Specific reference to the compliance of certain specification requirements shall be identified.

(b)

The Engineer shall review this submission. The Engineer’s approval shall be as follows.

QCS 2014

Section 06: Roadworks Part 15: Road Lighting

Page 8

(i)

With the Engineer’s comments and recommendations attached, a copy of the submission shall be forwarded to the departments concerned within the PWA, to obtain their approval.

(ii)

Where minor deviations exist from the specifications but do not affect the performance of the equipment or installation the Engineer’s recommendations to accept such deviations, his approval together with a copy of the submission shall be forwarded to the departments concerned within the PWA, to obtain their approval.

(iii)

Approval shall be transmitted to the Contractor in writing once the approval of the relevant departments within the PWA, has been given.

All submissions shall give clear, unambiguous details and performance data of the equipment proposed, together with all supporting calculations where necessary. Clear catalogue identification references shall be provided. Documents shall be in English.

4

The Engineer reserves the right to direct the Contractor to provide equipment of a make and type that is essential to achieve the Contract design criteria.

5

Approval of samples by the Engineer in consultation with the relevant departments within the PWA, does not in any way relieve the Contractor of his contractual obligation in respect of the suitability of the equipment or their final performance once installed, and the co-ordination with all the elements of the lighting works into a fully operational installation.

6

After receipt of equipment the Contractor shall arrange for them to be examined and approved by the Engineer’s Representative in consultation with the relevant department within the PWA, prior to installation.

7

Column and Mast Fabrication Requirements

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3

Specific Requirements for Columns

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In paved or walkways areas Enclosure plate is required. The Enclosure plate shall be cast Aluminium or Galvanized steel, comprising two removal halves per base with size matching the base plate. It shall be painted to match pole finish. Provided with backup plate to one halve of Enclosure Plate and with tapped holes to accept stainless steel screws countersunk into other half of Enclosure Plate.

The gap between base plate and top of foundation shall be grouted. Means of discharging any accumulated moisture shall be provided at the pole base and provision shall be made for adequate drainage. 9

Testing and Factory Visits The contractor shall facilitate authorised Engineer representatives, and/or their appointed representative, to examine the test and manufacturing facilities and witness manufacturing processes and sample testing related to the luminaire and associated components submitted for evaluation, at no cost to Ashghal or their appointed representative.

QCS 2014

Page 9

Saving Energy Lamp’s Luminaire specification data sheet arrangement or each model of luminaire the manufacturer shall produce a data sheet providing a detailed and comprehensive description of the luminaires characteristics and component parts. The data sheet will contain adequate information for the reader to select and specify a particular model from the luminaire range. This will include; (a)

luminaire diagram external dimensions, weight and windage

(b)

optical arrangement (lens and reflectors types and settings)

(c)

driver type (drive current, system power consumption)

(d)

luminaire output (lm)

(e)

luminaire efficiency (lm/W)

(f)

glare rating

(g)

control and switching options (photocell, programmed stand alone, CMS, etc.)

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Section 06: Roadworks Part 15: Road Lighting

STORAGE OF PLANT AND EQUIPMENT

1

All plant and equipment shall be stored off the ground under weatherproof cover ready for incorporation in the works. All electrical apparatus shall be examined and cleaned before installation. All open conduit ends shall be fitted with plastic caps or suitable protective covering to prevent the ingress of foreign matter. All drums with cables shall be protected from direct sunlight.

15.4

SPECIAL REQUIREMENTS

1

All notices from the Contractor shall be in writing and delivered by hand.

2

The Contractor shall consult the Engineer not less than one month before it is proposed to commence work to ascertain whether any underground installations will be affected by the proposed work, in which event the Contractor shall make all necessary arrangements with the Engineer to safeguard the installation. It will be the Contractors responsibility to liaise with the utility authorities and to arrange for all road opening notices

3

The Contractor shall give at least one week's notice in writing to the utility authority’s Engineer of the dates upon which it is intended to operate plant or equipment or carry out any work for which permission has been given in writing by the utility authority’s Engineer. Such operations of work shall only be carried out in the presence of the utility authority’s Engineer unless notice shall have been in writing from the utility authority’s Engineer that they do not require to be present.

4

The utility authorities may require work to be executed on their installation during the period of the Contract. The Contractor shall afford all facilities to the utility authority’s contractors or workmen until their diversion work is complete. The Contractor shall co-ordinate the work of the utility authorities and his own activities and when necessary shall amend his programme of working to suit all requirements of the utility authorities in connection with their diversion work and shall keep the Engineer informed in writing of all arrangements made.

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15.3

QCS 2014

Section 06: Roadworks Part 15: Road Lighting

Page 10

The Contractor shall locate and mark with suitable posts all the utility authority’s underground installations that are within the area of the Works and shall ensure that such markers are maintained in their correct positions at all times. The Contractor shall advise the utility authority’s agent of any installation not found where shown on the Drawings, or found but not shown or found damaged or subsequently damaged.

15.5

HIGH MAST LIGHTING

15.5.1

General

1

This work shall consist of the supply, installation upon prepared foundations, connections, commissioning and putting into satisfactory service the high masts complete with the operating mechanisms, luminaire support ring or bracket, luminaries, control gear, wiring and distribution equipment.

2

The mast luminaire support ring shall be designed to provide for the appropriate distribution of lighting either in one direction or in many directions thus making it possible to concentrate the required number of luminaires on any zone and fix them rigidly in any direction desired. Prepared foundations are specified in other sections of this specification.

15.5.2

High Mast Column

1

The high mast column shall be of the height specified on the Drawings, hot dipped galvanized to BS EN ISO 1461 or BS 791 of multi-sided cross-section with a continuous taper made of formed sheet steel in accordance with BS 4360 grade 43C and electrically welded. They shall be delivered to the site in manageable sections of not greater than 12 metres and be joined by means of pressure over-lapping or slip-joints, which shall have a minimum length of 1.5 times diameter of the joint. Site welding will not be allowed.

2

The walls of the masts shall have a minimum thickness of 6mm for the base section, 5mm for the central section and 4mm for the top section. The steel used shall have tensile strength between 490 and 630 MN/sqm and minimum yield strength of 355 MN/sqm.

3

The mast cross-sections shall be so designed that once installed and fully equipped, it shall have safety factors in accordance with Technical Report No. 7 of the Institute of Lighting Engineers – London and shall be capable of withstanding wind load resulted from the wind speed provided in Section 1 Part 1 Clause 1.5.2, and blowing in the most unfavourable direction at a height of ten meters above ground level. Appropriate reinforcement shall be provided where necessary to increase the strength. Its behaviour under wind induced oscillation shall be such that it shall not fail due to fatigue and the design should ensure that these oscillations be damped to a minimum of zero.

4

The maximum deflection at the top of the mast shall not exceed 2.5% of the mast height at the minimum wind speed provided in Section 1 Part 1 Clause 1.5.2.

5

A steel flange plate of adequate thickness and free from laminations shall be welded above and below the base of the mast developing fully the strength of the section. In addition supplementary gussets shall be provided between bolt holes if deemed necessary.

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Section 06: Roadworks Part 15: Road Lighting

Page 11

An access door shall be provided in the base of the mast of adequate dimensions to permit clear access to the back plate installed for the mounting of the circuit breaker assembly and junction box, winch, etc. The backboard shall be made of steel or other non-hydroscopic material. The door shall be completely weatherproof fitted with a hidden hinge and a heavy duty lock. The door area shall have appropriate reinforcement.

7

A stainless steel earthing 12mm diameter bolt shall be welded inside the mast near the access door and shall be complete with stainless steel washers and nuts.

15.5.3

High Mast Head Frame

1

The head frame shall be hot-dipped galvanized steel attached to the mast by means of a steel slip-fitter and secured by at least four stainless steel set screws. It shall be composed of spun aluminium or other approved weatherproof cover, housing the required number of steel cable sheaves and associated accessories for the operation and powering of the luminaire ring.

15.5.4

High Mast Luminaire Ring

1

The high mast luminaire support ring or carriage shall be constructed of hot dipped galvanized steel channel fitted with the appropriate number of luminaires, lamp gear mounting brackets, wiring chamber and mounting plate. It shall be in two halves joined by bolted flanges to permit removal from the erected mast. The luminaire shall be mounted on the luminaire rings by means of either a specially designed bracket allowing it to be swiveled in any desired direction or rigid bracket arm assembly. It shall be possible to lock each luminaire firmly in position, thus preventing any rotation or falling while moving the luminaire ring.

2

The carriage assembly shall be arranged to locate firmly against stops when in the secure position and these shall be of adequate strength to ensure that they cannot be damaged by over winding of the winch.

3

A shaped protective aesthetic canopy, designed to give a coordinated appearance of head frame with the luminaire ring, shall cover the head frame.

4

For masts fitted with a mobile luminaire ring, rollers with a centering mechanism shall be provided to ensure a perfect alignment of the luminaire ring both axially and in azimuth, while ascending or descending the mast. Rollers shall be made of water resistant non-marking composition material with oil-impregnated bronze brushings. All shafts and washers shall be stainless steel.

5

A weatherproof wiring chamber or terminal box shall be provided constructed from a corrosion resistant material or aluminium alloy and installed on the luminaire ring. It shall be equipped with the high temperature shrouded terminal blocks and neutral bar or block and shall include facilities on the luminaire ring to allow testing of luminaires while in the lowered position. The wiring chamber shall be fitted with an earthing stud accessible from inside and out for earthing connections. The housing shall be completely weatherproof.

6

The cables installed in the luminaire ring connecting each luminaire to the wiring chamber shall be factory pre-wired avoiding the need for field wiring, and shall have single core copper conductors with neoprene or cross-linked polythene or approved equivalent insulation and 2 sheath. Cables shall be either single core or 3 core 2.5mm with copper conductors and colour coding of the different phases being in conformity with the relevant cabling standards.

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Section 06: Roadworks Part 15: Road Lighting

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Cables from the terminal box shall run in PVC duct or metal duct fixed to or within the luminaire carriage to each luminaire from the wiring chamber.

15.5.5

Multi Core Mast Rising Cable

1

The cable connecting the MCCB assembly at the base of the mast to the wiring chamber on the luminaire ring, shall be a flexible multicore copper cable with conductors and neoprene or approved equivalent high temperature resistant insulation and sheath in accordance with BS 6977.

2

The colour coding of the different phases of the cable shall conform to the relevant cable standards. Each luminaire shall have its own neutral conductor connected to the neutral bar or block.

3

The mast cable shall consist of a circular multi core cable to BS 6977 600/1000V grade. Each conductor core shall be insulated with ethylene propylene rubber (EPR) and the complete core is sheathed with heavy duty polychloroprene (PCP).

4

A multicore electrical power cable shall be provided terminating in the base compartment with a special multi-pin plug and socket coupler fitted with a guard, and at mast head connected to the wiring chamber fixed to the luminaire ring. It shall be suitable for the bending, flexible and load carrying stresses involved.

5

The cable shall be fitted with a correctly rated multi pin weatherproof plug and socket within the base compartment of the mast which will enable the cable to be disconnected before lowering the luminaire carriage. The socket must be connected to the supply side of the circuit and may either be free cable coming from the fuse box or be fixed to the fuse box in the base compartment.

6

The wiring shall be such that the plug and socket can be isolated before disconnecting.

7

The cable shall be suitably restrained to prevent its own weight from causing the terminal box to energise the lanterns.

15.5.6

Raising and Lowering Equipment

1

The pulleys located within the headframe shall be of non- corrosive cast aluminium alloy material grooved to exactly suit the steel rope and cable diameters, and fitted with stainless steel shafts. The pulleys shall be housed in a chassis integral with a sleeve, which slopes over the top of the mast and is secured axially and in azimuth. The complete chassis assembly shall be hot dipped galvanized. A guard is to be provided for the separation of the wire rope and power cable before entering in the pulley and the locating of the steel wire rope and power cables in their groves when operating either loaded or slack. An arrangement shall be provided to ensure that the electric and steel cables are separated before passing over their respective pulleys, and close fitting guides shall ensure that the cables cannot disengage the pulley during operations.

2

The luminaire carriage shall have the provision made on it for supporting and gripping the weight of the supply cable without damage of the cable sheath.

3

The luminaire ring shall be supported by 3 steel ropes coupled to 2 steel ropes and suspended from the double drum winch by means of a manufactured steel coupling unit. A divider bar shall ensure the separation of the steel ropes during raising and lowering.

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An MCCB providing overload protection shall be incorporated to stop the ring when the effort required by the winch becomes superior to the nominal load.

9

The winch shall be fitted with suitable equipment to allow the winch to stop in a safe manner, without damage to the mast finish, in the event of a supply failure to the power tool. The winding mechanism should then be capable of being operated by hand.

10

Each winch supplied shall be uniquely identified. In addition it shall have its own individual test certificate recording the safe working load. Lubrication details shall also be permanently recorded on its housing for future maintenance purposes.

15.5.8

Finish

1

All welds shall be smooth with the splatter removed and the interior and exterior surface of the mast and ring shall be cleaned by pickling or blasting and shall be free of any grease.

2

All components shall be hot dipped galvanized by total immersion in a bath of molten zinc after completion of the fabrication. No further levelling up, finishing or modifications shall be carried out after completion of the galvanizing process. The minimum thickness of zinc coating shall be 450 gm/sqm on the inside and outside surfaces of the mast and ring. The galvanizing shall conform to BS EN ISO 1461.

3

Any damage to the galvanizing shall be rectified during erection by wire brushing the affected area and treating with an approved zinc restorative. Sufficient materials shall be applied to provide a zinc coating at least equal in thickness to the galvanized layer.

4

If required by the Engineer the underside of the flange plate and internal surface of the mast to a height of 0.5m shall be given a coat of heavy duty bitumen paint prior to erection.

15.5.9

High Mast Luminaires

1

The high mast luminaire shall have a ‘cut off’ distribution. It shall be of the side entry mounting type, with toughen a flat glass protector and integral control gear suitable for the operation of either a 400W with lumens per watt rating of no less than 48,000, or 600W with lumens per watt rating of no less than 88,000, 220-240V, 50Hz. High Pressure Sodium tubular lamp of E-40 base, as defined for the contract.

2

The luminaires to be adopted shall be high performance street lighting lanterns currently used for conventional roadway lighting routes to BS 5489 or equivalent suitable for use at a mounting height of 25 or 30 metre. It shall comply with IEC 60598 or other approved equivalent norms. The body shall be made of die-cast aluminium and shall be divided into two separate compartments.

3

The first compartment of the luminaire shall house the optical system with polished and anodized pressure aluminium reflector. The second compartment shall contain the electrical accessories (control gear) cable feed terminals and side entry mounting socket. This separation shall protect the electrical accessories from the direct radiant heat emitted by the lamp. The optical compartment shall be protected by a toughened flat glass protector and shall be dust and watertight to a protection rating of IP65.

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4

The access to the optical compartment shall be by tilting the protector frame around the hinge without tools. A heat resistant gasket fitted on the frame shall ensure the tightness of the optical compartment. The accessories such as ballast, ignitor, and capacitor shall be rewired and pre-assembled by a metallic plate that is mounted and fixed into the rear compartment. Special care shall be taken to allow easy maintenance and quick replacement of the accessories and to minimise the risk of falling.

5

The cable feed terminal and the earth-screw shall be fixed to the metallic compartment, a cable holder shall be mounted near the terminals. The side entry mounting sockets should accept a 125 mm. long spigot and 50 mm diameter OR adjustable from 42 to 60 mm dia. Exterior side of both compartments should be with grey colour in finish.

15.5.10 High Mast Distribution Equipment The high mast base compartment shall be fitted with a power control and distribution assembly installed in a pre-wired weatherproof box opposite the access door inside the base of the mast.

2

The assembly shall consist of a surface mounted sheet steel weatherproof box with a cover enclosing:

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One 3-pole main 60Amp MCCB together with a neutral link for luminaire circuits. The ratings of the MCCB shall be in accordance with the QGEWC regulations and suitable to the connected load and cable.

(b)

One single pole 20 Amp MCB with neutral link for each luminaire circuit of a suitable current rating.

(c)

One-pole MCCB with neutral link connected to the incoming supply and serving a 16A250 V DIN socket outlet complete with 3-pin plug to suit the raising and lowering mechanism.

(d)

A multi-pin plug and socket outlet with guard fitted with cable outlet for connection to the multi-core electric power cable provided from the MCCB to the luminaire ring wiring chamber.

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The MCCB’s shall be de-rated and calibrated to provide over-current and short circuit protection when used in an ambient temperature of 50oC and shall have the required breaking capacity. The incoming side of the triple pole MCCB with the neutral links shall be fitted with a 4-way, line-tap type terminal block, with each terminal capable of accepting 2 x 2 35mm copper conductors.

4

The multi-pin coupler for supply to the portable raising and lowering power tool shall be connected to the MCCB via a flexible connection to ensure accessibility.

5

Where an high mast assembly supplies a ground sign lighting unit or equivalent it shall be equipped with an additional 15 Amps circuit breaker to supply the sign lighting installation. The circuit breaker shall be installed inside the mast distribution box.

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15.5.11 Aircraft Obstruction Light 1

Where required by Civil Aviation Authorities, two red luminaires within cast aluminium bodies shall be fitted at the top of each high mast attached to the movable luminaire ring with a purpose made bracket and arranged to project through the canopy.

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Section 06: Roadworks Part 15: Road Lighting

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2

The luminaires shall be provided with a change over relay such that, in the event of lamp failure, the second lamp is automatically connected. Lamps shall be GLS Rough Service 100 watt suitable for an E.S. (E27) lampholder.

3

The obstruction lights shall be wired on a separate circuit protected by a separate SP & N circuit breaker with terminals to accept separate incoming cables.

15.5.12 Earthing and Lightning Protection All masts shall be provided with a separate system for earthing as a protection against lightning. This shall comply with BS EN 62305.

2

High masts shall be equipped with an air terminal of the correct height to provide the required zone of protection for the mast head frames and fixtures. The air terminal shall be bonded to the mast to ensure the discharge is dissipated via the earth ground terminal without damage to the steel winch ropes or electrical cables.

3

Separate earthing shall be provided for each item of control equipment within the mast assembly and connected to a central earthing point.

4

A 12mm diameter stainless steel or brass stud with nuts and washers in the base compartment connected to the main body of the mast structure shall be provided.

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15.5.13 High Mast Foundations Construction Requirements High masts shall be installed on concrete bases as detailed on the Drawings. The foundation design and construction shall be as based on the high mast manufacturers recommendations according to the ground and climatic conditions that exist at the site location. The erection of high masts and the assembly of the luminaire, head frame with raising and lowering gear shall be carried out strictly in accordance with the manufacturers’ instructions. The Contractor shall before commencement of the construction work confirm by means of structural calculations that the foundations proposed are suitable for use with the high mast installation he proposes to install. Holding down bolts and plumb adjustment nuts, washers, locknuts or nyloc nuts shall be galvanized steel or cadmium plated.

2

The holding down bolt/nuts complete with the anchor plate for casting into the foundation shall be provided by the high mast manufacturer together with a mild steel anchor bolt template with tube holes to ensure correct vertical and precision made horizontal bolt alignment.

3

The anchor bolts shall be of guaranteed performance high tensile steel.

4

All buried external surface of the high mast foundation shall be protected by brush painted tanking membrane and hard board protection.

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15.5.14 High Mast General Requirements 1

Final setting and adjustment of the luminaires shall only be carried out after all the masts along a route, junction or interchange are complete and operational.

2

Each high mast metal work shall be bonded to a separate earth rod as indicated on the Drawings and also to the separate earthing cable connected to the distribution system earth bar.

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The high mast shall be of specified height carrying luminaires as indicated on the Drawings. Each luminaire shall be fitted with the specific lamp or lamps arranged to be separately oriented to give the correct illumination at designated locations along the road surfaces.

15.5.15 High Mast Approval For the approval of the Engineer before manufacturing commences the Contractor shall submit detailed calculations and supporting data to show that the mast meets the design criteria detailed and shall include the following information: The deflection at the top of the mast at the designed wind speed.

(b)

The neutral frequency of the mast.

(c)

The critical wind speed for resonance.

(d)

The damping characteristics of the mast.

(e)

The steel stressed under resonant conditions.

(f)

The acceleration at the top of the mast under resonant conditions.

(g)

Welding procedure.

(h)

Procedure to ensuring that the flange plate is not laminated.

(i)

Details of the joints between the mast sections and between the bottom section and the flange.

(j)

Details of the base compartment with the method of reinforcement at the door area and means adopted for making the door weather and tamperproof.

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15.5.16 Maintenance Requirements

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The following items must be provided for the Engineer at the time of the commissioning of any high mast assembly: Power tools – 1 No.

(b)

‘L’ hooks – 6 No.

(c)

Operating handles – 2 No. Foundation Bolt/Nut and Head frame Nut/Bolt Spanners – 2 No. Sets.

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15.5.17 High Mast Portable Cage for Maintenance 1

The high mast system shall incorporate a mobile luminaire ring such that it is suitable for utilising a purpose made portable cage for maintenance purposes.

2

The cage shall be obtained from the high mast supplier and shall be capable of carrying two persons plus servicing equipment.

3

A safety system shall be provided for use with the cage according to the manufacturer’s recommendations. One safety cage per project shall be allowed within the pricing structure offered by the Contractor for the future use of the Engineer.

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15.5.18 High Mast Lighting Performance 1

The Contractor must provide guaranteed lighting performance data as part of his technical submission to confirm the minimum light values that will be maintained at each location and where specifically identified by the Engineer or representatives from the relevant departments within the PWA.

2

The minimum light levels that must be obtained shall be: Horizontal illumination Diversity Factor (Ave/Min)

30 LUX 4:1

LIGHTING COLUMNS

15.6.1

General

1

All columns and brackets shall be produced by ISO 9001 certificated lighting column manufacturers registered and certified for the manufacture, supply and certification of lighting columns under their quality assessment schedule.

2

All columns of the same mounting height and with the same arrangement shall be identical in construction.

3

Road lighting columns shall be hot dip galvanized steel, octagonal, multisided, tubular and stepped shape, of height as detailed in the Contract specification and drawings, complete with bracket of outreach, number of arms and of shape all again as detailed in the Contract specification or on the drawings.

15.6.2

Design Criteria for Columns

1

For all columns and masts the stress and deflection calculations shall be based on the maximum bracket and luminaire projection, on the bracket arm, with projected area, length and weight as designated.

2

In still air conditions, loaded with the designated luminaire positioned in any of the variable locations, there shall be no appreciable deflection of the column.

3

The maximum permissible deflection in the column or mast shall be 1° in any 1m length with

4

Columns must be designed to withstand the wind force.

5

The "K" factor for columns over 8 m in height shall be 2.2.

6

Columns shall be designed to support lanterns with the data given by the Engineer.

15.6.3

Details of Column

1

The column shall be made from hollow sections to BS EN 10210 in steel to BS 7613 grade 43C or any approved equivalent norms. The hollow sections shall have a minimum tensile strength of 430 N/mm² and minimum yield strength of 255N/mm².

2

Columns shall be in one piece tubular (round), stepped shape or multi-sided sheet steel and be of the flanged (bolted) type.

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Columns should be designed in accordance with BS 5649 in steel and finished with hot dip galvanized internally and externally with no other treatment in accordance with BS EN ISO 1461 or equivalent.

4

The jointing of the column shall be carried out by reducing the diameter of the base section to form an interface fit with the bore of the upper section. The upper section shall be heated and pushed over the lower section. The thermal shrinkage shall ensure a complete bond over the full area of the joint and develop the full strength of column at the transition. The final operation is to weld the lower section to the upper section and dress the weld to a smooth profile. Welding shall be carried out in accordance with BS 1011.

5

Strengthening shall be provided at the door opening. Care shall be taken to ensure that rounded edges are provided at the corners of the door opening to avoid stress concentrations.

6

The top of the column should be designed and provided as suitable to fix the bracket arm collar with the top of the column as shown in the Contract drawings.

7

All dimensions for the column shall be in accordance with the latest requirements of the PWA, and, if applicable, as detailed on the drawings. Modifications to suit the particular foundation/support details proposed by the manufacturer shall be submitted to the Engineer for approval prior to incorporation.

15.6.4

Details of Bracket

1

Brackets shall be formed of hollow sections to BS EN 10210 in steel to BS EN 10137 Grade 43C or equivalent.

2

The column bracket arms and spigots shall be so designed that when assembled with the shaft the design altitude of the arm and projection shall be as detailed in the contract requirements.

3

Welding on bracket arm shall be carried out in accordance with BS EN 1011.

4

Brackets shall be hot dip galvanized to BS EN ISO 1461 or equivalent. The bracket arm shall be so designed that when assembled on the column shaft the altitude of the arm and spigot shall be 5° above the horizontal unless otherwise stated in the Contract documents.

5

Length of the luminaire fixing spigot unless otherwise designated to suit the luminaire shall be 150mm, outside diameter of spigot shall be 42mm, thickness shall, be 4mm.

6

The securing arrangement of the bracket arm to the column shall be positive so as to ensure that the arm does not rotate and shall be such that the bracket can be fixed in any of four 90 degree positions in relation to the column door opening. 8 No. socket set screws of size M10 x 16mm or approved equivalent arrangement shall fix the bracket onto the columns using stainless steel screws.

7

The luminaire shall be securely fixed to the mounting post or bracket by means of a clamping system that will prevent movement in high winds. All component parts shall be manufactured from non-corrosive materials.

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Doors and Base Compartments for Columns

1

Each column and mast shaft shall have a base compartment large enough to offer easy access to the equipment therein.

2

The weatherproof door provided for each opening which shall be interchangeable between columns of the same mounting height. To avoid accidental spillage of water from irrigation of flooding the bottom of the door shall be at least 0.5m above the top of the foundation.

3

A stainless steel durable non-corroding tamper-proof lock device shall be provided of the triangular headed screw type, unless designated otherwise. Where applicable, door lock recess shall incorporate adequate drainage such that they are unlikely to become blocked and so form a water trap.

4

Door openings are to be kept to the minimum size consistent with the cable termination units and any control gear.

5

When installing lighting columns on a single carriageway the column doors shall be located at 90° to the kerb line and in such a location that the maintenance operative faces the oncoming traffic and to ensure that the door can be opened at all times without encroaching onto the highway. In the case of installing lighting columns within the central median the column door shall be located perpendicular to the road such that the maintenance operative will be facing across the line of the carriageway. The door openings shall be free from any irregularities and burrs.

6

Keys are to be provided with the first consignment of columns at the rate of 10 % of the total number of columns.

7

A baseboard of non-hygroscopic hardwood, minimum thickness 15 mm, shall be securely fixed in each compartment and shall be of sufficient size to accommodate the cable termination unit.

8

Single purpose earth terminals shall be provided in a readily accessible position, preferably on the left hand side of the opening and on the column door.

9

The baseboard shall be fixed using brass or stainless steel nut and bolt arrangement.

10

All door lock hinges and catches shall be greased before handover.

15.6.6

Details of Base Flange Plate

1

The base flange plate shall be manufactured from steel plate that is free from laminations. The main shaft of the pole shall penetrate the full depth of the base plate and is to be welded above and below using a semi automatic MIG shielded arc process. Additional strength shall be provided by gusset plates located between hole positions.

2

4 No. slots allowing for adjustment shall be provided in the flange plate of suitable size so as to accommodate the foundation bolt specified to fix the column on the RCC foundation.

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Details of Column Foundation

1

The manufacturer of the road lighting column shall submit the dimensions and specification of his proposed foundation including the steel reinforcement details to the Engineer for approval.

2

The foundation shall accommodate 4 No. holding down bolts of size 25mm x 800mm for columns up to 10 metres high and 33mm x 900mm for 12 and 16 metres high columns, supplied with two nuts and two washers to each bolt.

3

Foundations shall be constructed such that they avoid being a hazard to pedestrians and bicyclists on footways and shared use paths. The top surface of concrete column foundations on pathways shall not be higher than ground level, and shall not be higher than 50 mm above ground level on all other surfaces.

15.6.8

Passively Safe Lighting Columns

1

Design Criteria

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15.6.7

All Passively Safe lighting Columns shall comply with BS EN 12767 – Passive safety of support structures for road equipment – requirements, classification and test methods, 2007 or all road lighting columns within the clear zone (as AASHTO Roadside Design Guide Table 3.1 or Chapter 10 Roadside Safety Urban or Restricted Environments) shall be protected by an approved barrier system.

(b)

Each Passively Safe Lighting Column shall be anodized aluminium or galvanized steel as specified in the Contract Documents. Design of aluminium columns shall comply with BS EN 40, Part 6 and its incorporated references. Design of steel columns shall comply with BS EN 40, Part 5 and its incorporated references.

(c)

In addition to section 15.6.2-1 the passively safe columns in still air conditions, loaded with the designated luminaire positioned in any of the variable locations, there shall be no appreciable deflection of the column. The maximum permissible deflection for passively safe poles shall not exceed 4% of the total length of the pole when furnished with bracket arm, and 2% of the total length of pole with no bracket arm. Columns must be designed to withstand a base wind speed of 30 metres/second. Columns shall be designed to support lanterns with the data given by the Engineer.

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(a)

(d)

Per BS EN 12767, Annex F, passively safe tubular hollow section steel or aluminium posts provided shall have a nominal diameter less than or equal to 89 mm, and a nominal wall thickness of 3.2 mm. Where steel poles are specified in the Contract Documents, steel grade S355J2H shall be provided.

(e)

Aluminium columns shall be finish coated with an anodized aluminium finish providing resistance to fading, peeling, cracking or corrosion. The guarantee provided by the manufacturer shall be a minimum of 10 years against fading, peeling, cracking or corrosion of the finish.

(f)

The maximum mass of combined luminaire support and fixtures attached to breakaway supports shall be limited to 450 kg and the maximum column height shall not exceed 18.0 metres.

(g)

Where slopes are greater than 6:1, no passively safe support shall be used without the approval of the Engineer. Passively safe supports shall not be used on any columns mounted on median barriers, concrete or otherwise. No slip base mechanisms may be used on Qatar roadways.

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Section 06: Roadworks Part 15: Road Lighting

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Columns shall be certified by the manufacturer to comply with BS EN 12767 and shall achieve the Passive Safety Performance Classes as indicated in Table 15.1. Table 15.1 – Passive Safety Performance Classes

Pole Support Requirement Roadway Posted Speed

CBD Other

100:HE:1-3 100:NE:1-3

CBD – Central Business District

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Term Descriptions

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Where columns may fall on other carriageways below (i.e. flyovers).

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(a) 70:HE:1-3 (b) 100:HE:1-3 (c) 70:LE:1-3 (d) 100:LE:1-3

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≤ 40 kph

˃ 40 kph

Impact Speed Class*/ Energy Absorbing Type / Occupant Safety Level**

Location

100:HE:1-3

HE – High Energy Absorbing LE – Low Energy Absorbing NE – Non-Energy Absorbing

Certification of breakaway support shall be collected from the manufacturer and submitted for Engineer approval prior to procurement. Certification documentation shall confirm the Impact Speed Class, Energy Absorbing Type and Occupant Safety Level of the supplied luminaires.

The column shall be rated to support Cloth Banners up to the length, width and height as required in the Contract Documents. Each column shall be provided with a 240V earthed outlet rated for outdoor conditions in compliance with Section 21 Part 10.2.2 herein.

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* Poles shall be procured in order of class per availability from the manufacturer. ** The Occupant Safety Level (OSL) provides for increasing levels of safety by reducing impact severity. The preferred level of safety is OSL 3 and shall be procured as first choice when available from the manufacturer.

(b)

3

When required by the provisions of the Contract Documents, all poles, whether aluminium or steel in type, shall be supplied with a frangible element or breakaway base tested and certified to provide passive safety elements as to be in compliance with BS EN 12767, with special attention to National Annex (informative) to BS EN 12767:2007.

Lighting System Requirements (a)

Work related to the Passively Safe Lighting Column installation provided for in this specification shall include the supply, installation, testing, commissioning and putting into satisfactory operation all systems as required by the Contract Documents and the Specification.

(b)

Electrical connections for lighting columns shall be quick disconnect type at ground level, such that they provide for electrical isolation within 0.4 seconds upon impact of the lighting pole, and be furnished as required by BS EN 12767:2007 NA.8.

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(c)

Prior to procurement, the Contractor shall provide shop drawings and supporting calculations required by the Specification, as well as the provision of all required supporting technical literature and samples in connection with the acceptance of proposed equipment approved by Ashghal’s authorized representative.

(d)

Due to the long lead times of such equipment, the Contractor shall order the poles within 1 week of shop drawing approval. The equipment supplied shall include all necessary items for a complete installation in accordance with the Specification and other Contract Documents in order to provide for specified luminaire operation.

(e)

Contractor shall provide all necessary accessories, wiring and equipment from lamp to base, feeder pillar to last luminaire, to complete a functional lighting system regardless of their inclusion in the Contract Documents.

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Lighting Columns (i)

The Passively Safe Lighting Columns shall be procured from an Ashghalapproved manufacturer. The manufacturer shall submit no less than three references for contact on past performance, supplying previous installed contract’s contact person, title, agency or company name, phone number and e-mail address to Ashghal Design’s and Ashghal Operation and Maintenance’s authorized representatives as part of the approval process.

(ii)

Columns shall be constructed with their anchor bolts at no more than 100 mm above ground level. Anchor bolts furnished with the column support shall be galvanized steel or stainless steel in type.

Luminaire

(c)

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Each luminaire fitted on the Passively Safe Lighting Columns shall meet all illumination requirements set forth by Ashghal and the photometric specifics as outlined in the Contract Drawings.

Foundations

Contractor shall submit the dimensions and specification of proposed foundations for support of the Passively Safe Lighting Columns. Drawings and specifications shall be prepared and sealed by a licensed structural engineer. The structural engineer shall provide certification that the proposed foundation design supports the performance of the breakaway mechanism, and is designed properly to prevent movement or rotation in the surrounding soil.

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Section 06: Roadworks Part 15: Road Lighting

15.6.9

Decorative Lighting Columns

1

Decorative lighting systems are non-standard, themed luminaire and pole styles. The luminaires range from ornate globes known as acorns to four-sided glass fixtures having a distinct character. The luminaires are mounted on the decorative lighting columns in a postmounted arrangement or with a bracket arm. The Contractor shall coordinate final decorative lighting column and foundation placement with the Engineer to avoid problems related to the placement of trees, other street furniture and underground utilities.

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Each Decorative Lighting Column shall be anodized aluminium or galvanized steel as specified in the Contract Documents. Design of aluminium columns shall comply with BS EN 40, Part 6 and its incorporated references. Design of steel columns shall comply with BS EN 40, Part 5 and its incorporated references. Galvanized steel columns shall be supplied with aluminium cladding sufficient to provide the decorative features when detailed as such in the Contract Documents.

3

Galvanized steel columns shall be supplied with aluminium cladding sufficient to provide decorative features when detailed as such in the Contract Documents.

15.7

LIGHTING UNITS

15.7.1

General

1

Road lighting luminaires (light fitting) shall be semi cut-off or cut off and side entry mounting type complete with bowl and integral control gear of rating 100W, 150W, 250W, or 400W, 220-240V, 50Hz as specified in 15.9.

2

All types of lamps shall be energy saving lamps (LED (light emitting diode), Induction lamps) manufactured according to International Electrotechnical Commission IEC or International Standards, and accepted or approved by Qatar Standards.

3

The luminaires for roadway lighting shall be to IEC 60598 and shall be capable of achieving the lighting performance specification requirements set out in the Contract specification in accordance with BS 5489 , EN 13201 and ANSI/IESNA RP-008 at the mounting heights identified within the Contract.

4

Luminaires shall be side entry mounting and semi cut-off or cut off type with integral control gear for use with either 1x 100W, 1x 150W or 1 x 250W, 220- 240V, 50Hz, high pressure sodium tubular lamp of E-40 base. The E-40 lamp shall have a porcelain skin. The lamp supports shall ensure that the lamp position in respect of the optical system remains fixed throughout its operation. The body shall be made of die cast aluminium and shall be divided into two compartments. The first compartment shall house the optical system with a pressed high purity one piece aluminium reflector that is anodized and polished. The positioning of the reflector shall be such that should it nsslished. Tt lector

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Section 06: Roadworks Part 15: Road Lighting

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The accessories such as ballasts, starters, capacitors etc., shall be pre-wired and preassembled in the rear compartment on a detachable metallic gear tray fixed securely to the main body of the luminaire in such a way as to ensure effective earth continuity.

6

Special care shall be taken to allow easy maintenance and quick replacement of the accessories and to minimise the risk of falling.

7

The incoming cable feed terminal block and the earth-screw shall be fixed to either the gear tray or metallic compartment. A cable restraining device shall be mounted near the incoming terminal block. All metal parts shall be effectively earthed to the luminaire earth-screw that shall be readily visible and accessible once access is obtained to the rear compartment. The spigot entry socket of the luminaire shall be compatible with the column bracket and able to accept a 125mm long by 50mm diameter or adjustable from 42mm to 60mm diameter spigot.

15.8

CONTROL GEAR

15.8.1

General

1

All items of control gear shall be fitted with shrouds over all terminals to prevent accidental contact during lamp replacement or routine equipment maintenance. All control gear shall have a clearly marked circuit diagram to show its terminal connections in relation to all other components. Control gear (choke, capacitor, ignitor etc.) shall be suitable to withstand temperatures up to 86°C and shall have a purpose made earth terminal. Internal connections shall be with heat resistant non-hydroscopic insulated stranded copper conductors, cleated and with porcelain connectors.

2

Ballast (choke) shall be closed type polyester filled can. It shall be suitable for single phase voltage operation and silent in operation. All tappings shall be brought to suitably marked standard terminals to which the lamp and supply connections shall be made.

3

The capacitor shall give a minimum power factor of 0.85 lagging. They shall have a tolerance of + or – 10% of its marked value. Where non-metallic capacitors are offered these shall be supplied with a fixing band that shall not damage the capacitor when fitted. Where the capacitor has an aluminium body it shall be provided with a separate earth terminal.

4

Ignitors shall be mounted within the control gear compartment of the luminaire. Each ignitor shall be fitted with a device that will detect the presence of a faulty lamp and automatically limit the generation of HV pulses. The ignitors shall be suitable for use with the lamp, ballast and power factor correction capacitor included within the control gear circuit.

15.9

LAMPS

15.9.1

General

1

Lamps shall be energy saving lamps with clear tubular hard glass envelope with E-40 base suitable for use on 220 - 240 V, 50Hz, AC. Lamps shall be manufactured according to International Electrotechnical Commission IEC or International Standards, and accepted or approved by Qatar Standards.

2

Energy saving lamps ( that have a minimum of 50% energy saving than the standard high pressure sodium vapour gas lamps)shall be:

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(a)

High Intensity Discharge (HID) ,

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(b)

Induction lamp types;

(c)

Light Emitting Diodes (LED)

(d)

and any other types of energy saving lamps accepted and approved by Qatar Standards .

These lamps shall either have a built in or an external ignitor. Initial Lumen output for High Intensity Discharge (HID) lamps shall be no less than 4,500 lumens/watt for the 50 watt lamps, no less than 6,500 lumens/watt for the 70 watt lamps, no less than 12,500 lumens/watt for the 100 watt lamps, no less than 17,500 lumens/watt for the 150 watt lamps, no less than 33,150 lumens/watt for the 250 watt lamps or no less than 48,000 lumens/watt for the 400 watt lamps,

15.10

LIGHTING SYSTEM FOR UNDERPASSES

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The basis for the lanterns for use within both the lighting of the vehicular, pedestrian and animal underpasses pertains to lanterns designed for cornice surface mounting within each underpasses, complete with lamp, fuse and associated control gear. The lighting arrangement within each type of underpass shall be based on the use of a common lantern designed such that it can incorporate either a multi lamp or single lamp luminaire arrangement of a variable wattage.

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15.10.1 General

The lanterns for vehicular underpasses shall consist of either 1x 150 Watt SON/T (no less than 17,500 lumens/watt) and 1 x 250 watt SON/T (no less than 33,150 lumens/watt) high pressure sodium vapour luminaires, LED lamps or energy saving lamps with Lumen/Watt equivalent to the above wattages, complete with all materials as specified herein and in the Contract Documents and as required to provide a complete lighting installation.

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15.10.2 Vehicular Underpass

The lanterns for pedestrian underpasses shall consist of either 1x 70 Watt (no less than 6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure sodium vapour luminaires, or Lumen/Watt-equivalent LED lamps or energy saving lamps, complete with all materials as specified herein and in the Contract Documents and as required to provide a complete lighting installation.

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15.10.3 Pedestrian Underpass

15.10.4 Animal Underpass 1

The lanterns for animal underpasses shall consist of either 1x 70 Watt (no less than 6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure sodium vapour luminaires, or Lumen/Watt-equivalent LED lamps, or energy saving lamps complete with all materials as specified herein and in the Contract Documents and as required to provide a complete lighting installation.

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15.10.5 Lantern Construction for use in Vehicular, Pedestrian and Animal Underpasses An underpass lantern shall consist of housing, front cover, reflector, socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts composing a complete unit. The lantern shall provide illumination, be mechanically strong and easy to maintain. Its optical housing shall have protection against the ingress of moisture and dust to degree IP55 of IEC529 under all operating conditions.

2

The optical seal which shall include the reflector mounting shall be adequate to maintain this degree of protection. With the exception of the reflector, lamp holder mounting and associated cable all other equipment shall be housed at the rear of the optical system and shall be readily accessible by access through the lantern front plate. These components shall include the lantern control equipment, associated cable and isolating fuse. The cable connections to the lampholder within the lantern shall be of the heat resistant type with silicon, glass fibre or other approved insulation.

3

The housing and front cover shall be made of stainless steel.

4

The reflector shall be made of aluminium sheet of such grade and quality that :

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The reflecting surface shall have a specular finish.

(b)

The reflecting surface shall have a dense protective coating of oxide not less than 1.2 2 mg/cm , applied by the anodic oxidisation process.

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(a)

The reflector shall be of such material and construction as to provide low brightness and minimize glare. The latches, nuts, screws, washers, pins and other parts shall be made of non-corrosive metals or of metals with non-corrosive finishes as approved by the Engineer. The seal of the optical system shall be accomplished with a gasket material that will not deteriorate with age. This gasketing shall be continuous and shall ensure a heat and weatherproof seal. Suitably located knockouts to suit the cable conduit shall be provided in the housing. The lamp socket shall be provided with grips or other suitable means to hold the lamp against vibration.

6

The fascia plate of the lantern shall be manufactured from toughened glass protected, if necessary due to a high incidence of vandalism by means of the manufacturers purpose made wire mesh guard.

7

Between adjacent luminaries a stainless steel ‘in fill’ plate shall be provided such that the whole assembly gives the appearance of a continuous cornice arrangement. The main sub circuit cables interconnecting each underbridge luminaire from the underpass isolating control box shall be routed between fittings within the luminaire or ‘in fill’ plate by means of a purpose made cable tray arrangement. Within the structure the cabling shall be routed via galvanized steel conduit cast within the underpass walls and soffit of size suitable to accommodate the number of single core or multicore cables required whilst maintaining the stipulated space factor according to the relevant regulations. The cabling shall be either single core or multi core 6mm² copper conductors within high temperature grade double insulated or flexible cable.

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15.10.6 Underbridge or Undercrossing Lantern and Installation The lantern for use within both the underbridge and undercrossing lighting shall be designed for directly mounting immediately above the kerb edge of the carriageway and shall be complete with lamp, fuse and associated control gear. The lighting arrangement shall be such that it can incorporate either a single lamp of a variable wattage.

2

The underbridge or undercrossing lantern shall consist of housing, cover, reflector, socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts composing a complete unit. The lantern shall provide illumination, be mechanically strong and easy to maintain. Its optical housing shall have protection against the ingress of moisture and dust to degree IP55 of IEC529 under all operating conditions.

3

The optical seal which shall include the reflector mounting shall be adequate to maintain this degree of protection. With the exception of the reflector, lamp holder mounting and associated cable all other equipment shall be housed at the rear of the optical system and shall be readily accessible by access through the lantern front plate. These components shall include the lantern control equipment, associated cable and isolating fuse. The cable connections to the lampholder within the lantern shall be of the heat resistant type with silicon, glass fibre or other approved insulation.

4

The housing and front cover shall be made of stainless steel.

5

The reflector shall be made of aluminium sheet of such grade and quality that :

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The reflecting surface shall have a specular finish.

(b)

The reflecting surface shall have a dense protective coating of oxide not less than 1.2 2 mg/cm , applied by the anodic oxidisation process.

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(a)

The reflector shall be of such material and construction as to provide low brightness and minimize glare. The latches, nuts, screws, washers, pins and other parts shall be made of non-corrosive metals or of metals with non-corrosive finishes as approved by the Engineer. The seal of the optical system shall be accomplished with a gasket material that will not deteriorate with age. This gasketing shall be continuous and shall assure a heat and weatherproof seal. Suitably located knockouts to suit the conduit shall be provided in the housing. The lamp socket shall be provided with grips or other suitable means to hold the lamp against vibration.

7

The fascia plate of the lantern shall be manufactured from toughened glass protected, if necessary due to a high incidence of vandalism by means of the manufacturers purpose made wire mesh guard.

8

The main sub circuit cables interconnecting each underbridge or undercrossing luminaire from the underbridge or uncrossing isolating control box Within the structure the cabling shall be routed via galvanized steel conduit cast within the underbridge or structure walls and soffit of size suitable to accommodate the number of single core or multicore cables required whilst maintaining the stipulated space factor according to the relevant regulations. The cabling shall be either single core or multi core 10mm² copper conductors within high temperature grade double insulated or flexible cable.

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15.10.7 Underpass, Underbridge and Undercrossing Lantern Control Gear and Lamps The control gear shall be designed to operate the lamp of the power rating and type indicated and it shall be able to start the lamp and control it continuously for ambient temperatures up to +55°C. The choke shall be tropicalised and have terminals to accept 240 V supply voltage. Each terminal shall be brought out to a separate shrouded termination. Multi-lamp gear operating more than one lamp shall not be employed.

2

The capacitor shall give a minimum power factor of 0.85 lagging. They shall have a tolerance of +/– 10% of its marked value. Where non-metallic capacitors are offered these shall be supplied with a fixing band that shall not damage the capacitor when fitted and, if metallic, shall be provided with a separate earth terminal. The permitted operating temperature of the capacitor shall be marked on its case.

3

Each lamp shall operate using only one choke and one capacitor. Any combination of two or more capacitors having the equivalent value of capacitance will not be accepted.

4

Chokes and capacitors shall comply with the relevant British Standard Specification or an acceptable International equivalent and shall be fully compatible with the complete associated operation lamp circuit.

5

The ignitor for energy saving lamp shall be of the electronic solid state type and shall be arranged so that the ignitor circuit stops working after the lamp has started. It shall be totally enclosed. The circuit shall include a shunt capacitor to isolate the mains from high frequency start pulses; this capacitor may also be used for power factor correction. The length of wiring between the ignitor and the lamp shall not exceed that recommended by the Manufacturer for satisfactory lamp ignition and re-ignition of an extinguished lamp.

6

The control gear shall meet the following specifications:

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It shall be suitable for 50 Hz, 240 V AC + 10% operation.

(b)

It shall regulate the output power to 12% for the input voltage noted above.

(c)

It shall have an overall power factor of at least 0.85 when operated under rated lamp load.

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It shall operate the lamp without affecting adversely the lamp life and performance as specified herein.

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(e)

It shall withstand a 2500 V dielectric test between core and windings.

(f)

The choke shall be encapsulated in an approved resin compound and totally enclosed.

7

The lamps for vehicular underpasses shall consist of either 1x 150 Watt SON/T (no less than 17,500 lumens/watt) and 1 x 250 watt SON/T (no less than 33,150 lumens/watt) high pressure sodium vapour luminaires, LED lamps or energy saving lamps with Lumen/Watt equivalent to the above wattages, complete with all materials as specified herein and in the Contract Documents and as required to provide a complete lighting installation.

8

The lamps for pedestrian or animal underpasses shall consist of either 1x 70 Watt (no less than 6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure sodium vapour luminaires, LED or energy saving lamps with Lumen/Watt-equivalent, complete with all materials as specified herein and in the Contract Documents and as required to provide a complete lighting installation.

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15.10.8 Underpass, Underbridge or Undercrossing Isolating Box 1

At each underpass, underbridge or undercrossing location an isolating box assembly shall be provided to control and isolate the respective lighting. This assembly shall be constructed from either galvanized steel or stainless steel with a hinged vandal resistant lockable front cover complete with sealing gasket protection against the ingress of moisture and dust to degree IP54 of IEC529 under all operating conditions providing. A three phase mcb isolator shall be located within this housing to control the power supplies to each lighting sub circuit. The galvanized steel conduit providing the cabling routing within the structure shall be secured at the isolating box assembly by means of a locknut arrangement.

15.11

LED LIGHTING UNITS

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15.11.1 Lighting Units The degree of Ingress Protection provided by the luminaire, including the facility for a switching device, shall be rated at least IP66 in accordance with EN60529 (IEC529). Specification for degrees of protection provided by enclosures (IP code). This shall be certified by an independent IP testing and examination laboratory accredited by UKAS or equivalent accreditation body.

2

The degree of Impact Protection provided by the luminaire against external mechanical impact shall be rated at least IK10 (metals and plastics) and IK08 (glass) in accordance with EN62262:2002 (IEC62262:2002) Degrees of protection provided by enclosures for electrical equipment against external mechanical impacts (IK code). This shall be certified by an independent IK testing and examination laboratory accredited by UKAS or equivalent accreditation body.

3

The luminaire assembly shall be tested and approved by an independent ENEC (European Norms Electrical Certification) national Certification Body and awarded the ENEC mark or equivalent international standards. Contractor shall provide verifiable certificate featuring contact information of Certification Body.

4

The luminaire shall be designed and suitably rated to ensure correct operation and continuous trouble free service under the prevailing climatic conditions. The luminaire shall be designed to withstand the effects of direct sun exposure during the day and dusty weather conditions including the occasional sandstorm. The luminaire manufacturer shall guarantee the performance and life time claims of lumen maintenance and luminaire life of the luminaire under the stated climatic conditions.

5

The luminaire housing shall be constructed from corrosion resistant marine grade aluminium alloy conforming to BS EN 1676, 1559-1, 1559-4 and 1706 and powder coated by an Akzo Nobel approved applicator, or equivalent, conforming to EN12206-1:2004 Paints and varnishes. Coating of aluminium and aluminium alloys for architectural purposes. Coatings prepared from coating powder.

6

The manufacturer shall supply a RAL colour chart depicting the range of powder coat colours available for the external finish of the luminaire. Luminaire colour shall be specified at the time of ordering.

7

The optical assembly and control gear components shall be integral to the luminaire body.

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For maintenance the luminaire shall allow tool-less access and incorporate quick disconnect features and universal fittings. All component parts shall be easily accessible and securely mounted to prevent accidental falling and manufactured from corrosion resistant materials or treated to prevent corrosion. The luminaire cover shall include an optional security feature to enable locking by means of a tool. The cover shall also incorporate a safety switch to disconnect power on opening and any upward rising hinged canopy shall be secured in an open position by means of a brace to prevent accidental closing.

9

The luminaire shall be procured from a prominent luminaire manufacturer that publishes product specifications measured in compliance with the IEC/PAS performance requirements or equivalent.

10

The complete luminaire shall be at least 98% recyclable.

11

The luminaire shall be vandal resistant. The ingress of insects through any system vent or aperture shall be prevented by means of a filter.

12

The luminaire shall be compliant with the Waste Electrical and Electronic Equipment (WEEE) Directive (2002/96/EC) and the Restriction of the use of certain Hazardous Substances in electrical and electronic equipment (RoHS) Directive (2002/95/EC).

13

Each luminaire shall have a barcode securely attached internally within the gear compartment identifying the luminaires reference/catalogue number, total wattage and LED current setting and other attributes as required by Ashghal and as required of the Enterprise Asset Management System (EAMS). The barcode type shall be compatible with the handheld device authorized for use by Ashghal.

14

All internal and external wiring of the luminaire shall comply with EN60598-1:2008 Luminaires, General requirements and tests and shall be flexible and suitably rated and insulated to withstand the voltages and temperatures encountered in service.

15

Any luminaire wiring passing through metal shall have suitable grommets or otherwise be protected to avoid abrasion of the insulation.

16

All luminaire terminals and supply connections shall comply with EN60598-1:2008. The conducting material of any terminal block shall be made of brass and shall have screw down plates bearing on the wires. Terminals where screws bear down directly on wires will not be acceptable.

17

Luminaires shall be earthed in accordance with EN60598-1:2008. An earth terminal forming part of the luminaire body shall be provided. All parts of an earth terminal shall be made of brass.

18

Luminaires shall be “future proofed” by allowing the LED modules to be upgraded easily in situ, as LED efficiency improves. Upgrading of luminaires, or replacement of faulty components, with manufacturer approved components shall not have any detrimental impact whatsoever on the luminaires’ manufacturer warranty. Prototypes shall not be accepted.

15.11.2

Lighting Performance

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Highway luminaires shall be suitable to achieve the lighting class standards as detailed in the Qatar Design Management Manual, as referenced in ANSI/IESNA RP-008, and as applicable to Primary, Secondary and Tertiary roads in The State of Qatar, under the control of Ashghal and other areas as required.

2

The luminaire shall be compliant with EN60598-1:2008 Luminaires. General requirements and tests, and EN60598-2-3:2003 Luminaires. Particular requirements. Luminaires for road and street lighting.

3

The luminaire shall be able to restrict glare and control obtrusive light in accordance with the full “cut-off” and “semi cut-off” concepts and associated luminous intensity classes defined in ANSI/IESNA RP-008 or an equivalent, Ashghal-authorized standard. Individual project contract drawings and design specifications shall detail the luminous intensity class requirement.

4

The luminaire shall control light output to limit light pollution and minimise sky glow in accordance with Commission Internationale de l'Éclairage (CIE) 126-1997 Guidelines for minimizing sky glow and meet the requirements therein for maximum permissible upward light output ratio (ULOR) expressed as the percentage of luminous flux acceptable in each of four different Environmental Zones.

5

The efficacy of the luminaire is given by the total lumen output divided by the power into the system and shall be equal to or greater than 100 lm/w (lumens per watt) operating within the climate conditions as stated herein. The contractor shall obtain a statement from the luminaire manufacturer declaring that quoted performance figures correspond to the stated ambient air temperature and ensure that the specifics of operating in the Qatar environment are written into any applicable section of the manufacturer’s warranty agreement.

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15.11.3 Thermal Management

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The luminaire shall be capable of withstanding severe climate conditions, as stated in Section 21, Part 1. General Provisions for Electrical Installation, clause 1.1.14.

2

As a minimum, manufacturers shall use 50 ˚C as the night time ambient temperature with 95% humidity.

3

The luminaire shall be designed to provide satisfactory heat dissipation for any powered component parts and maintain safe operating temperatures at all times under the stated climatic conditions. Heat dissipation shall be by passive thermal management, active or mechanical cooling is not acceptable.

4

All materials used in the luminaire shall be resistant to high temperature UV (ultra violet) exposure and be 90% UV-stable.

5

The luminaire shall incorporate a passive thermal management system, active cooling such as fan assisted systems will not be accepted. The manufacturer shall demonstrate that the luminaire is suitable for continuous operation in the Qatar environment. Within the stated climate conditions the LED junction temperatures shall be shown to remain within the range required to limit the risk of accelerated degradation of the LEDs based on the stated life expectancy of the luminaire.

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Junction temperature cannot be measured directly and must be derived using calculation formulae and temperature measurements read from a thermocouple device attached to a series of defined reference points (thermal pads) on the outer casing (package) of the LED. Thermal verification testing is carried out as a laboratory based operation with ambient conditions simulated.

7

The luminaire manufacturer shall submit a statement declaring that quoted LED performance figures correspond to the stated ambient air temperature and ensure that the specifics of operating in the Qatar environment are written into any applicable section of the warranty agreement.

8

The maximum allowable ambient temperature for the LED lighting shall be stated, in which the LED lighting can operate without adversely affecting any components life, luminaire light output or colour stability. This shall take into consideration the maximum case temperature of the driver and the design LED junction temperature.

9

Manufacturers shall state the predefined critical temperature level at which the dim down and switch off protection events occur and relate to junction temperature and ambient temperature. The luminaire shall be constructed in such a way that this protection method shall not occur during climate conditions stated within this specification.

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15.11.4 Testing

LED Luminaire lighting performance shall be measured using an independent photometric testing laboratory accredited by UKAS or equivalent accreditation body. The test procedure and measurements shall be carried out in accordance and compliance with IES_LM-79-08 Approved Method: Photometric Measurements of Solid State Lighting Products. The photometric test report shall list all significant data for each SSL product tested together with performance data and also pertinent data concerning conditions of testing, type of equipment, and reference standards. The photometric test procedure shall also be used to calculate correction factors in allowance of the stated climate conditions.

2

Photometric data for each luminaire optical setting shall be available in electronic file format in accordance and compliance with IES_LM-63-02 Standard File Format for Electronic Transfer of Photometric Data and Related Information and EN130321:2004+A1:2012 Light and lighting. Measurement and presentation of photometric data of lamps and luminaires. Measurement and file format. The photometry files shall be compatible for use with industry recognised road lighting design software packages or as requested by Ashghal and include applied correction factors specific to the declared ambient conditions.

3

Lighting performance of the LED luminaire in terms of design spacing’s relative to a specified road lighting class should be comparable to a modern HID lamp based luminaire with similar lumen output.

4

The luminaire manufacturer shall submit a statement declaring that quoted photometric performance figures correspond to the stated ambient air temperature (not LED junction temperature) and ensure that the specifics of operating in the Qatar environment are written into any applicable section of the warranty agreement.

5

The luminaire shall be tested in accordance and compliance with EN62471:2008 (IEC62471:2006) Photobiological safety of lamps and lamp systems or an equivalent standard. Any assumptions made during testing shall be clearly stated.

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The luminaire LED light source shall be tested in accordance and compliance with IES_LM-80-08 Approved Method: Measuring Lumen Maintenance of LED Light Sources. The LM-80-08 test report produced for the LED light source shall meet the eligibility criteria necessary for submission to the U.S Department of Energy (DOE) Energy Star Program Requirements for Solid State Lighting Luminaires.

15.11.5 In Situ Temperature Measurement Test (ISTMT) In order to relate the LM-80 test to the luminaire and stated climatic conditions, testing shall be completed that simulate this application. This shall be achieved by In Situ Temperature Measurement Test (ISTMT) which follows ANSI/UL 1598-2004 Luminaires.

2

The luminaire manufacturer shall provide a written undertaking to the satisfaction of Ashghal\s authorized Engineer to warranty the materials and performance as follows: LED arrays shall have a written warranty for a minimum of 50,000 hours at the ambient temperature specified herein and shall be replaced on a one for one basis upon failure. An LED array will be deemed to have failed when:

(b)

equal to or greater than 10% of the individual LED chips in an array has failed or an array does not provide the required lumen maintenance (L70).

(c)

Drivers shall have a written warranty for a minimum 50,000 hours and shall be replaced on a one for one basis.

(d)

Luminaire housing and all external components such as; lenses, gaskets & fastenings and the fixture finish shall have a written warranty for a minimum twenty (20) years against the deterioration of, but not limited to, mechanical failure, UV degradation, corrosion, yellowing, blistering, chalking, cracking, peeling or fading.

(e)

The Warranty shall be transferable without limitations in its entirety to Ashghal, Public Works Authority, Qatar.

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(a)

Equivalent or more onerous standards can be proposed, by the manufacturer, as an alternative to the detailed standards, with the exception of Qatar documents. Evidence shall be submitted detailing the equivalent or more onerous sections that deviates from the intended standard.

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15.11.6 Control Gear 1

The luminaire control gear (driver) shall be produced by a prominent manufacturer of semiconductor components and comply with IEC 62384 DC or AC supplied electronic control gear for LED modules - Performance requirements. The manufacturer shall confirm that the packaged driver assembly is fabricated from high quality integrated circuit components including long-life electrolytic capacitors and provide data relating to the reliability of the device, in the climatic conditions stated in this specification.

2

The drivers shall be encapsulated / potted and Class II double insulated (IEC61140) and have a minimum energy efficiency of 85% and power factor ≥0.9 (full load). The control gear shall feature Surge Protection Device (SPD) for lightning strikes (IEC62305), short-circuit protection and transient overvoltage protection (IEC61643-1 / IEC61000-4-5).

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The LED drivers shall be housed on a removable gear tray accessible with the luminaire cover open and be compatible with the Qatar power supply. The supply cable shall pass through the mounting post, or bracket, directly into the luminaire through an M20 cable gland located at the base of the luminaire mounting socket.

4

For protection in the event of temperatures reaching predefined critical levels, both LEDs and drivers shall have thermal protection, which will initially dim down and eventually switch off the light. Manufacturers shall state the predefined critical temperature level at which the dim down and switch off protection events occur and relate to junction temperature and ambient temperature. The luminaire shall be constructed in such a way that this protection method shall not occur during climate conditions stated within this specification.

5

The driver system shall be compatible with Lighting Control Systems / Lighting Management Systems (LMS), using both analogue (1-10V) and Digital Addressable Lighting Interface (DALI) protocols including WiMAC or other similar Ashghal-approved driver system. The driver system shall also be capable of being configured for single, and multi-stage, stand-alone dimming configurations when not connected to a CMS.

6

The drivers shall be programmable and permanently configured to operate under the principle of “constant flux” output or maintenance factor harvesting or similar, Ashghalapproved configuration method. During this process light output is initially dimmed to an equivalent end of life level value and then the operating current is gradually increased throughout service life to compensate for lumen depreciation and maintain a constant lighting level. The advantage of this system is to give energy savings and improve LED life and reliability. The manufacturer shall provide details of how this facility is maintained following replacement of a faulty driver or LED array.

7

The driver shall be capable of operating within the climate conditions previously described and shall have documentation and certification supporting the claimed minimum life expectancy of 50,000 hours in the stated conditions within this specification.

8

The driver manufacturer’s device data sheet will provide specification details and the maximum permissible ambient temperature range in which the driver can operate (free air convection) at the defined driver current. The luminaire manufacturer shall demonstrate that the LED driver is suitable for continuous operation in the Qatar environment. Within the stated climate conditions the driver compartment enclosure shall be shown to remain within the range required to limit the risk of driver failure during operation based on the stated life expectancy of the luminaire.

9

The luminaire manufacturer shall submit a statement declaring that quoted driver performance figures correspond to the stated ambient air temperature and ensure that the specifics of operating in the Qatar environment are written into any applicable section of the warranty agreement.

10

The luminaire shall conform to CE marking directives including the European Electromagnetic Compatibility (EMC) Directive EN 61000-3-2:2009 (IEC 61000-32:2009) Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic current emissions (equipment input current ≤ 16 A per phase)

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15.11.7 LED Lamps The LEDs shall be produced by a Ashghal Approved manufacturer of solid state lighting (SSL) components and comply with the related standards and guidelines set by the Illuminating Engineering Society of North America (IESNA) and the JEDEC Solid State Technology Association and approved by Qatar Standards.

2

The light source is required to control light output with the aim of optimising luminaire performance and efficiency in relation to the specific lighting application. The luminaire, or luminaire series, shall provide the facility for varying luminous flux output ranging from 5klm up to at least 40klm using an appropriate number of LEDs and a suitable control method for each different lumen package.

3

The luminaire LED module shall comply with International Electrical Commission Publicly Available Specification IEC/PAS62717 LED modules for general lighting – Performance requirements.

4

The LED arrays shall be capable of operating within the climate conditions previously described and shall have documentation and certification supporting the claimed minimum life expectancy of 50,000 hours at L70 in the stated conditions as within this specification.

5

Technical details shall be provided of the light source optical system and range of optics or optical settings available for each model of luminaire including performance characteristics. The optical system is required to control light output with the aim of optimising luminaire performance and efficiency in relation to the specific lighting application. The system should meet the lighting requirements of most rights of way types and configurations and maximise the “light output ratio” (LOR) of the luminaire.

6

The inadvertent failure of any LEDs during the life of the luminaire shall not bring about any reduction in uniformity of light output. Therefore, the multi-layer method of light distribution shall take precedence over multiple spot methods.

7

Diffuser systems may be required for some lighting applications to eliminate the effect of multiple-source shadows.

8

Chromaticity tolerance and associated colour consistency of luminaire LED modules shall be measured in terms of the CIE 1931 chromaticity diagram and the CCT quadrangles defined by the American National Standards Institute (ANSI) C78.3772008 Specifications for the Chromaticity of Solid State Lighting Products for Electric Lamps. The ANSI quadrangle is made up by smaller quadrangles, commonly referred to as bins. The x y chromaticity components of each LED module shall be enclosed by one bin and the bin size shall not exceed a 4-step MacAdam ellipse. The binning process shall be in compliance with National Electrical Manufacturers Association (NEMA) SSL 3:2010 High-Power White LED Binning for General Illumination.

9

The chromaticity shift shall be measured and reported in accordance with IES_LM-80-08 Approved Method: Measuring Lumen Maintenance of LED Light Sources.

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For highway lighting the Correlated Colour Temperature (CCT) of the light emitted from the luminaire shall be in the range ≥4000K with a Colour Rendering Index (CRI) of ≥60. The manufacturer shall state the CCT ranges available with a ±275K warranted window. The CCT and CRI shall include the effects of colour shift over the life of the luminaire. Other CCT ranges may be applicable to individual projects and manufacturers shall be notified as required.

11

Lumen maintenance (L) is the luminous flux emitted by the light source at any specified time during its operational life and is expressed as a percentage of the luminous flux emitted at the start of life (L%). The rated lumen maintenance life of the LED light source shall not exceed L70, or 30% lumen depreciation at the specified temperature conditions.

12

The luminaire manufacturer shall define the estimated service life of the light source in terms of operating hours and rated lumen maintenance. The minimum standard expected shall be 50,000 operating hours at L70 at the temperature conditions specified herein.

13

The method of deriving rated lumen maintenance life beyond the limits of lumen maintenance determined from actual measurements shall be demonstrated. The method for projecting the lumen maintenance of LED light sources from the data obtained by the procedures found in IES document LM-80-08 shall be in accordance and compliance with IES_TM-21-11 Projecting Long Term Lumen Maintenance of LED Light Sources.

14

In combination with rated life predications the reliability of the LED modules shall also be expressed in terms of the percentage (fraction) of failures in accordance with IEC/PAS 62722-2-1:2011 Luminaire performance - Part 2-1: Particular requirements for LED luminaires. The failure fraction (Fy) corresponds to the percentage of LED‟s that fail before end of rated life. This failure fraction expresses the combined effect of all components of a module including mechanical, as far as the light output is concerned. The effect of the LED could either be less light than claimed or no light at all.

15

The failure fraction shall also be expressed in terms of its component parts, gradual failure fraction (By) and abrupt failure fraction (Cy). The reliability curve relative to operating hours is calculated using statistical formulae and data gathered under test conditions during luminaire monitoring periods.

16

Luminaire maintenance factors (LMF) to follow model used in BS5489-1:2003+A2:2008 Annex D Table D1 with figures extrapolated to extend cleaning cycle interval up to 6 years and also adjusted to take account of environmental conditions specified herein.

17

Lamp flux maintenance factor (LFMF) shall be calculated by the manufacturer in accordance with calculated lumen depreciation relative to a predefined cleaning cycle interval. Currently the perceived cleaning interval is biannually due to the intense dust laden atmosphere.

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15.11.8 Quality Criteria for LED Lighting 1

Manufacturers shall submit data in accordance with IEC/PAS 62717 Performance requirements – LED modules for general lighting and IEC/PAS 62722 Performance requirements – LED luminaires for general lighting.

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15.11.9 LED manufacturers data Manufacturer shall provide a standardised set of quality criteria, measured in compliance with the appropriate standard. The performance claims shall be matched against traceable data. The performance data required is summarised below and shall be headed Quality Criteria: (a)

Rated input power (in W)

(b)

Rated luminous flux of the luminaire (in lm)

(c)

luminaire efficacy (in lm/W)

(d)

Luminous intensity distribution

(e)

Photometric code Rated Colour Rendering Index (CRI)

(ii)

Correlated Colour Temperature (CCT in K)

(iii)

Rated chromaticity co-ordinate values (initial and maintained)

(iv)

Maintained luminous flux

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(i)

Rated life (in h) of the module and the associated rated lumen

(g)

maintenance (Lx)

(h)

Failure fraction (Fy), corresponding to the rated life of the module in the

(i)

luminaire

(j)

Ambient temperature (ta) for the luminaire

(k)

Power Factor

(l)

Intensity Distribution

(m)

Drive Current

(n)

Optical Risk Group

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This data shall be submitted on an Ashghal-approved form. Forms shall be submitted to Ashghal for approval prior to submitting data for consideration. Further data shall be provided to evidence compliance with all aspects of this specification. Additional data shall be provided as and when requested by Ashghal.

15.12

OVERHEAD SIGN GANTRY LANTERN AND INSTALLATION

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The basis for the lanterns for use on the overhead sign gantries or bridges for the illuminating of overhead guide signs mounted on the sign support structure or on the gantry sign walkway supported on the gantry sign support brackets. The lanterns shall be complete with lamp, isolating fuse and associated control gear.

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15.12.2 Sign Gantry Lantern The lanterns shall be LED type and shall be rated per lamp at 2 x 50 watt (no less than 4,500 lumens/watt), 2 x 70 watt (no less than 6,500 lumens/watt), 2 x 100 watt (no less than 12,500 lumens/watt), 2 x 150 watt (no less than 17,500 lumens/watt) and 2 x 250 watt (no less than 33,150 lumens/watt) LED lamps and shall consist of housing, cover, reflector, refractor, socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts composing a complete unit. At half life, the maintained luminous flux shall be a minimum of 75% of the initial luminous flux.

2

The lantern shall provide efficient illumination, be optically sealed, mechanically strong and easy to maintain.

3

The reflector mounting, wiring terminals and control gear components shall be readily accessible. When closed for operation, the optical assembly shall be sealed to provide protection against the ingress of moisture and dust to degree IP55 of IEC529 under all operating conditions.

4

The seal between the refractor and the housing shall be adequate to maintain this degree of protection. The refractor shall be held in such a manner as to allow for expansion and contraction of the refractor. Cable connections to the lamp holder within the lantern shall be of the heat resistant type with silicon, glass fibre or other approved insulation.

5

The optical system shall consist of a hydroformed aluminium primary beam reflector which shall be precisely profiled and contoured to distribute light across the inner surface of the refractor. The prismatic refractor shall be of moulded borosilicate thermal shock-resistant glass. The inner surface shall have an intricate array of prisms to direct light across the face of the sign. The outer surface shall be smooth to facilitate self-cleaning. The reflector shall be of a retro-dispersing type designed to eliminate the halo of excessive luminance to assure more uniform sign luminance.

6

The terminal board shall be located beneath the reflector at the conduit entry and shall 2 accommodate 10 mm electric cables.

7

The reflector shall be fastened to the housing by means of a minimum of four stainless steel screws with keyhole slot to facilitate easy removal and replacement. Levelling pads are to be provided on the inside and bottom of the main housing to permit accurate installation.

8

There shall be mounting within of the stainless steel housing to permit the lantern to be mounted directly to the supporting structure.

9

The refractor shall be form-fitted to the stainless steel door frame and shall have a single piece gasket with a sealing pad to effectively seal the assembly and housing. The assembly shall be fastened to the housing by means of separable hinges at the front and spring tempered, stainless steel at the rear. The lamp socket shall be provided with grips or other suitable means to hold the lamp against vibration.

10

The terminals of all ballasts, capacitors and control gears shall be shrouded.

11

Each sign lighting system shall be subject to the approval of the Engineer. Particular attention shall be given to the mechanical strength of all components, and to the security of their method of the sign supports.

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15.12.3 Sign Gantry Lantern Control Gear and Lamps The control gear shall be designed to operate the lamp of the power rating and type indicated and it shall be able to start the lamp and control it continuously for ambient temperatures up to +55°C. The choke shall be tropicalised and have terminals to accept 240 V supply voltage. Each terminal shall be brought out to a separate shrouded termination. Multi-lamp gear operating more than one lamp shall not be employed.

2

The capacitor shall give a minimum power factor of 0.85 lagging. They shall have a tolerance of + or –10% of its marked value. Where non-metallic capacitors are offered these shall be supplied with a fixing band that shall not damage the shell and be provided with a separate earth terminal. The permitted operating temperature of the capacitor shall be marked on its case.

3

Each lamp shall operate using only one choke and one capacitor. Any combination of two or more capacitors having the equivalent value of capacitance will not be accepted.

4

Chokes and capacitors shall comply with the relevant British Standard Specification or an acceptable International equivalent and shall be fully compatible with the complete associated operation lamp circuit.

5

The control gear shall meet the following specifications:

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It shall be suitable for 50 Hz, 240 V AC + 10% operation.

(b)

It shall regulate the output power to 12% for the input voltage noted above.

(c)

It shall have an overall power factor of at least 0.85 when operated under rated lamp load.

(d)

It shall operate the lamp without affecting adversely the lamp life and performance as specified herein.

(e)

It shall withstand a 2500 V dielectric test between core and windings.

(f)

The choke shall be encapsulated in an approved resin compound and totally enclosed.

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(a)

The lamps shall be LED type and shall be rated per lamp at 2 x 50 watt (no less than 4,500 lumens/watt), 2 x 70 watt (no less than 6,500 lumens/watt), 2 x 100 watt (no less than 12,500 lumens/watt), 2 x 150 watt (no less than 17,500 lumens/watt) and 2 x 250 watt (no less than 33,150 lumens/watt) LED lamps and shall consist of housing, cover, reflector, refractor, socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts composing a complete unit. At half life, the maintained luminous flux shall be a minimum of 75% of the initial luminous flux.

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15.12.4 Sign Gantry Isolating (Safety) Switch, Conduit and Associated Cables At each sign gantry location an isolating (safety) shall be provided at walk way level of the structure. It shall be fabricated galvanized steel complete with a vandal resistant hinged access door. A three phase mcb isolator shall be located within this housing to control the power supplies to each lighting sub circuit. The galvanized steel conduit, secured to the gantry structure by means of purpose made saddles to suit the size of conduit, providing the cabling routing within the structure shall be secured at the isolating box assembly by means of a locknut arrangement. The size of the conduit shall be suitable to accommodate the number of single core or multicore cables required whilst maintaining the stipulated space factor according to the relevant regulations. A 3-phase mcb isolator shall be located within the isolating (safety) switch to control the lighting sub circuit upon each gantry structure. The cabling shall be either single core or multi core 10mm² copper conductors within high temperature grade double insulated or flexible cable.

15.13

PHOTO ELECTRIC CONTROL CELL

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15.13.1 General

Photo electric control cells shall comply with the requirements of BS 5972 and offer a Class II protection from electric shock as defined in IEC 60598.

2

Unit must be completely weatherproof, hermetically sealed against the ingress of moisture. It shall be resistant to vibration or change in temperature. It shall be housed in a strong impact resistant low profile translucent housing, the surface of which shall be non- oxidizing and impervious to deterioration.

3

The photo electric control unit (PECU) shall be guaranteed for a period of not less than six years, failures within that period of time to be replaced free of charge.

4

They will be capable of working in an ambient temperature of up to + 60 C.

5

The operation level should be preset to ON 80/100 Lux the ratio of ON to OFF should be approximately 1:2. There shall be no means of manual adjustment to the PECU’s calibration and it shall not need to be orientated to operate as required.

6

There should be a minimum 15 second delay to prevent the unit from functioning due to short period high illumination such as lightning etc.

7

The power supply to the PECU shall be 240V 50Hz. A.C with a contact output rating of 30A at 240V (resistive).

8

The PECU and associated relay or switching device shall have pre matched responses and housed in the same envelope. The contact rating shall be 1500-Watts (1800 V.A) and should be fitted with a snap action to prevent chatter. In the case of the load to be switched then the PECU can switch directly, a contactor shall be used.

9

The photocell shall be located within the road lighting feeder pillar such that it can be easily removed. It shall be housed within a small compartment with an acrylic fascia plate set into the surface of the feeder pillar for the satisfactory operation of the photocell. The control circuitry for the correct switching of the road lighting will be housed within the adjacent feeder pillar. The associated specification requirements will be dealt with within that section of the specification.

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10

The upper LED luminaire cover shall have the facility for installation and wiring of one of the following devices: an integral miniature photocell, NEMA socket (detachable photocell), telemetry device. This facility shall be included within the IP testing.

15.14

ROAD LIGHTING COLUMN CUTOUT / ISOLATORS

15.14.1 General 1

Cutouts in columns shall be phenolic moulded, three phase, and suitable for looping two 4 Core 25 mm XLPE/SWA/PVC cables.

2

Cutouts shall : Incorporate miniature circuit breakers complying to BS EN 60898 with a minimum breaking capacity of 4kA.

(b)

Be of the combined single phase and neutral type.

(c)

Incorporate an earth terminal.

(d)

Be suitable for concentric or PVC armoured cables of up to 25mm2 cross-sectional area with capacity for looping in and out.

(e)

Have all metal parts tinned.

(f)

Be provided with a minimum of 2 fixing screws.

(g)

Be manufactured from material which is non-hygroscopic and non-tracking.

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Terminals and contacts shall have a rating of not less than 40 Amp and be suitable for the use of miniature circuit breakers 6 A, 10A or16 A ratings, selected from the Table 15.2 below:

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(a)

Wattage

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Table 15.2 Ratings of Miniature Circuit Breakers

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For 1 Lamp

For 2 Lamps

50W

70W

100W

150W

250 W

400 W

6

6

6

6

10

10

6

6

6

10

16

16

The cutouts shall comply with the 16th Edition of the IEE Wiring Regulations.

5

A cutout used as a means of isolation shall have the facility for padlocking.

6

The service cutout shall have a moulded enclosure, offering a minimum protection of IP22, capable of withstanding severe impact.

7

Separate terminals shall be provided for live, neutral and earth conductors complete with terminal shields to prevent accidental contact with all live conductors.

8

Cutouts shall be sized to accommodate the designated cables, but with a minimum of 25mm2 cables.

9

Cable armouring shall be bonded as an integral part of the cutout, and complete with cable armour clamp shrouds.

10

The cutout shall be suitable for mounting on a wooden backboard or DIN rails.

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11

Where there is a requirement for the use of an isolator they shall incorporate in-built fused loop terminals for the feeds to signs, bollards etc.

12

All isolating devices shall be double pole for single-phase systems and four poles for three phase systems.

13

All isolators shall be rated to suit the local environmental conditions of Qatar where these differ from those stated in BS EN 60947-3

15.15

FEEDER PILLAR

15.15.1 General Road lighting feeder pillars shall be totally enclosed weatherproof with fibreglass reinforced polyester cabinet of ground mounting type complete with accessories suitable for mounting outdoor..

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15.15.2 Cabinet

The feeder pillar cabinet, unless previously approved by the Engineer, shall be of fibreglassreinforced polyester and ultra violet ray resistant. The cabinet surface shall be totally weather and corrosion resistant with a completely smooth exterior. The outer 0.5mm - 1.0mm should consist of pure polyester. The colour of the cabinet shall be grey. The colour shall be completely light stabilised and impregnated from the surface through the thickness of the material.

2

Pillars shall be ground mounting type by means of a steel frame with concrete foundation. The cabinet shall have a base frame with a minimum ground clearance of 200mm between the body and the mounting area (bottom). The base frame shall have at least four holes to bolt down the pillar to the concreted steel frame. The cabinets base frame shall be removable. The feeder pillar shell shall incorporate lifting devices for the safe movement of the feeder pillar.

3

The cabinet top (canopy) shall be arranged so as to prevent the ingress of rainwater and provide air circulation.

4

The cabinet shall be provided with a front door complete with internal hinges and fixing screws fixing at top and bottom. A tamper proof lock will be provided centrally and all locks shall operate by a standard master key. Two keys for each pillar shall be provided. The door closing will have a perfect weatherproofing arrangement. The enclosure shall have a designated IP rating of IP54 in accordance with IEC 60529.

5

Approximate cabinet size shall be 1000mm high by 620mm length by 300mm width..

6

Natural ventilation shall be provided to limit the temperature rise to the manufacturer’s recommendations. Such ventilation shall not reduce the stated IP rating of the cabinet and shall be screened to prevent the entry of vermin. Where recommended by the manufacturer dust filters shall be provided.

7

A data plate shall be fixed to the inside of the pillar detailing information as deemed necessary by the PWA and/or the Engineer.

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Detailed distribution board schedules are to be provided within the each feeder pillar these to be located on the inside of the cabinet and stored in a weather protected plastic pocket securely fixed to the shell of the housing.

15.15.3 Components of Feeder Pillars 1

1 No. 200Amp mains breaker (MCCB) of three phase 415V - interrupting capacity according to BS 3871: 240V – 85kA 415V – 35kA A facility to lock off the assembly in the open position shall be provided. 1No. 200Amp 4 pole magnetic contactor, three phase with coil voltage of 240V within an IP 54 enclosure. The contacts of the contactor shall be fitted with a snap action to prevent chatter.

3

A control circuit shall be provided connected to the control coil of the contactor. The circuit shall be protected by means of a 4A HRC control fuse within a weatherproof enclosure. The control circuit shall be such that in the event of a failure of the photocell control unit a time switch identified below will override the operation. In addition a manual override switch shall be provided to operate the road lighting at times outside the periods during which the lights are normally operational.

4

The time switch shall be a 24-hour dial time switch motor driven single phase 30 Amp. 220 240V 50 Hz. with a clock accuracy of + or – 5minutes/year and shall have a 48-hour synchronous spring reserve to maintain clock operation and output switching during power supply failure or disconnection. Time switch should be protected with a HRC fuse or MCB. Arrangement for connecting a photoelectric control switch shall also be made within the pillar.

5

A 3-phase MCB metal clad or plastic distribution board complete with single pole 240V MCB’s of interrupting capacity according to BS EN 60898. The number and size of the outgoing circuits shall be as per the feeder pillar schedules. Terminations shall be capable of accommodating sub circuit cable of size 25mm2. There shall be at least 25% spare outgoing circuit capacity.

6

MCB’s and protective devices shall be rated to withstand a minimum short-circuit current of 9kA.

7

Neutral terminal bar shall be provided separately. Neutral conductors shall be insulated from earth to allow use on TN-S systems. The neutral connections shall have separate connections for each outgoing cable. Where a neutral busbar is provided it shall be mounted in parallel with the phase busbars and arranged so that each neutral connection is physically identified with the appropriate circuit. A separate earth bar shall be provided at the bottom of the feeder pillar and shall be of sufficient length to accommodate a connection for each circuit including 25% spare capacity. The neutral busbar shall be coloured black and the earth busbar coloured green and yellow.

8

Busbars shall be of full rating having taken into account any holes, they shall be constructed from high conductivity copper and mounted on insulators and mounted at the rear of the feeder pillar. Busbars shall be insulated with non-hydroscopic, non-tracking insulation. All live parts shall be screened.

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Insulated dividing barriers shall be provided between both phase contact assemblies and between phase and neutral.

10

Each feeder pillar shall accommodate at least 1No. brass cable gland with locknut, earth tag and PVC shroud for the incoming supply cable together with individual brass cable glands 25mm CW gland according to BS 6121 complete with lock nuts, earth tags and PVC shrouds for all outgoing cables, including an allowance for spare capacity, for stranded copper cables up to 25mm² 4 core XLPE SWA PVC.

11

Colour-coded leads shall identify all wiring for phase and neutral cables. Outgoing circuits shall be labelled with the circuit reference and circuit breaker rating. Wherever possible all internal wiring shall be enclosed in trunking or conduit.

15.16

ROAD LIGHTING CABLES

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15.16.1 Underground Cables

Underground road lighting cable shall be copper stranded 10/16/25mm² x 4 core XLPE SWA PVC cable of stranded copper conductor 600/1000 VAC.

2

Cables shall be low tension 600/1000 volt multi core stranded copper conductors, insulated with XLPE compound, core laid-up, extruded PVC tape bedded, steel wire armoured and PVC sheathed overall underground cables to BS 5467: 1977.

3

The cable shall be capable of withstanding vigorous climatic conditions of ambient temperature up to 50°C (the temperature can be accompanied by a relative humidity of up to 100% at 30°C).

4

It should also be noted that cables can be buried in sand and laid partly in ducts at a depth of up to 600mm in footpaths and 750mm in roadways. The ground temperatures can vary from 35-40°C in summer to 8-12°C in winter. Cable drums may be stored in the open for up to 1 year and will be exposed to direct sunlight. Accordingly, cables shall be designed to withstand such conditions without deterioration of the electrical or mechanical properties.

5

Cables shall have the following construction details: Conductors:

High conductivity stranded copper - shaped conductors shall comply with BS 6360: 1981 with XLPE insulation.

(b)

Bedding:

Bedding shall be an extruded layer of XLPE compound.

(c)

Colour of Cores:

Red, Yellow, Blue and Black.

(d)

Armouring:

Single layer of galvanized steel wire.

(e)

Finish (over sheath): Extruded black PVC over sheath which conforms to BS 6346:

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1987 for thickness and to BS 6746: 1987 for properties. The external surface shall be embossed with the voltage designation, cable size and manufacturers name 15.16.2 Packing of Cables 1

Underground cables shall be packed in sealed wooden cable drums each of 500 metres length with a plate stating the following details: (a)

Manufacturer's name and country of origin

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Section 06: Roadworks Part 15: Road Lighting

(b)

Cable type and size

(c)

Length of cable per drum

Page 46

15.16.3 Insulated PVC Sheathed Circular High Temperature (85°C) 1

Flexible cable should be of conductors of high conductivity copper stranded wires, 2.5 sq. mm, insulated with high temperature PVC compound, three cores, green or yellow, blue and brown, twisted together, filled and sheathed with high temperature PVC compound, 300/500V.A.C. according to BS 6141, Table 15 or equivalent norm.

15.17

MARKER TAPE FOR UNDERGROUND POWER CABLES

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Marker tape shall be installed wherever cables are to be directly buried in the ground to warn of the presence of power cables.

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15.17.2 Material & Quality

The marker tape shall be of low density polyethylene, of thickness at least 100 micron. Its width shall be 40cm and be yellow in colour, with black marking indicating the presence of road lighting cable in both English and Arabic. Its location in respect of the cable position is identified within the Contract documentation.

2

The material shall be colour fast, and resistant to chemical action in typical ground conditions experienced in Qatar. These may vary from extremely wet to extremely dry, and with very high salinity. The ground temperature may vary from 0 to 40°C.

3

The material shall be mechanically durable. The manufacturer shall demonstrate the samples complying with this specification have been tested for compliance with BS 2782, Part 3, Method 326A to 326C or an equivalent standard.

15.18

MARKER POSTS

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15.18.1 General 1

Where instructed by the Engineer, the Contractor shall install marker posts and slabs. These shall be of reinforced concrete, steel or heavy duty plastic of an approved type suitable for use in Qatar. Unless instructed otherwise pre-cast reinforced concrete or equally approved marker posts or slabs shall be installed at intervals of not more than 50m along all underground cable routes, joint pits (if any), at all changes of direction and at both ends of road crossings.

15.19

EARTHING

15.19.1 General 1

The integrity of the earthing system within the road lighting network shall be maintained.

2

Each item of equipment shall be individually effectively earthed within each lighting assembly and feeder pillar by means of a dedicated earth to a central earthing point. This shall be regardless of any other terminals available. All connections shall use crimped terminations.

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For circuit conductors of 16mm and 25mm a circuit protective conductor of cross-section 2 not less than 16mm shall be incorporated.

4

All removable metal doors or metal frames shall be earth bonded.

5

Within the feeder pillar the central earthing point shall be connected to the incoming earth provided by QGEWC.

6

At each feeder pillar location an earth rod shall be installed complete with an approved earth pit and cover plate. It shall have a resistance to true earth of not more than 10 ohms. The size of the earth rod shall be 16mm by 2.5m in length. It shall be driven to a depth that penetrates the summer water table by at least 1m. It shall be connected to the central earthing point of the feeder pillar via a bare stranded copper conductor of cross-sectional 2 area 70mm .

7

At the end of each lighting sub circuit an additional earth electrode as detailed above shall be connected to the central earthing point within the last lighting column base compartment. The connection between the earth electrode and the column central earth terminal shall be via a 2 bare stranded copper conductor of cross-section 16mm .

8

Routing of the earth cable to the ground conductor within the last column of each feeder pillar outgoing subcircuit shall be via a 100mm. PVC duct within the column foundation.

15.20

INSTALLATION

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15.20.1 General Requirements

The Contractor is responsible for all liaisons, through the Engineer, with the departments concerned within the PWA, in respect of programming the installation and commissioning of the complete road lighting system. He shall also ensure through the Engineer that the relevant departments within the PWA are at all times kept informed of the current progress of the work. Throughout the road lighting installation works the engineering representative from the relevant departments within the PWA, must be invited to carry out periodic inspections of the works. The Contractor shall ensure that his approved subcontractor programmes works are in the designated sequence in accordance with the approved programme. On completion of each phase of the works progress to the next phase will be subject to the approval of the Engineer’s Representative and/or the relevant departments within the PWA.

2

A qualified person having a thorough experience in road lighting and associated equipment shall supervise the execution of all electrical work.

3

Only workmen who have had experience in the erection of road lighting shall be employed on the work of erection.

4

Before carrying out any electrical works to existing services, authorisation must be obtained in writing from all relevant authorities.

5

The Contractor shall carry out all electrical tests and ensure satisfactory results as set out in the ILE Code of Practice for Electrical Safety.

6

Where an existing installation has been extended the relevant parts of the existing system and equipment earthing shall be inspected and tested for compliance with the IEE Wiring Regulations.

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A completion certificate as detailed in the IEE Wiring Regulations shall be issued following the inspection and testing of the installation and any corrective action found necessary.

15.20.2 Temporary Lighting Where the existing installation is to be disconnected during the Contract Period, temporary lighting shall be provided. Any temporary lighting proposals must have the approval of the PWA prior to installation.

2

At no time shall design road lighting standards be lower than those existing prior to the start of the Contract.

3

The Engineer must approve any form of temporary lighting and associated lighting levels.

4

Temporary lighting shall not be removed or disconnected until the permanent installation has been inspected and approved by the Engineer and has been energised.

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15.20.3 Removal of Existing Columns

Prior to any work being undertaken the Contractor shall obtain from the relevant departments within the PWA a copy of the latest revised record drawing of the existing lighting network within the contract limits. The Contractor is to identify from these records those columns affected by the Contract and require removal or relocating. A copy of any record obtained shall be forwarded to the Engineer for his use.

2

Existing columns shall be removed under supervision of the Engineer’s Representative in consultation with the relevant department within the PWA. Existing cables shall be disconnected, made safe and protected to the satisfaction of the Engineer in consultation with the relevant departments within the PWA prior to removal of the columns.

3

No existing road lighting shall be switched off, dismantled or removed without the prior approval of the Engineer and the relevant departments within the PWA. Where the existing road lighting has been removed the Contractor, to ensure safe vehicular and pedestrian movement within the designated area, shall provide necessary temporary lighting complete at his cost. Existing signs shall also be relocated at the Contractors cost to ensure compliance with the current traffic regulations.

4

All lamps, luminaries and fittings shall be removed before excavating around the column prior to its removal. Tie ropes shall support the columns at all times.

5

The Contractor shall carefully excavate existing material from around the column base, including concrete taking care not to damage any adjacent cables or services. No assembly shall be removed until it has been fully excavated.

6

The columns shall be lifted from the foundation by means of a crane approved by the Engineer. The foundation shall be backfilled with suitable approved material and temporarily reinstated.

7

All columns, cables, lamps and luminaries to be removed under the Contract shall be taken to store as directed by the Engineer and remain the property of the PWA. Where such items are instructed to be taken to the stores of the PWA, proof of delivery should be obtained by means of a signed receipt from the relevant departments within the PWA and witnessed by the Engineer’s representative.

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Section 06: Roadworks Part 15: Road Lighting

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Existing road lighting, where it is to be relocated within the Contract, shall be carried out in accordance with the relevant sections of the contract specifications, as if new. Prior to reinstalling all equipment it shall be inspected and any damage reported to the relevant departments within the PWA, via the Engineer.

15.20.4 Detailed Drawing for RCC foundation The foundation for the 3 metre to 12 metre lighting columns shall be in accordance with the details provided within the Contract Documents. The reinforcement detail shall be detailed by the Contractor based on the recommendations of the column manufacturer to meet the column assembly design criteria detailed in paragraph 15.6.7 of this specification. Contractor shall consider the use of augured foundations in areas where soil and lighting utility reservation necessitate it, as per the Contract Documents.

2

The foundation detail for the lighting columns or masts between 16 metres to 30 metres will be as recommended by the column manufacturer for the climatic conditions applicable to the State of Qatar taking due consideration of the equipment to be supported. Contractor shall consider the use of augured foundations in areas where soil and lighting utility reservation necessitate it, as per the Contract Documents.

3

Final configuration of the proposed foundation will be subject to the approval of the Engineer and the PWA.

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15.20.5 Road lighting Column/Lantern Installation

Road lighting columns shall be erected on pre-constructed bases offset from the carriageway, as defined in the contract Specification, via anchor bolt arrangement.

2

Prior to erection of the lighting pole no bracket arm or lighting fixtures shall be mounted on the column shaft.

3

Only purpose made cranes with nylon slings will be accepted for the purpose of lifting the columns onto the anchor bolts. Metal chains are not acceptable.

4

The bottom securing nut/washer arrangement or shims shall be used to align the lighting column vertical. The location of the base compartment door shall be agreed prior to the installing of the column shaft, but unless notified otherwise the door opening shall be located such that any operative working within the column shall face the on-coming traffic.

5

Once installed, the final alignment and verticality of the column shall be checked in two directions at 90 degrees to each other by theodolite or other approved method. The final verticality is to be approved by the Engineer’s Representative prior to the column bracket and luminaire as specified being installed and commissioned.

6

The underground cables shall be terminated into the cut-out/isolator assembly mounted within the lighting pole base compartment. An additional length of 500mm shall be allowed at each incoming cable termination and shall remain underground for future reconnections.

7

Wiring between the terminal block in the luminaire and the components in the base of the column or each unit shall be using high temperature 3 core, green or yellow, blue and brown, 2.5mm2 copper flexible cables to BS 6141.

8

All installation requirements described in the ILE Code of Practice Clause 11 shall apply.

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Section 06: Roadworks Part 15: Road Lighting

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A double insulated 6.0mm2 stranded copper earth wire with clamped tag bonded to earth lug on column and the column door earth terminal shall be provided.

10

All cable routes shall be clear of control gear and limited to horizontal and vertical runs. Cables entering terminals shall show no bare wire nor shall the insulation be taken into the electrical conducting part of the terminal. All cable shall be neatly bunched together and securely taped.

11

Terminal blocks shall be clearly marked and the wiring shall be so arranged that the luminaire can be dismantled, for purposes of routine cleaning and lamp replacement, without any electrical wiring disconnections.

12

After installation each lighting column shall be identified by a reference number in accordance with the requirements of the PWA.

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15.20.6 Road lighting Feeder Pillar Installation

The road lighting feeder pillar shall be erected on pre-constructed base off set to the carriageway, as defined in the Contract specification, via anchor bolt arrangement.

2

Prior to erection no internal equipment shall be installed which could be damaged either in transit to site or during the erection phase.

3

The bottom securing nut/washer arrangement or shims shall be used to align the feeder pillar vertical.

4

The electrical installation within the feeder pillar shall be undertaken as detailed elsewhere in the specification.

5

All underground cables when terminated shall allow for a minimum length of 500mm to be left underground to allow for future reconnections

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15.20.7 Road lighting Cable Installation 1

The installation of all cables shall be in accordance with the requirements of QCS Section 21.

2

Excavation of Road lighting Cable trenches for cable size from 10mm to 35mm x 4 core are to be of the following dimension:

2

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Depth: 600mm Width: 500mm 3

Cable trenches shall be cleared of all stone and sharp projections and shall be drained. All cables shall be laid on a bed of 150mm approved fine aggregate sand or quarry scalping. Cabling to and between columns will be by means of copper stranded 4core XLPE.SWA.PVC cable. (Size as indicated and based on the connected electrical load and length of cable from power source) and shall be at the depth of 450mm. A layer of 150mm dune sand or quarry scalping is to cover the cable. No joints in Cable shall be permitted.

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Section 06: Roadworks Part 15: Road Lighting

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LV cables laid shall be laid straight between lighting columns with an allowance for 500mm spare underground cable adjacent to each column. Cables can be placed in the same trench with a lateral spacing between cables of 50mm. In the event of HV cables being placed in the same trench then there shall be a separation of at least 300mm. All cables shall have a clearance of at least 300mm from all other services including telephone or communication cables.

5

The Contractor shall arrange for inspection of the cable, trenches and cable installations by the Engineer’s Representative, in conjunction with the relevant departments within the PWA prior to backfilling.

6

All cables shall be handled, installed and terminated in accordance with the manufacturer’s recommendations. The manufacturer’s recommended ambient temperature limitations for the handling of cables shall be strictly adhered to.

7

All cables, once removed from the cable drum, shall be immediately laid in position. No cable shall remain laying on the surface for more than is practicably possible.

8

Cabling is to be looped into each column and terminated by means of an approved lighting column cut out.

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Underground ducts shall be provided where cables

Cross roads or other paved areas with vehicular access.

(b)

Cross unpaved areas regularly used by vehicles.

(c)

Enter buildings.

(d)

Vehicular entrances to properties.

(e)

Pass through corrosive soils or elsewhere as designated, they shall be drawn into underground pipe ducts.

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15.20.8 Road Crossing Ducts

A steel draw wire or nylon or polypropylene cord shall be inserted in each duct run immediately after its installation. A 2m surplus shall be left at each end of each run, neatly coiled and attached to a crossbar preventing the wire or cord from being drawn into the duct.

3

Underground pipe ducts shall be heavy gauge unplasticised PVC (high impact resistant PVC, 3.6mm wall thickness) conduits with tapered sleeve or spigot and socket joints encased in concrete as detailed in the Contract drawings and in accordance with the requirements of the PWA.

4

All ducts shall have a nominal internal diameter of 150 mm unless designated otherwise.

5

The internal diameter of ducts used to provide cable entries into structures shall have a space factor less than 25 %, unless otherwise designated.

6

All dual systems shall be installed so that no undue strain is placed on cables when pulled in. Cable manufacturer’s recommendations shall be followed.

7

All underground cable ducts shall, so far as possible, be run in straight lines.

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Duct runs crossing roads shall be straight and, wherever possible, perpendicular to the axis of the road. They shall be laid at a depth of 800mm backfilled and reinstated in accordance with QCS.

9

Except in the case of short isolated duct runs such as road crossings, underground cable duct runs shall terminate in suitable drawpits.

10

Cable ducts passing under roads carrying heavy vehicles shall be completely surrounded with concrete of grade SRC 30 as per the standard detail.

11

Ducts shall be laid so as to drain naturally towards one or both ends, where adequate provision for drainage shall be made. Adequate precautions shall be taken to prevent the cable duct system acting as a stormwater or groundwater drainage system. A minimum fall of 1 in 200 shall be provided for drainage purposes.

12

Any work carried out requiring the use of split ducts shall be carried out in such a manner as to preserve the withdrawability of the cables concerned.

13

Notwithstanding the type of duct to be used generally, cable ducts laid in ground which is liable to subsidence shall be of heavy gauge PVC with spigot and socket joints, and shall be installed on a concrete bed as designated above, but without concrete surround.

14

If two or more cables are to be installed in the same duct, the aggregate of their crosssectional areas shall not exceed 30 % of the cross-sectional area of the duct.

15

All trenches excavated for the laying of cable ducts shall be completely backfilled and rammed before cable installation work begins.

16

Immediately following the installation of any duct run, the interior of the duct shall be thoroughly cleaned by twice drawing through the ducts a mandrel, once in each direction. Following this, the ends of each run shall be sealed with a suitable hardwood or plastic sealing plug which shall be left in position until cable laying is about to begin.

17

The polished hardwood mandrel shall be 300mm long having spherical ends and a diameter 6mm less than the nominal duct diameter.

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15.20.9 Backfilling and Re-instatement 1

All trenches and pole pit/foundations shall be backfilled, compacted and re-instated in accordance with the QCS requirements.

15.20.10 Road lighting Cable Terminations and Testing 1

Unless otherwise designated, cable glands shall be of brass and comply with BS 6121 where applicable, and shall be of a design appropriate to the type of cable being terminated.

2

Glands for cables with metallic inner sheaths shall incorporate a bonding connection.

3

Except where it is impracticable to do so, the cable cores shall be taken through the terminating box directly to the terminals of the equipment, without crosses, and shall be made off with sweated cast brass cable sockets, or an approved type of hydraulically crimped socket.

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Section 06: Roadworks Part 15: Road Lighting

Page 53

4

Terminations for armoured cable shall incorporate a method of rating off the armour which ensures a permanent earth bond between the cables terminated to the satisfaction of the Engineer. The cable armour shall be bonded to the earth terminal block in each column.

5

All cable sealing boxes shall be marked on the outside with 15 mm diameter painted discs, in the appropriate colours, to indicate the disposition of the phase and neutral conductors within them.

6

Compression glands installed externally shall be classified IP66 and be provided with closefitting PVC shrouds.

15.20.11 Electrical Power Supply Upon the completion of the associated work, arrangements will be made via the Engineer to provide the electrical power to each road lighting feeder pillar based on a 415V 50Hz supply. Once available, and after inspection, the lighting system shall be tested prior to connection. The Engineer shall arrange for full consultation with the relevant departments within the PWA during this phase of the lighting works.

15.21

TESTING AND COMMISSIONING ON SITE

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15.21.1 General

In addition to the requirements of the Contract Specific Specification all testing and commissioning shall be carried out according to the requirements of the relevant BS , CP, IEE regulations, or other standards and regulations as may be stated or implied in this Specification.

2

Each completed system with the installation shall be tested as a whole under operating conditions to ensure that each component functions correctly in conjunction with the rest of the installation.

3

The Contractor shall afford access at all times to the relevant departments within the PWA to enable them to inspect work during and after erection and to be present at all tests.

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15.21.2 Electrical Tests 1

As soon as is practicable after the completion of installation the tests described below, together with such other tests and measurements to prove compliance with the contract requirements shall be made.

2

An insulation tester shall be used to measure the insulation resistance between each conductor and the remaining conductors and between each conductor and the metallic sheath (if any) and armouring. The test voltage to be applied shall be at least 1000 V.

3

The above tests shall be carried out both before and after any pressure tests and the insulation resistance shall not be less than the figures in the appropriate BS.

4

A voltage test of 15 minutes duration shall be applied in accordance with BS 5467 Appendix 88, BS 6622 Appendix C8 or BS 6346 Table 5, as applicable.

5

Proposals for the appropriate test in respect of other types of cable shall be submitted for approval.

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An earth continuity test shall be carried out to verify that the cable armouring and metal sheath, if any, have been properly bonded to earth.

7

Phase rotation and phase correspondence shall be tested to prove that the cables have been correctly connected.

8

Where a new cable has been jointed to an existing cable with the express permission of the Engineer, the voltage test designated above may be carried out at a reduced voltage if the existing cable has been in service for more than five years. In such a case the test voltage shall be determined by applying a factor K to the value given in the appropriate British Standard as referred to above.

9

The Contractor shall afford access at all times to the representatives of QGEWC and the relevant departments within the PWA to enable them to inspect work during and after erection and to be present at all tests.

10

Upon completion of laying and terminating underground cable runs, the Contractor, in the presence of the Engineer or his duly authorised representative, shall carry out pressure tests in accordance with relevant British Standards. The Contractor shall provide all apparatus and labour required for such tests and within a reasonable time thereafter shall present the Engineer with certificates of the tests.

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A certificate of Initial Lighting Performance of Installation shall be issued when tests have been passed as follows: The initial photometric tests shall be made after the installation has been in lighting operation for between l00 and 150 hours

(b)

The location of test positions shall be distributed along the length of the installation and shall be as directed by the Engineer. All service tests throughout the testing period shall be made at these positions.

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15.21.3 Photometric Performance Testing

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Readings shall be taken with a portable calibrated luminance meter holding a current valid calibration certificate. The measurements in accordance with the procedures laid down by the CIE and shall be taken by a qualified lighting engineer who shall confirm that the lighting performance data as identified in the contract specification has been satisfactorily obtained.

3

Measurement of the supply voltage at adjacent lighting columns and posts shall be taken at the time of each test and the illumination measurement shall be adjusted for any variation from the supply voltage value declared in the contract specification. Allowance shall be made for the use of control gear taps if necessary immediately before the initial tests are made. The lamps and all components of the luminaire that may affect the optical performance shall be cleaned and correctly adjusted.

4

The Engineer shall witness all photometric testing, unless otherwise notified in writing. A minimum of 7-days’ notice shall be given to the Engineer before testing begins. After testing the certificates shall be submitted to the Engineer for approval. Representatives from the relevant departments within the PWA shall be invited to witness the lighting performance testing.

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Section 06: Roadworks Part 15: Road Lighting

Page 55

RECORD DRAWINGS

15.22.1 General Within thirty days from the date of completion of the whole or any section of the lighting works the Contractor shall provide fully detailed "as built" drawings and schedules in respect of all sections of work completed together with all relevant operating and maintenance instructions. The drawings shall: Fully indicate with accurate dimensions the sizes, types and position of equipment, cables, ducts, joints, feeder pillars etc., with particular regard for the need to accurately locate buried cables after completion.

(b)

Show the circuit arrangements for the relevant section of the road lighting installation.

(c)

Show full details, ratings and function of each item of equipment.

(d)

Include any other relevant information to ensure the safe and satisfactory operation of the particular section of the road lighting works.

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The Contractor shall submit, within the time stated above, two copies of the Record Drawings for the approval of the Engineer. Upon and after receipt of such approval the Contractor shall provide records in both digitised and hard copy format of reproducible transparent negative drawings, and two sets of prints on paper to the Engineer for his retention.

3

In addition to the foregoing, the Contractor shall provide in each feeder pillar and distribution unit a good quality print on paper showing the road lighting distribution line diagram of that particular section. These prints shall be mounted on the inside of the door of each feeder pillar and distribution unit and shall be covered in clear plastic to prevent undue deterioration.

4

In order to achieve accurate Record Drawings all relevant information relating to the lighting works shall be entered on to the stated drawings and kept for immediate use once the work has been carried out. The marked prints shall be available for inspection at the Contractor's site office at any reasonable time during the progress of the lighting works.

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END OF PART

QCS 2014

Section 06: Road Works Part 16: Traffic Signals

Page 1

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16 TRAFIC SIGNALS ......................................................................................... 2 16.1 GENERAL ...................................................................................................... 2 16.1.1 Summary 2 16.1.2 References 2 16.1.3 Submittals 2 16.1.4 Quality Assurance 3 16.1.5 Delivery, Storage and Handling 3 16.1.6 General Project/Site Conditions 4 16.1.7 Warranties 4 16.2 SUPPLY OF TRAFFIC SIGNAL EQUIPMENT .............................................. 4 16.2.1 General 4 16.2.2 Identification of Equipment 5 16.2.3 Traffic Signal Posts 5 16.2.4 Traffic Signal Gantries 5 16.2.5 Three-Aspect Traffic Signal Heads 6 16.2.6 Two-Aspect Pedestrian Signal Heads 7 16.2.7 Traffic Signal Controllers 8 16.2.8 Pedestrian Operated Push-Buttons 10 16.2.9 Flexible Traffic Signal Cable 10 16.2.10 Armoured Traffic Signal Cable 10 16.2.11 Loop Cables 11 16.2.12 Loop Feeder Cables 11 16.2.13 Pulling Chamber Cover 11 16.2.14 Unplasticised Polyvinyl Chloride (PVC-U) Ducts 12 16.2.15 General Compatibility 12 16.3 INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT ................................. 12 16.3.1 General 12 16.3.2 Poles, Gantries and Signal Heads 12 16.3.3 Installation of Traffic Signal Controller 13 16.3.4 Cabling 13 16.3.5 Circuit Protection and Earthing Requirements 14 16.3.6 Permanent Electrical Power Supply 15 16.3.7 Inductive Loops for Vehicle Detection 16 16.4 TESTING AND COMMISSIONING .............................................................. 20 16.5 GUARANTEED MAINTENANCE OF TRAFFIC SIGNAL EQUIPMENT ............................................................................................... 21 16.5.1 General 21 16.5.2 Operational Maintenance 21 16.5.3 Emergency Maintenance 23 16.5.4 Contractor’s Vehicles 23 16.5.5 Contractor’s Equipment 23

QCS 2014

Section 06: Road Works Part 16: Traffic Signals

Page 2

TRAFIC SIGNALS

16.1

GENERAL

16.1.1

Summary

1

This Part includes the provision of traffic signal equipment and related street furniture at controlled roadway junctions and pedestrian crossings.

2

Related Sections

16.1.2

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Section 1 Section 5 Section 9 Section 10 Section 21

.

16

References

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The following standards are referred to on this Part: BS 1361......................Cartridge fuses for a..c circuits in domestic and similar premises BS 381C .....................Specifications for colours for identifications BS 5493......................Code of practice for protective coatings of iron and steel structures against corrosion. BS 7430......................Code of practice and regulations for earthing BS 7671......................Requirements for electrical installations BS 88..........................Cartridge fuses for voltages up to and including 1000 Vac and 150 Vac

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BS EN 1011................Process of arc welding carbon and carbon manganese steels BS EN 12368..............Road traffic signals BS EN 13108..............Fine cold asphalt BS EN 60529..............Degrees of protection provided by enclosures BS EN ISO 146 ..........Hot dip galvanised coatings on iron and steel articles

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AASHTO Standard specification for supports for highway signs, luminaires, traffic signals DIN 40050 ..................Enclosures for electrical equipment DIN 6163 Part 5..........Diffusion lenses for traffic signals QGEWC (E) Regulations for Electrical Installations QGEWC (E) Regulations for Protective Multiple Earthing 16.1.3

Submittals

1

The Contractor shall submit to the engineer for approval shop drawings for each type of signal pole, gantry and mounting frame for signal heads to be provided under the Contract along with structural calculations. The drawings shall show materials specification and finishes for each component proposed for use. All weld types and sizes shall be identified on the shop drawings.

QCS 2014

Section 06: Road Works Part 16: Traffic Signals

Page 3

The Contractor shall submit to the engineer for approval design calculations for the proposed signal poles and gantries. The design calculations shall be carried out in accordance with the AASHTO Standard specification for supports for highway signs, luminaires, and traffic signals

3

The Contractor shall propose a design for the foundations for each type of signal pole and gantry and shall submit design calculations and drawings to the Engineer for approval.

4

The Contractor shall submit to the engineer for approval a schematic wiring diagram for all the installations. The Contractor shall also submit a wiring layout drawing for the cable loops and the cross-sectional details of the cut in the road surface.

16.1.4

Quality Assurance

1

Contractors for the works shall be experienced specialists in the field of traffic control systems with a minimum of 5 years experience of the installation, commissioning and testing

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of such systems in a similar environment.

The Contractor shall submit a technical submission for the proposed subcontractor giving details of previous installations date installed, client, technical data for proposed materials, and experience record of proposed installation staff, supervisors and management.

3

Installation of traffic signal equipment shall only be conducted by approved specialist subcontractors. The specialist subcontractors shall be approved by the PWA.

4

The performance and design requirements work shall be in compliance with QGEWC Regulations for Electrical Installations.

5

All equipment supplied shall, in general, conform to the same style, colours and functions as that already in place in Qatar. The supplier may be required to provide, at his own expense, samples of his proposed equipment.

6

All equipment and installation shall be in accordance with the latest edition of the Qatar Traffic Manual. For all signalled intersections and pedestrian signal control crossings the timing sequence of signals displayed to drivers during phases shall be as per information given by the PWA and/or Traffic Police.

16.1.5

Delivery, Storage and Handling

1

Before delivering a traffic signal controller to site, the Contractor shall arrange a factory acceptance test in his workshop. The programmed and internally complete controller shall be connected to a labelled light board capable of simulating all traffic signal aspects controlled by that particular controller. The Contractor shall ensure that all equipment and devices are available to show that the controller fully complies with operational requirements. The factory acceptance test shall consist of the following checks:

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(a)

visual check of internal wiring and controller assembly

(b)

operation of green conflict monitor

(c)

intergreen times

(d)

group times

(e)

detector logic (where applicable)

(f)

stage to stage change logic

(g)

lamp switching.

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Section 06: Road Works Part 16: Traffic Signals

Page 4

2

The Contractor shall be responsible for the delivery of all items to the project site or to any site as required by the Engineer.

16.1.6

General Project/Site Conditions

1

All equipment and associated components shall be designed and suitably rated to ensure proper maintenance, continuous trouble free service under the prevailing climatic conditions. All equipment and installation shall operate satisfactorily in a temperature range of 0 C to +55 C and under humidity conditions ranging from 10 % to 100 %. Warranties

1

All warranties and guarantees for traffic signal equipment shall commence from the day of commissioning. The warranty period shall be that as designated by the manufacturer but shall in any case not be less than 400 days

16.2

SUPPLY OF TRAFFIC SIGNAL EQUIPMENT

16.2.1

General

1

It shall be the Contractor’s responsibility to ensure that all equipment supplied is approved. The Engineer will advise on approved suppliers.

2

It shall be the Contractor’s responsibility to honour the designated warranty periods..

3

The Contractor, shall make himself aware of any lead times required for delivery of equipment and programme his works accordingly. It shall be the Contractor’s responsibility to ensure that equipment is available as needed, any delays to works resulting from the unavailability of equipment shall be deemed to be the responsibility of the Contractor.

4

The Contractor shall be responsible for the correct delivery, storage and handling and storage of all equipment up to the time it is commissioned.

5

All equipment shall comprise of units of a type that have been used successfully in other installations in a similar environment, from a minimum period of six months and shall be subject to approval of the engineer. Particular attention shall be given in the selection and design of equipment and components to the exclusion of water, moisture and dust.

6

Components and materials that may perish and deteriorate in the climatic conditions of Qatar shall be avoided. All equipment shall be so constructed as similar units that shall be readily available and completely interchangeable both mechanically and electrically.

7

The location layout of each installation and the number of phases and stages for each traffic controller shall be as designated Controllers shall provide the signal sequences and phasing designated for each installation.

8

The structural design and traffic signal posts and traffic signal gantries shall be in accordance with provisions of AASHTO standard specification, Supports for Highway Signs, Luminaires, Traffic Signals, or an approved alternative.

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16.1.7

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Section 06: Road Works Part 16: Traffic Signals

Page 5

Identification of Equipment

1

The Contractor shall mark or clearly label all modules, units and main parts of a system with a functional code or title, type number, serial number as approved by the Engineer.

2

Marking shall maintain legibility throughout the life of the equipment under the prevailing environmental conditions.

3

The labelling system shall comply with the GIS system (as defined in the data dictionary) used by the Government of Qatar and the PWA.

16.2.3

Traffic Signal Posts

1

Traffic signal poles shall be of the tubular steel type with a flanged base, having an internal electrical termination point accessible through a lockable inspection window. The supply of a traffic signal pole shall include; holding down bolts, nuts, washers and shims required for erection; pole; terminal block; locking cover for inspection window complete with three sets of keys; all grommets; glands and cable anchor points.

2

Traffic signal poles shall have dimensions conforming to those given in the contract Drawings.

3

The traffic signal poles shall be of mild steel construction. Corrosion protection shall be through the use of a hot dipped galvanised coating conforming to the requirements of British Standard BS 5493 and BS EN ISO 1461, depth of galvanised coating shall be 85 microns. All welded connections shall conform to British Standard BS EN 1011.

4

The termination point shall consist of a terminal block positioned internally within the traffic signal pole. The terminal block shall be fully accessible through a lockable inspection window. The terminal block shall be securely fixed to the traffic signal pole.

5

The terminal block shall be electrically isolated from the traffic signal pole and shall have a minimum capacity of 2 x 20 No. connectors. Each connector shall have a minimum rated capacity of 100 watts at 240 volts.

6

The connectors on the terminal block shall be in compliance with the requirements of the QGEWC.

7

The traffic signal pole shall have the facility to secure incoming cables at a point prior to them being connected to the terminal block

8

The traffic signal pole shall be fitted with an electrical earthing stud, such that at least four earth connections can be made to it.

16.2.4

Traffic Signal Gantries

1

Traffic signal gantries shall be of the tubular steel type with a flanged base, having an internal electrical termination point accessible through a lockable inspection window. The supply of a traffic signal gantry shall include: holding down bolts, nuts, washers and shims required for erection; pole caps; terminal block; locking cover for inspection window complete with three set of keys; all grommets, glands and cable anchor points. Traffic signal gantry shall be styled in accordance with Contract Drawings.

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16.2.2

QCS 2014

Section 06: Road Works Part 16: Traffic Signals

Page 6

The traffic signal gantries shall have minimum dimension conforming to those given in the Drawings. The design of the gantries is open to submission by the supplier.

3

The supplier shall provide full details of the materials used and the method of construction employed when quoting for this item, this shall include workshop fabrication drawings, material specifications and calculations pertaining to the structural design of the gantry. The gantry shall be capable of supporting three aspect traffic signal heads, each having a total weight of 25 kg, inclusive of mountings. The number and position of heads are to be as designated.

4

With regard to termination points, cable anchor points and earthing points, these shall be as specified in Section 6 Part12 of this Specification

5

The supplier shall furnish full details of the foundation requirements for his proposed gantry, this shall include details of dimensions, reinforcement, quality of concrete and fixings. Anchor bolts shall be Grade 8.8 and shall be hot-dip galvanized to BS EN ISO 1461.

6

The gantry and foundation design shall be such that the gantry is completely detachable from the foundation, should this be required.

7

The gantry shall have a system such that it can be adjusted subsequent to installation, to allow for leveling and turning.

8

The supplier shall furnish full details of the proposed foundation for his proposed gantry, this shall include details of dimensions, reinforcement, quality of concrete and fixings. The gantry and foundation design shall be such that the gantry is completely detachable from the foundation, should this be required. Anchor bolts shall be Grade 8.8 and shall be hot-dip galvanised to BS EN ISO 1461. The gantry shall have a system such that it can be adjusted subsequent to installation, to allow for levelling and truing.

9

The electrical termination point shall consist of a terminal block positioned internally within the gantry. The terminal block shall be fully accessible through a lockable inspection window. The terminal block shall be securely fixed to the gantry.

16.2.5

Three-Aspect Traffic Signal Heads

1

Three-aspect traffic signal head dimensions shall be as designated. The Contractor shall submit drawings of the proposed units.

2

Signal heads shall comprise of a polycarbonate body containing three traffic signal aspects, coloured red, amber and green and shall include:

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(a)

lamps

(b)

reflectors

(c)

lenses

(d)

transformers

(e)

visors

(f)

anti-phantom devices (if designated)

(g)

brackets, frames and all fixtures and fittings required for mounting

(h)

backing board.

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3

Signal heads shall be constructed, in as far as is possible, out of high quality polycarbonate plastic. Any metal fittings shall be suitably protected against corrosion.

4

The design and construction of signal heads shall allow for all of the following features: hinged lens panels to allow quick access to the lamps

(b)

flexible, detachable visors

(c)

easily adjustable mounting system

(d)

capability of internally fitting optical arrow mask.

The signal heads shall use, for each aspect, a 10 volt halogen lamp of type SIG 64015/1 50W or SIG 64015 - 50W. The lamp holder and connectors shall be compatible with the type of lamp used. The lamps shall conform to BS EN 12368. The supply voltage to the signal head shall be 240 volts ( 5 %) and shall be converted to the lamp voltage by the use of a standard design transformer (El Type). Each aspect shall have an individual transformer,

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these transformers shall be fitted with noise suppression equipment. The transformers will be required to operate in ambient temperatures up to 60° C. The transformers shall have a minimum operational life of five years with an effective switch-on ratio of 3300: 4380. Signal heads shall be capable of being mounted on the traffic signal pole or gantry as designated or, in the case of traffic signal gantry, as may be proposed by the Contractor. The mounting system used shall be such that no predrilling or permanent attachment of brackets to the signal pole or gantry is required. The mounting system shall be such that the signal head shall be capable of being adjusted through an arc of 30 degrees about its vertical axis. It shall be possible to mount two three-aspect traffic signal heads side by side on a single pole such that the vertical faces being presented to oncoming traffic of each head remain in the same plane. It shall be possible to mount the signal heads asymmetrical from the centreline of the pole. The signal head shall be rendered splash proof by means of an lP54 enclosure. The item description covering signal heads shall include, where necessary, extra mounting brackets to enable the above facilities.

7

The optical reflector shall be made of a high grade aluminium, mirror finished. Diffusion lenses shall be constructed with an internal cobweb pattern and shall be coloured red, amber or green as defined by the colour limits laid down in the DIN Standard DIN 6163 Part 5.

16.2.6

Two-Aspect Pedestrian Signal Heads

1

Two-aspect pedestrian signal heads shall have the designated dimensions. The Contractor shall submit drawings of the proposed units.

2

Signal heads shall comprise of a polycarbonate body containing two pedestrian signal aspects, coloured red and green and shall include:

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(a)

lamps

(b)

reflectors

(c)

lenses

(d)

transformers

(e)

visors

(f)

anti-phantom devices (if designated)

(g)

brackets, frames and all fixtures and fittings required to mount the signal head.

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The material, electrical and mounting requirements for the signal head shall be the same as the requirements for the three aspect traffic signal head.

4

The optical requirements for the signal head shall be the same as the requirements for the three aspect traffic signal head with the additional requirement that each aspect of each two aspect pedestrian signal head be supplied with a 'Walking Man' and 'Stopping Man' optical mask.

16.2.7

Traffic Signal Controllers

1

Traffic signal controllers shall be microprocessor based and capable of meeting all the designated requirements. The Contractor shall submit drawings of the proposed units.

2

Supply shall include:

(b)

all required additional modules and circuits

(c)

all internal wiring

(d)

all detector modules and control circuits

(e)

plates, fixings and fastenings, glands, seals and clips.

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basic control hardware including relays housings and cabinets

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The controller shall be provided with the following operational modes: computer control

(b)

standby co-ordinated

(c)

local mode with multi-plan operation

(d)

flashing

(e)

manual mode

(f)

signal on/off mode.

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Means will be provided within the controller housing to select and to test each of these modes of operation.

5

For pedestrian crossings the controller shall be capable of showing a green flashing man before the end of each pedestrian phase.

6

All controllers shall include a dimming feature.

7

Controllers shall be of a manufacturers type approved by the PWA and/or Traffic Police.

8

All equipment supplied shall be compatible with the existing traffic signal controllers in use in the state of Qatar.

9

Where the supplier cannot provide evidence of his equipment having been previously successfully used with the above traffic signal controllers, he shall be required to demonstrate, at his own expense, the compatibility of his equipment.

10

Traffic signal controllers shall be programmed as designated and as agreed with the Engineer. It shall be the Contractor’s responsibility to provide competent personnel to programme the controller.

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Each controller shall be supplied with full documentation which shall include : (a)

wiring diagrams

(b)

timing charts

(c)

intergreen tables

(d)

stage diagrams

(e)

any other relevant information relating to the operation.

Three copies of the documentation shall be supplied with each controller. The controller shall be housed in the cabinet of sufficient size to accommodate the controller and all other associated equipment and shall provide easy access for maintenance and test purposes. The controller and associated equipment shall be arranged within the cabinet so that they will not interfere with the entry and exit cables. The cabinet to house signal controllers shall be constructed of aluminium sheet of thickness 3 mm in accordance with BS

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EN 12368 or with non-metallic materials where the properties for abrasion resistance, exposure to the elements are equal or better than aluminium cabinet. Cabinets shall be painted to a colour and specification agreed by the Engineer. The cabinet shall be weatherproof, rain proof and dust proof and be able to maintain proper operation of equipment. The Contractor shall construct a suitable foundation for the cabinet. and it shall allow for the entry and exit of all cables. The cabinet shall be secured to the foundation by anchor bolts. The traffic signal controller shall be micro-processor based and capable of meeting all the requirements of the operational Specification and any further requirements as specified by the Engineer. The supply of a traffic signal controller shall include for: the basic control hardware including relays housings and cabinets, all additional modules and circuits required to meet the operational Specification, all internal wiring, all detector modules and control circuits, plates fixings and fastenings glands, seals and clips.

14

Traffic signal controllers shall be of an approved type and supplied by an approved manufacturer taken from the most recent list prepared by the Public Works Authority.

15

Traffic signal controllers shall be programmed according to the operational Specification and as agreed with the Engineer. It shall be the Contractor’s responsibility to provide competent personnel to programme the controller.

16

The traffic signal controller shall also have the following capabilities:

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(a)

To give a flashing red pedestrian man before switching to a red man at the end of pedestrian cycle.

(b)

The controller shall include a timing feature.

(c)

The controller shall support two power supply inputs coming from two different substations. The purpose is to continuously operate the controller in case of power failure on one substation by automatically transferring to the other power supply input.

(d)

The controller shall be made to ensure that the dual power supply input is stabilized at 240 volts.

(e)

The controller can be operated manually.

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(f)

The controller shall be capable of providing flashing green before switching to yellow/amber at the end of vehicle green phase

(g)

The controller shall be capable of providing continuous flashing yellow/amber in the channelized island.

Each traffic signal controller shall be fully documented, this shall include: wiring diagrams, timing charts, intergreen tables, stage, diagram and any other relevant information relating to the operation. Three (3) No. copies of the documentation shall be supplied with each controller.

16.2.8

Pedestrian Operated Push-Buttons

1

Pedestrian operated push-buttons shall comply with the requirements and regulations of the QGEWC.

2

The push-button shall include traffic signs as per the Qatar Traffic Control Manual either as an integral part, or be mounted separately on the traffic signal pole or gantry.

3

Push-buttons shall comprise of a metal or plastic body containing a push-button switch and an illuminated text panel in Arabic and English.

4

The unit shall have a light that provides confirmation after a pedestrian has pushed the button.

5

The dimensions and position of the push-buttons shall be proposed by the supplier and approved by the Engineer.

6

Push-buttons shall be constructed of metal or high grade plastics.

16.2.9

Flexible Traffic Signal Cable

1

Flexible traffic signal cable shall comprise of four cored, PVC coated, internal core PVC coated, cable. The cable shall be PVC sheathed wiring, catalogue description being NYM-J, page 2/3 or equivalent.

2

The cable shall be of a rated voltage and current carrying capacity suitable for the proposed cable runs. The Contractor shall submit calculations showing the voltage drop for the cable.

3

Cable shall be supplied in 500 metre lengths and wound onto a suitable cable drum.

4

Cable shall have a minimum cross-section area of the conductor in each core of 1.5 mm2

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and the overall diameter of the cable shall be 11 mm. The individual core may be either solid or stranded. Each core shall be uniquely identifiable by coloured PVC sheathing. 16.2.10 Armoured Traffic Signal Cable 1

Armoured traffic signal cable shall comprise of a multi-cored (number of cores as specified), PVC coated, copper wire armoured, internal core PVC coated, cable. Catalogue description being, PVC-CWA-PVC or equivalent.

2

Cable shall be supplied in 500 m lengths, wound onto a suitable cable drum.

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Cable may be supplied in three sizes, 7 core, 12 core or 19 core. The minimum area of the conductor in each core shall be 1.5 mm2. The individual cores may be either solid or stranded. Each individual core shall be uniquely identifiably by either having a uniquely coloured PVC sheathing or by its PVC sheathing having a unique, repetitive marking.

16.2.11 Loop Cables Loop cables shall consist of a heat resistant coated core cable. Loop feeder cables shall comprise of a communication type cable, PVC coated having six pair of individually coated cores. The Loop shall be manufactured by Never Fail Loop Systems, USA (local representative Traffic Tech (Gulf), P.O. Box 9377, Telephone Number 4621814) or similar approved.

2

Loops shall be constructed from polypropylene conduit with 9.5mm inside diameter and 16mm outside diameter. Conduit shall be filled with hot rubberised asphalt which allows the loop to remain flexible once cooled to prevent incursion of moisture and set the turns of wire firmly in place. Loops shall have 127mm expansion/contraction joints at intervals along the loop to allow for movement. Each expansion/contraction joint shall have a 229mm long schedule 80 polypropylene cover slide to be placed over the joint.

3

Lead-in wires shall be encased in a non-conductive 2250 psi flex hose constructed with a seamless extruded polyester fiber braid reinforcement and a non-conductive, seamless extruded urethane non-perforated jacket. Fill lead-in hose completely with hot rubberised asphalt. Twist wires in all lead-ins with a minimum of three turns per 305 mm for the entire length of the lead-in. Attach lead-ins to loop heads with a sch. 80 CVPC tee.

4

Loop cable shall have one individual core, the conductor of which shall have a crosssectional area of 1.5 mm2. The loop cable such that the coating is able to withstand direct application of temperatures up to 175 °C.

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16.2.12 Loop Feeder Cables

Loop feeder cable shall have six pairs of individual cores, each of which having a conductor of cross-sectional area of 0.6mm2. Each individual core shall be uniquely identifiable by either, having a uniquely coloured PVC-U sheathing or by its PVC-U sheathing having unique, repetitive marking.

2

The use of alternative types of cable may be permitted with the express written permission of the Engineer.

3

Each individual core shall be uniquely identifiable by either having a uniquely coloured PVC sheathing or by its PVC sheathing having a unique, repetitive marking.

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16.2.13 Pulling Chamber Cover 1

Pulling chamber covers shall be of ductile iron.

2

The pulling chamber covers shall have a square opening of the dimensions shown on the project drawings.

3

The pulling chamber covers shall be inscribed with wording to identify the type of service and the system reference. The exact wording shall be to the approval of the Engineer.

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16.2.14 Unplasticised Polyvinyl Chloride (PVC-U) Ducts 1

Unplasticised Polyvinyl Chloride shall be supplied in two different sizes, 2 inches diameter or 4 inches diameter (50mm or 100mm). The colour shall be dark gray. The PVC-U shall be either encased burial type or direct burial type. Catalogue description being, PVC-U Electrical Conduit & Tubing and Utility Duct, NEMA TC-6 or NEMA TC-8 or equivalent.

2

Unplasticised polyvinyl chloride ducts shall be supplied in 6 metre lengths with solvent weld socket on one end. The minimum wall thickness shall be 1.52 mm for 2 inches diameter and 2.08 mm for 4 inches diameter.

16.2.15 General Compatibility All equipment supplied shall, in general, conform to the same style, colours and functions as that already in place in Qatar. The supplier may be required to provide at his own expense, samples of his proposed equipment. These samples shall become the property of the PWA, whether or not an order is placed.

2

All equipment supplied shall be compatible with the approved traffic signal controllers and supplied by an approved manufacturer according to the most recent approved list of the PWA.

3

Where the supplier cannot provide evidence of his equipment have been previously used successfully with the above mentioned traffic signal controller, he shall be required to demonstrate, at his own expense, the compatibility of his equipment.

16.3

INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT

16.3.1

General

1

It shall be the Contractor’s responsibility to ensure that all traffic signal installation work is conducted by skilled, competent personnel.

2

The Engineers approval of any subcontractor or individual personnel in no way relieves the Contractor of his responsibility to ensure that traffic signal equipment is correctly installed.

3

The Engineer shall reserve the right to inspect and approve all installation practices.

4

Installation of traffic signal equipment shall only be conducted by approved companies taken from the most recent list prepared by the PWA.

16.3.2

Poles, Gantries and Signal Heads

1

Signal posts and gantries shall be installed onto their prepared foundations, using two levelling nuts or an appropriate fixing method approved by the Engineer. The pole or gantry shall be plumbed square, irrespective of the orientation of surrounding features.

2

The Contractor shall take every precaution to prevent damage to the pole or gantry's protective coating, during installation. Where the protection is damaged or breached the Contractor shall take immediate action to make repairs.

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Where designated, posts and gantries where necessary shall be painted with an approved paint, colour grey (BS 381C) before installation of signal heads and push-buttons..

4

Signal heads and push-buttons shall be installed as shown on the contract drawings. Final positioning and fixing shall not be undertaken without the Engineer’s approval.

5

Signal heads, once fixed, shall be covered with an opaque protective material such that it is clear to motorists that the signals are not in operation.

16.3.3

Installation of Traffic Signal Controller

1

The Contractor shall install the controller housing in the position defined by the Engineer. The Contractor shall ensure that the housing is positioned so that when the access doors are opened to their fullest extent they will not obstruct the sidewalk or cause a danger in any way to members of the public. The housing shall not be positioned adjacent to the kerb as to render it liable to damage by vehicles or so that the safety of persons working on the controller is not endangered.

2

The Contractor shall organise the connection of the electricity supply to the controller housing and any other peripheral equipment requiring an electricity supply by direct liaison with the QGEWC (E) Consumer Section. The Contractor shall ensure that the power supply is contained within its own separate duct, up to the point at which it enters the controller housing. The electrical supply shall at no point share the same ducts or chambers as the traffic signal cabling. The Contractor, where necessary, shall be responsible for providing any housings required for QGEWC apparatus. Where a separate housing is required it shall be positioned directly adjacent to the controller housing.

3

The Contractor shall endeavour to complete as much of the internal wiring of the controller as possible inside his workshop, such that on-site work within the controller housing are kept to a minimum. All external cables terminating within the controller shall be clearly labelled as to their function, destination and nominal voltage. These cables shall, on entering the controller housing, be clamped and supported such that any stress or strain on the cables themselves shall not be transmitted to the controllers internal components. Spare or redundant cables entering the controller housing are to be terminated in such a fashion that they do not interfere in any way with access to the controllers internal components. The conductors of these cables are to be electrically isolated and sealed against the ingress of moisture.

4

It shall be the Contractor’s responsibility to provide all competent personnel and specialist equipment to enable the controller to be programmed.

16.3.4

Cabling

1

The Contractor shall install all cables in the ducts as designated. He shall take all reasonable care to ensure that no undue stress or strain is placed on the cable during installation and shall adhere to the cable manufacturer’s published data with regard to allowable minimum radius of curvature. The Contractor shall ensure that duct drawstrings remain in place subsequent to cable installation.

2

A single dedicated cable shall service each individual traffic signal pole. This cable shall be of the designated size and shall have a minimum of 10 % spare capacity. On entering the signal

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pole the cable shall be firmly anchored to the pole. At least 3 m of spare cable shall be allowed for within the signal pole, over and above that length which is required to reach the termination block.

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Spare or redundant cores within the cable shall be terminated at the termination block and labelled 'Spare'. The core acting as earth protection shall be connected directly to the body of the signal pole by means of the pole’s earthing stud. The cable armouring shall not be used as the protective earth conductor.

4

With the exception of loop cable to loop feeder cable connections, the jointing of cables shall not be permitted. Where jointing of the cables is permitted, this shall be undertaken using a suitable jointing kit of an approved type which allows the integrity of the protective earth conductors to be maintained. Loop cable to loop feeder cable joints shall only be located within an access chamber.

16.3.5

Circuit Protection and Earthing Requirements

1

The Contractor shall provide protection against dangerous earth-leakage currents by the use of fuses or excess-current circuit breakers compliant with the QGEWC (E) Regulations for

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Electrical Installations. The Contractor shall ensure that all installations shall be such as to allow for the operation of the protective devices to operate upon the occurrence of a fault within the time period specified for fixed equipment installations and that all non-current carrying metallic parts shall be connected to the earth terminal in such a manner as to ensure that a hazardous voltage cannot exist on exposed conductive metalwork. All cabinets, posts and other metal hardware comprised by the traffic signalling equipment shall be bonded via protective conductors to the main earth terminal with an earthing conductor to the main terminal by a protective conductor. The main earthing terminal or bar shall comply with QGEWC (E) Regulations for Electrical

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installation and shall be connected to the earthing point provided by the QGEWC (E) with a copper earthing conductor in accordance with the Regulations. It shall have a minimum cross-sectional area of 6.00 mm2 and shall be green/yellow stripe coded. The earthing conductor is defined as a protected conductor connecting a main earthing terminal or bar of an installation to an earth electrode of other means of earthing. Where a residual current circuit breaker is used, the cross sectional area of the earthing conductor shall comply with the requirements of QGEWC (E) Regulations. The connection to metalwork shall be made internally to a secure terminal on a part of the enclosure which is a permanent fixture. The terminal shall be constructed of a material which will minimise chemical corrosion resulting from contact with the protective conductor or other metal part. Conductor terminations shall be by the use of soldered or crimped connectors or screwed terminations, or other approved methods.

4

Earth and other protective conductors shall be selected and installed so that they comply with the QGEWC (E) Regulations for Electrical Installations, the BS 7430, BS 7671 and the Regulations for Protective Multiple Earthing where appropriate. All protective conductors shall be colour coded green/yellow stripe. Where protective conductor is part of a multicore cable and a green/yellow stripe colour coded core is not available, the Contractor shall ensure that the protective conductor is adequately identified. Each cable shall enter the controller housing via a stuffing gland in the gas plinth gland plate. The stuffing gland shall be so designed as to prevent the diffusion of gas and support the cable. The earth stud of the cable terminator shall be correctly bonded to the earth bar in accordance with the QGEWC (E) Regulations, using a 6.00 mm2 conductor (2.50 mm2 for loop feeder cables).

5

The earthing requirements at the head of each traffic signal pole shall be as follows:

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the earth terminal of the gland, shall be connected to the earth terminal of the pole with a protective earth conductor correctly terminated with crimp connectors and having a minimum cross-sectional area of 6.00 mm2

(b)

the protective conductors from each signal head, pedestrian head, push-button unit or other equipment shall be connected together at the head of each pole and connected to the earth terminal in the controller housing by means of one dedicated core of the armoured signal cable servicing that pole

(c)

the earth connection at the head of the pole specified in (b) above, shall be connected to the earth stud of the pole with a bonding conductor having a minimum area of 6.0 mm2 and by means of a crimped connector, or similar

(d)

push-button units fixed to a signal pole shall be earthed to the earth stud of the pole with a separate protective conductor terminated with crimp connectors and having a minimum cross-sectional area of 6.00 mm2

(e)

There shall be electrical connections by means of conductors having a copper equipment cross-sectional area of not less than 6.00 mm2 between the earthing

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are, or may reasonably be expected to become, in electrical contact with the general mass of earth are so situated that simultaneous contact may reasonably be expected to be made by any person with such structures, pipes or other metalwork (or any metalwork in electrical contact therewith).

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terminal and all metal structures, metal pipes and other metalwork (not being metalwork forming part of a telegraphic, telephone or signalling circuit) which

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These connections shall be made as near as practicable to locations where users or maintenance staff approach the facility. Permanent Electrical Power Supply

1

The Contractor shall be responsible for liaison with QGEWC (E) to provide a power supply to the traffic signal controller and shall be responsible for all works required to provide this supply.

2

The electricity supply shall be 240 V AC 50 Hz single phase.

3

The Contractor shall organise, with the approval of QGEWC (E), one of the following earthing systems:

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16.3.6

(a)

TN-S System. Where QGEWC (E) will provide an earthing point which affords a continuous metallic return path to the earth of the supply system. The Contractor’s earthing conductor shall be connected to this point

(b)

TN-C-S System (PME). Where QGEWC (E) will provide a combined neutral earth supply. The earthing Contractor’s earthing terminal and a lead from the earth terminal shall be left available for the QGEWC (E) to connect to the incoming supply. A similar neutral conductor lead shall also be left available for the same purpose

(c)

TT System. Where a means of earthing will not be provided by the QGEWC (E) the earthing terminal will be connected to an effective earth electrode compliant with the QGEWC (E) Regulations for Electrical installations. Where the TT System is provided by the QGEWC (E) the Contractor shall install an earth leakage circuit breaker to comply with the QGEWC (E) Regulations.

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The Contractor shall ensure that the equipment complies in all respects with the regulations and requirements of the QGEWC (E).

5

The Contractor shall be responsible for all cable laying and jointing.

6

It shall be the responsibility of the Contractor to inform the Engineer of the earliest date when he will be ready for the QGEWC (E) to make the service connections.

7

The Contractor shall supply the equipment to be terminated to the QGEWC (E) service with phase and neutral conductors of not less than 4 mm2 and earthing conductor of not less than 6 mm2. The QGEWC (E), shall connect the controller conductors and earth conductor to the terminal provided by the QGEWC (E).

8

The QGEWC (E) cut-out shall incorporate a high breaking capacity fuse carrier and fuse to BS 88 or BS 1361 of the correct rating. The rating shall be specified by the Contractor to comply with the type requirements of the QGEWC (E) Regulations. The maximum permissible earth fault loop impedance shall be those stated in the QGEWC (E) Regulations.

16.3.7

Inductive Loops for Vehicle Detection

1

Slot cutting shall be carried out by a specialist subcontractor. The Contractor shall be responsible for marking out all slot configurations and shall supervise the work of the subcontractor. The slot cutting subcontractor shall make arrangements to provide an adequate water supply to enable him to carry out the necessary works. The approximate position of inductive loops and route of feeder cables will be as designated. The Contractor shall specify the loop configurations at each site, the detailed layout of individual loops and the number of turns per loop. This information shall be supplied to the Engineer. When loop configurations are specified by the Engineer, such information as required will be supplied to the Contractor. In order to obtain a high standard of installation, the Contractor's staff and subcontractors shall be fully briefed by the Contractor and given written instructions describing the technical requirements of this specification and method of installation. This shall cover depth and preparation of slots, backfilling, jointing, ducting under kerbs, earthing and commissioning of equipment.

2

Subsurface detector housings for loop detection equipment are not acceptable to the Engineer. Detector housings shall be positioned so as to reduce the possibility of damage in the event of a road traffic accident and shall not present an obstruction or visual intrusion. In cases of doubt, the advice of the Engineer shall be sought. Positions of detector housings shall be to the approval of the Engineer. Where a remote detector housing is used, each one shall be connected to the controller by 'Twinflex' cable. The cable will be ducted to the controller unless the Engineer's agreement is obtained to cutting a slot in the carriageway. Voltages on this cable shall not exceed 50 V AC or 120 V DC whether between conductors or

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to earth. The Contractor shall provide two sets of keys to all equipment housing supplied as initial issue. The Contractor shall be responsible for removing all surplus materials from site at the completion of the works.

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The cable specified may in exceptional circumstances be replace with an armoured multicore cable (i.e.. triple vehicle extensions with speed discrimination) double vehicle extensions with speed assessment. The cable specified shall be terminated at the controller with a cable gland or castellated bar approved by the Engineer. The gland shall be bonded to the earth point using a 4 mm2 flexible earthing cable terminated with crimp connection tags. The remote end of the cable shall be connected to the plate and 4 mm2 flexible earthing cable terminated with crimp connection tags or by other means approved by the Engineer. In addition one core of the armoured cable shall be used as an earth continuity conductor and shall be bonded to the earth point on the controller and to both the equipment earth and the metalwork of the housing at the remote end of the cable. The cable specified shall be provided with a minimum of 25 percent spare conductor capacity (armoured and nonarmoured multicore cables only).

4

The detector shall operate satisfactorily with a feeder up to 100 metres in length. The feeder is defined as the cable between the loop tails and the detector housing. Where adjustments are required to sensitivity and presence time, these shall be made during initial setting-up and no further adjustments shall be necessary. The equipment, including loop and feeder, shall operate correctly within all carriageways of reasonable condition without any reduction in performance as follows: air temperature (-10°C to 60°C)

(b)

relative humidity up to 100 % (non-condensing)

(c)

carriageway flooded under 1 cm water, or dry

(d)

carriageway subjected to continued heavy use by buses and heavy goods vehicles

(e)

sidewalk and kerbs subjected to misuse by vehicles

(f)

feeder assumed to be buried in soil or sand which may be dry or wet

(g)

the detector shall not operate from electrical noise pick-up on the loop or feeders.

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Slot-cutting operations shall not be conducted in wet weather. Wet weather to be defined as such conditions where the Engineer considers it would be unsafe to carry out slot cutting operations. Slots shall be cut using a motorised machine fitted with a diamond saw blade. The layout of the loop configuration shall avoid areas of poor reinstatement in the road surface caused by other roadworks or works. Slots shall be cut at least one metre from any such disturbance. Slots shall be cut at least one metre from any ferrous objects such as manhole covers. In concrete road surface, the Contractor shall not cut slots less than 1.5 metres from transverse joints between adjacent concrete sections. The depth of loop slots shall be (50 + 7.0 n) mm with a tolerance of + 10.0 mm / - 0.0 mm. In concrete surfaces the depth shall be (25 + 7.0 n) mm with a tolerance of + 5.0 mm / - 0.0 mm where 'n' is the number of cables and the first figure is the minimum depth of cover. The depth of each slot shall be checked with a depth gauge along the whole length of the slot. The Contractor shall ensure that there are no irregularities in the base of the slot. Where an angle more acute than 13 degrees in formed at the junction of two adjacent loop slots, then the slot junction shall be truncated with a saw cut at the apex of the junction; i.e., one blade thickness from the inside edge of the slot corner, and this cut shall be to the same depth as the adjoining slots. The junction shall not be truncated with a cold chisel. Slots cut for feeder cables shall be 20 mm wide (core cables 25 mm) with a tolerance of 3 mm, to give a cover of 65 mm in bituminous surfaces (45 mm in concrete surfaces) with a tolerance of + 10.0 mm / -0.0 mm. Only one feeder cable shall occupy each slot.

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Section 06: Road Works Part 16: Traffic Signals

Page 18

The loop feeder cables shall take the most direct route to the indicated cable chamber. This slot is specified as being 20 mm wide, therefore care shall taken not to obliterate any road markings in whole or part. In the first instance the most direct route from the loop position to the kerb line shall be taken. The loop feeder cables shall be joined in the carriageway only with the approval of the Engineer. The joint slot shall be 10 mm wider and 10 mm longer than the overall dimensions of the completed joint. The depth of the slot shall be sufficient to give a minimum 40 mm cover above the joint. The joint slot shall be positioned either at a traffic lane boundary or at crown of the road so that it is not subjected to the maximum stresses exerted by road vehicles. Each loop shall be separated from adjacent loops by a minimum of 100 mm. The Contractor's supervisory staff shall check the quality of workmanship before laying cable and backfilling. All debris and slit shall be cleared from the base of the slot and the slot blown dry with compressed air before cable laying.

7

For laying loop cables the cable shall be dry before installation. The Contractor shall ensure that the cable lies evenly in the bottom of the slot, and shall secure the cable in such a position if necessary. Sharp implements shall not be used to seat the cable in the slot. Loop tails shall not extend more than 20 metres from the loop before being joined to the feeder cable. Loop tails shall be twisted. Each twisted tail shall have a dedicated slot to the joint with feeder cable. Loop tails shall normally be joined to the feeder cable within cable inspection chambers. Cables shall not be bent to a radius of less than 12 times their diameter or less than a radius recommended by the manufacturer whichever is the greater. Where cables enter the sidewalk a small area of carriageway is to be excavated and a uPVC duct laid through the kerbs for each feeder cable. The duct shall be level with the base of the slot from which the feeder cable emerges. The excavated area shall be backfilled with fine aggregate concrete to the duct invert level. The cables shall then be backfilled with compacted fine cold asphalt and hot oxidised bitumen R85/40. The kerb stone shall be reinstated. Feeder cables in soft verge or beneath sidewalks are to be laid in ducts at a minimum depth of 500 mm below ground level unless otherwise specified by the Engineer. Feeder cables laid unducted in trenches shall be laid on a 75 mm bed of sand free from stones and other sharp materials with a further 75 mm of similar sand placed over the cable. Where feeder cables are laid unducted in soft verges, the cable position shall be indicated with a plastic warning tape laid at a depth of 150 mm to 200 mm from ground level and vertically above the cable. The tape shall be printed with suitable warning message repeated at one metre intervals. Where feeder cables are required to cross French drains or other coarse bed materials in central reservations, the cable shall be looped and protected with flexible plastic ducting. Ducting is to be provided by the installation Contractor.

8

Cable joints shall be approved by the Engineer. Feeder cables shall be electrically connected to the loop tails with insulated crimp connector using a ratchet type of crimping tool. The Contractor shall ensure that the cable conductor has been correctly crimped by visually checking the cable and also by applying a vigorous pull test to the cable on either side of the joint. The electrical connectors shall be encased in a joint approved by the Engineer and the Contractor shall ensure that the connectors are staggered to avoid the possibility of any short circuits. The Contractor shall ensure that any instructions issued by the cable joint manufacturer are provided in writing to his installation and supervisory staff. These instructions shall form part of this specification. The Contractor shall ensure that the joint is waterproof before backfilling. With the exception of cable joints between loop and feeder cables, no other joint shall be permitted in the loop/feeder configuration. Cables shall be terminated in the controller or detector housing using terminal connection blocks which are adequate in size for the diameter of conductors used. Screws shall not bear directly onto conductors, either a protective leaf in the terminal or a crimped pin on the end of the conductor shall be used.

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Section 06: Road Works Part 16: Traffic Signals

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Immediately before backfilling, the Contractor shall ensure that all slots are clean and dry and that all silt and debris has been removed from the base of the slot. Loop slots shall be backfilled with a low viscosity epoxy resin, approved by the Engineer, to give a minimum of 10 mm cover above the uppermost cable. The resin specified shall be poured at a viscosity of between 500 and 1000 pascal seconds. The Contractor shall provide the Engineer documentary evidence from the resin manufacturer of the temperature necessary to achieve this viscosity. The Contractor shall satisfy the Engineer, before epoxy resin operations commence, that the specialist subcontractor’s on-site equipment is able to raise the epoxy resin and maintain it at the temperature necessary to achieve the viscosity specified. The remaining volume of loop slot shall be backfilled with blown grade hot oxidised bitumen to the level of the road surface. Feeder cable slots shall be backfilled with fine cold asphalt compacted around the cable. The upper 20 mm of the slot shall be filled with hot oxidised

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bitumen. Joint slot shall be backfilled with epoxy resin to a level 10 mm above the completed joint. The remaining volume shall be filled with hot oxidised bitumen. The hot oxidised bitumen specified shall be heated to a pouring temperature of 185 °C and shall be poured

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from an enclosed container which shall be preheated before use. The fine cold asphalt specified shall comply with the requirements of BS EN 13108. The asphalt shall be soft and easily worked when applied, and shall be hand compacted to the satisfaction of the Engineer. Alternative compounds proposed by the Contractor shall be approved by the Engineer. The contractor shall be responsible in determining the exact location of the loops and shall supervise the work of the sub-contractor. The sub-contractor shall mark the locations of the performed inductive loops. Each shall be separated from adjacent loops by a minimum of 100mm and shall be laid on top of the road base or 230mm form the road surface.

11

The cable shall be dry before installation. The sub-contractor shall lay the performed inductive loops and stretch it as per the marked locations. The T-joint of the loops shall be positioned to the nearest chamber/pull box/detector hand hole. The loops shall be fixed by using a clamps and nails to achieve the desired shape

12

The loop wires from the preformed loop to the adjacent chamber/pull box/detector hand hole shall be twisted together into a pair with minimum of three turns per 305mm and encased in polypropylene conduit and/or 2250 psi hydraulic hose between the performed loop and the adjacent chamber/pull box/detector hand hole. Lead-in conduit shall be 100% injected with hot asphalt sealant to prevent the entrance of water at the chamber/pull box/detector hand hole.

13

Asphalt shall be manually laid around the loops to protect it from the pavement machine/equipment.

14

Upon completion of the installation works, the Contractor shall lay the asphalt on the entire carriageways by using the approved pavement machine.

15

Each loop shall be tested sequentially by three methods: by megger (measured by mega ohms), by resistance (in ohms), by inductance (measured in micro henries).

16

In case of existing pavement, a groove shall be cut by using a slot cutting machine. The frames and home-runs shall be placed into the cuts. The cuts shall be filled with hot melted asphalt-rubber sealant conforming to the manufacturer’s recommendations.

17

All the installation works shall conform to the manufacturer’s specifications.

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Section 06: Road Works Part 16: Traffic Signals

Page 20

16.4

TESTING AND COMMISSIONING

1

Before delivering a traffic signal controller to site, the Contractor shall arrange a factory acceptance test in his workshop. The programmed and internally complete controller shall be connected to a labelled light board capable of simulating all traffic signal aspects controlled by that particular controller. The Contractor shall ensure that all equipment and devices are available to show that the controller fully complies with operational requirements. The factory acceptance test shall consist of the following checks: visual check of internal wiring and controller assembly

(b)

operation of green conflict monitor

(c)

intergreen times

(d)

group times

(e)

detector logic (where applicable)

(f)

stage to stage change logic

(g)

lamp switching.

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(a)

All traffic signal equipment shall be commissioned to the satisfaction of the Engineer.

3

It shall be the responsibility of the Contractor to supply all equipment and personnel required to commission the traffic signal equipment.

4

On completion of installation, and before commissioning, the Contractor shall undertake the following tests to the satisfaction of the Engineer and in accordance with the QGEWC (E) Regulations.

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visual inspection

(b)

continuity test of all protective conductors

(c)

insulation resistance test; insulation resistance shall not be less than 100 megaohms

(d)

polarity check

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(a)

earth loop impedance test.

Where a residual current circuit breaker is installed, tests in accordance with the QGEWC (E) Regulations shall be complied with. The Contractor shall provide the equipment necessary to complete the tests and shall provide all other test equipment to demonstrate that the installation is compliant.

6

After the traffic signal and controller equipment is installed on site and after it is connected to all its associated equipment, the Contractor shall arrange for a site acceptance test. The site acceptance test will recheck all the points covered in the factory acceptance tests and in addition shall include visual and electrical tests on all posts, gantries, heads, push-buttons and cabling. The Contractor shall ensure that the area of site covered by the installation being tested is cleared of all debris, plant and machinery. The Contractor shall be responsible for the supply of any personnel required to conduct the site acceptance test. The Contractor shall provide any vehicles required to conduct the site acceptance test. The Contractor shall ensure that all equipment and devices are available to show that the controller fully complies with the operational requirements.

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Page 21

Each loop and feeder configuration of the vehicle detection system shall be tested as follows and the results given in a test certificate for the loop installation. This certificate shall include all pertinent information for the testing. The Contractor shall submit a pro-forma certificate to the engineer before carrying out the commissioning. (a)

With the loop circuit disconnected from the detector, the impedance to earth of the two loop and feeder conductors shall be measured at a test voltage of 500V DC applied for at least one minute. This shall not be less than 10 megaohms. The two ends of the loop circuit shall be connected together for this test

(b)

With the armouring of the feeder cable disconnected from the earth point, the impedance to earth of the armouring shall be measured at a test voltage of 500V DC applied for one minute. This shall not be less than 10 megaohms

(c)

With the armouring of the feeder connected to the earth point of the equipment housing, the impedance to earth of the armouring shall be measured. This impedance shall not be greater than 0.5 ohms

(d)

The inductance of the loop and feeder circuit shall be measured. This shall be comparable with the theoretical value previously supplied to the Engineer

(e)

The frequency of operation of each configuration shall be measured. Where two loop circuits share a common feeder cable their frequency of operation shall be separated by at least 5 kHz

(f)

The Contractor shall adjust the sensitivity and presence time of each detector to the requirements specified by the Engineer. The Contractor shall demonstrate correct operation of the detector at the sensitivity specified

(g)

The Contractor shall ensure that an inductance change caused by vehicles in one loop shall not induce spurious observations in any adjacent loop system.

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Section 06: Road Works Part 16: Traffic Signals

Any loop or feeder which fails these tests shall be replaced by the Contractor at his expense.

9

Upon satisfactory completion of the factory acceptance and site acceptance tests, and when the Engineer is fully satisfied that correct installation and adherence to the operational requirements has been attained. The PWA will issue a final commissioning certificate. The installation, or any part thereof shall not be opened to general traffic until this certificate is received.

16.5

GUARANTEED MAINTENANCE OF TRAFFIC SIGNAL EQUIPMENT

16.5.1

General

1

During the initial maintenance period complete record of component failures shall be kept by the Contractor in order to provide information on the reliability of various components.

16.5.2

Operational Maintenance

1

The Contractor shall provide full operational maintenance coverage for a period of 400 days subsequent to the issuance of the final commissioning certificate.

2

The Contractor shall use only maintenance contractors approved for this work by the PWA.

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Section 06: Road Works Part 16: Traffic Signals

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During the maintenance period, the Contractor shall be responsible for providing coverage for the following: (a)

Replacement or repair and installation of any failed equipment

(b)

Daily corrective maintenance

(c)

Quarterly maintenance Check the cycle length, green time, intergreen time and all other signal timing parameters as given in the timing chart. (ii) Check the timings of the different signal programmes and test the switch over them manually and by time clock. (iii) Test loop detectors for activation and re-tune if necessary. (iv) Test ELCB and any other circuit breakers. (v) Replace any items that show significant wear and/or are operating outside of the manufacturer’s tolerances. (vi) Test operations of pedestrian push buttons (vii) Check timing of Flashing Units (viii) Service controller in accordance with manufacturer’s specifications (ix) All signal heads, reflectors, optical lenses and backing boards shall be cleaned (both internally and externally) in accordance with the manufacturer’s specifications (Bi-annual maintenance - The following works are to be carried out in addition to those described in section (c)

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(ii) (iii)

All signal poles and gantries shall be painted and renumbered. The signal poles and gantries shall be coated with primer, red-oxide, and two coats of colour grey paint. The paint specification/colour shall be approved by the Engineer. All inspection chambers shall be cleaned properly. Timings for all signals shall be altered as directed by the Engineer at the beginning and end of the month of Ramadan. Minor changes to the controller’s operational configuration (Changing of phasing /staging, green times and intergreen times) as deemed necessary by the PWA’s traffic signal engineer.

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(e)

All protective earth conductors shall be inspected and tested. All lamp fittings and connectors shall be dismantled and cleaned. Signal heads shall be checked for correct alignment and all brackets and clamps tightened. (iv) All electrical connectors are to be checked and cleaned where necessary. Annual maintenance - The following works shall be carried out in addition to those described in sections (c) and (d)

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The Contractor shall ensure that personnel are available to maintain equipment such that failed equipment shall be replaced or repaired within four hours of notification of the fault. Where controller configuration changes are required, the Engineer shall allow a reasonable period for the Contractor to respond.

5

Failed equipment shall be replaced/repaired within 4 hours of notification of the fault.

6

Where controller configuration changes are required, the Engineer shall allow a reasonable period for the Contractor to respond.

QCS 2014

Section 06: Road Works Part 16: Traffic Signals

Page 23

Emergency Maintenance

1

In the case of accidental damage or 'knock downs' or any other equipment failure deemed to be outside of the Contractor’s control, shall not be required to take responsibility for repair or replacement. However it shall be the Contractor’s responsibility to provide the immediate onsite response to a police or the PWA request.

2

Upon the PWA having effected a remedy to any emergency maintenance requirement, it shall be the Contractor’s responsibility to ensure that all repairs or replacements have been conducted to a standard such that no warranties become invalid.

3

If the Contractor feels that any repair or replacement is not of sufficient standard to maintain his warranty he shall notify the PWA with 14 days of any such repair or replacement having been conducted.

16.5.4

Contractor’s Vehicles

1

The Contractor shall arrange a vehicle mounted hydraulic platform with boom and any additional vehicle for the use of his staff whenever required throughout the maintenance period.

2

The vehicles shall be provided with a flashing amber roof light array.

3

The contractor shall be responsible for any cost associated with the vehicles.

4

The hydraulic platform shall be capable of performing the required vertical and horizontal manoeuvres safely and satisfactorily, including adequate platform capacity and boom articulation.

5

The contractor shall gain approval from the Engineer as to the vehicle acceptability prior to supplying the said vehicle.

16.5.5

Contractor’s Equipment

1

The Contractor shall be responsible for supplying any regular or special equipment or tools required for the satisfactory undertaking of the works. In particular this shall include, but not limited to:

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16.5.3

(a)

Specialised commission/testing equipment for all the current traffic signal (Siemens, Futurit, Peek and Tyco) controllers to allow Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT).

(b)

Portable keyboard interfaces to allow interrogation and on-site programming of microprocessor signal controllers for all the traffic signal systems.

(c)

Workshop based aspect simulators to allow for Factory Acceptance Tests.

END OF PART

QCS 2014

Section 06: Road Works Part 17: Road Drainage

Page 1

ROAD DRAINAGE................................................................................................... 2

17.1 17.1.1 17.1.2 17.1.3 17.1.4

GENERAL REQUIREMENTS .................................................................................. 2 Scope 2 References 2 Quality Assurance 3 Delivery, Storage and Handling 3

17.2

DRAINAGE PIPES & PIPELINES ............................................................................ 3

17.3

EXTENDING PIPELINES ........................................................................................ 4

17.4

ROAD GULLIES ...................................................................................................... 4

17.5

MANHOLE COVERS AND GULLY GRATINGS ...................................................... 4

17.6

SOAKAWAYS ......................................................................................................... 5

17.7

SOAKAWAY BOREHOLES ..................................................................................... 6

17.8

TESTING AND CLEANING SURFACE WATER DRAINS ....................................... 7

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TRENCH SOAKAWAYS .......................................................................................... 7 General 7 General 7 Pipe 7 Geotextile Fabric 8 Single Sized Coarse Aggregate 8 Catchpit Chambers 9 Road Crossings 9 Geocellular Stormwater Attenuation / Soakaway Trenches 9 The maximum installation depth, to base of units, shall normally not exceed the height of 10 17.9.9 Reinstatement above Trenches 10 17.9.10 Testing 10

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17.9 17.9.1 17.9.2 17.9.3 17.9.4 17.9.5 17.9.6 17.9.7 17.9.8

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17.10 GEOCELLULAR TANKS ....................................................................................... 10 17.10.1 Geocellular Units 10 17.10.2 Geocellular Tank Arrangement 10

QCS 2014

Section 06: Road Works Part 17: Road Drainage

17

ROAD DRAINAGE

17.1

GENERAL REQUIREMENTS

17.1.1

Scope

1

This Part includes: stormwater drainage works draining the road carriageway and directly adjacent areas, including: (i)

road and other pavement gullies and gully pots

(ii)

pipes of minimum 150mm diameter including bedding materials used to connect gully pots to inspection chambers and intermediate manholes

groundwater drainage using filter drains within the road corridor

(c)

soakaways specifically related to road stormwater and groundwater collection and disposal

(d)

connections to stormwater drainage systems including culverts, open channels and closed stormwater drainage pipelines.

(e)

Geocellular attenuation and soakaway trenches and tanks.

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(b)

Related Sections and Parts:

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(a)

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Geosynthetics

Section 5

Concrete

Section 8

Drainage Works

Section 20

Drainage Works for Buildings

Part 3

External Drainage Works

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Part 18

References

1

The following standards are referred to in this Part:

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17.1.2

BS EN 124 ..................Gully tops & manhole tops for vehicular and pedestrian areas BS 4962 ......................Plastic pipes and fittings for subsoil drainage BS 5911 ......................Concrete pipes ancillary concrete products BS ISO 14654 ............Epoxy coated steel ISO 9001 ....................Quality assurance in production and installation BRE digest 365 - Soakaway Design

QCS 2014

Section 06: Road Works Part 17: Road Drainage

Page 3

Quality Assurance

1

The manufacturer of all manholes and gully gratings shall be accredited to a third party quality system such as ISO 9001. The supplier shall submit a copy of his accreditation showing the scope of products covered.

17.1.4

Delivery, Storage and Handling

1

All manhole covers and gullies shall be clearly marked with the technical standard of manufacture, the loading class, the name identification mark of the manufacturer and the mark of the certification body.

17.2

DRAINAGE PIPES & PIPELINES

1

The materials, manufacture, finish, installation inspection and testing of all drainage pipes and fittings for roadworks shall comply with the requirements of Part 3 of Section 20, except as modified by this section of the specification.

2

The type of pipe to be used and the diameter shall be as designated on the drawings or in the project specification.

3

Pipes may be of vitrified clay, concrete, glass reinforced plastic or UPVC. Each of these pipe types shall meet the designated requirements for standards, materials, manufacture, strength, length and dimension of tolerances joints, workmanship and finish, inspection and basis of acceptance given in Part 3 of Section 20.

4

Unless designated otherwise only one type of pipe shall be used within any individual drain or service duct between consecutive chambers.

5

The Contractor shall ensure that plastic pipes are not subject to deterioration due to exposure to sunlight between manufacture and installation in the ground.

6

The excavation, bedding, laying and backfilling around pipelines shall be carried out in accordance with Part 2 of Section 8.

7

Soft spots below the bottom of an excavation shall be removed as directed by the Engineer and the resulting void backfilled with granular material to the approval of the Engineer.

8

Any additional excavation below the bottom of the line required shall be made good with granular material.

9

The pipes shall be laid at the designated levels and gradients. The deviation in level from that designated at any point shall not exceed 20 mm unless agreed otherwise by the Engineer.

10

Pipes shall be laid so that each one is in contact with the bed throughout the length of its barrel.

11

Parts and fittings shall be examined for damage and shall be cleaned immediately before laying. Any pipes that are damaged shall not be used in the works.

12

Measures shall be taken to prevent soil or other material from entering pipes and to anchor each pipe to prevent moving before the work is complete.

13

The pipe bedding material shall be as designated on the project drawings or in the contract documents.

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17.1.3

QCS 2014

Section 06: Road Works Part 17: Road Drainage

Page 4

EXTENDING PIPELINES

1

Where it is designated that existing drains are to be extended and connected to new drain chambers or channel, the connections shall be made during the construction of the new drain. The Contractor shall inform the Engineer in writing of the proposed position for the connection and the detail of the connection. The position of the connection shall be recorded by the Contractor on a drawing.

2

The new connecting pipe shall be aligned such that the angle between the existing pipe and the new pipe is not greater than 60 %.

3

Before entering or breaking into an existing drain, the Contractor shall obtain approval from the authority responsible for the pipeline.

17.4

ROAD GULLIES

1

The type, position, dimensions and clear openings of gullies will be as designated on the drawings or in the project specifications.

2

Gullies shall be constructed so that no part of the spout or trap has a cross sectional area less than 2/3 that of the outlet.

3

Precast concrete gullies shall comply with BS 5911 Part 2.

4

Cast iron and steel gully gratings shall be kerb type gullies complying with BS EN 124 unless

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17.3

otherwise shown on the Contract Drawings. The upper surface of gully gratings shall be flat except where otherwise designated. Slots in gratings or between gratings and frames shall not be orientated parallel to the direction of traffic, except where the slots are less than 150 mm long or less than 20 mm wide.

6

The frames shall be bedded on a 1 to 3 cement sand mortar.

7

Backfilling to precast gullies shall be carried out to formation level with general fill. Where mechanical compaction is impractical, the backfill shall be concrete of the designated grade.

8

Gully connections shall be constructed of minimum 150mm diameter Unplasticised PVC (PVC-U) pipes in accordance with BS 4660 or ESVC pipes in accordance with BS EN 295. Where required by the Engineer, these shall be bedded and surrounded with concrete with movement at the joints permitted by the insertion of compressible material which shall extend to the outside of the concrete surround.

17.5

MANHOLE COVERS AND GULLY GRATINGS

1

Manhole covers and gully gratings shall be formed from ductile iron with an element of graphite spheres to produce a molecular structure that gives the required tensile strength and shock load resistance.

2

Drainage products may be produced from grey iron and shall be hard wearing, inherently stable and highly resistant to flexing.

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Section 06: Road Works Part 17: Road Drainage

Page 5

The type of manhole cover; i.e., square, rectangular, double triangular, single cover shall be as designated on the drawings.

4

During installation the frames shall be properly bedded and levelled to prevent rocking or any lateral movement of the frame.

5

Covers and frames shall be kept together as a supplied unit and interchangeability between various covers and frames shall not be permitted.

6

All castings shall be supplied with a black epoxy coating finish.

7

The tops of all manhole covers shall have a non-slip surface to provide adequate grip.

8

When so designated, the supplier shall arrange for specific lettering to be cast into the top of the covers. The lettering shall be up to a maximum of 4 letters or digits.

9

Manhole covers and gullies shall meet the requirements of BS EN 124, European Standard for access covers of gully tops for vehicular and pedestrian areas.

10

All manholes covers and gullies supplied shall have been verified as being manufactured to BS EN 124 by third party assessment body for both quality procedures and technical

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requirements.

The manholes’ covers or gullies shall meet one of the loading categories specified in BS EN

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Table 17.1

Class

Loading, Tonnes

A 15

1.5

B 125

12.5

C 250

25

D 400

40

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Loading Categories for Manhole Covers on Gullies

12

For a manhole entry to sewer and surface / ground water manholes a minimum of 750mm square clear opening shall be provided. For entry to TSE chambers a minimum of 675mm square opening shall be provided.

13

For manholes situated in the carriageway a three point cover seating shall be adopted to prevent any movement or rocking.

14

Where hinged gully gratings are installed the edge with a hinge shall face the traffic to ensure the cover closes if inadvertently left opened and hit by traffic.

17.6

SOAKAWAYS

1

Soakaways shall be constructed using precast concrete rings. Concrete works shall comply with the requirements of Section 5 of the specification. Concrete shall be Grade C50 for the precast concrete rings and the cover slab, using Sulphate Resisting Portland Cement.

QCS 2014

Section 06: Road Works Part 17: Road Drainage

Page 6

2

The cover slab shall be of the dimensions and contain the reinforcement as shown on the drawings or detailed in the Project Specifications.

3

The structural concrete shall be designed for durability and shall include as a minimum the following specification: (a)

minimum cover 40mm

(b)

all surfaces to be painted with an epoxy protective coating meeting the requirements of Section 5 Part 14 of the specification. The protective coating shall be factory applied to precast elements.

4

The soakaways shall have an internal diameter of 1.8 m unless otherwise designated and

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shall be of a minimum depth of 3 m unless otherwise designated. The precast concrete rings shall be at least 150 mm thick and shall have three evenly spaced

No permanently embedded metal parts shall be left with a cover less than 40 mm from the

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lifting points.

surface. The precast rings shall be constructed with 50 mm diameter holes at 400 mm

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centres in rows spaced 300 mm apart. The holes shall be alternately offset. The bottom ring shall be founded on insitu blinding concrete 200 mm deep.

8

The soakaway shall be surrounded by granular material which shall infill the whole void between the soakaway and the undisturbed ground around the excavation.

9

The granular material shall be laid in tamps in 150 mm layers and shall nowhere be less than

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7

The granular material shall be clean durable, sharp-angled fragments roughly cubical or pyramidal in shape, of un-weathered rock of uniform quality graded and tested in accordance with Tables 14.3, from a source approved by the Engineer

11

Cast iron covers and frames shall be to BS EN 124 of the designated loading class.

12

Geotextile material lining to the outside of the soakaway excavation shall be in accordance with Table 17.2 of this Section. The placing and laying of the material shall be in accordance with the manufacturer’s instructions and Part 15 of this Section.

13

The geotextile material shall not be left exposed to the sun for a period greater than 7 days before burying.

17.7

SOAKAWAY BOREHOLES

1

The Contractor shall drill soakaway boreholes at the locations shown on the drawings. Unless designated otherwise the boreholes shall be 150mm diameter.

2

Boreholes shall be initially taken to a depth of 20 m. At this depth the borehole shall be

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thoroughly flushed clean using compressed air and clean water.

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Section 06: Road Works Part 17: Road Drainage

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The borehole shall then be completely filled with clean water and the rate of dissipation recorded. If the rate of dissipation is found to be less than required by the design criteria given in BRE digest 365 - Soakaway Design then the bore holes shall be deepened in 5 m depth increments and flushed until a satisfactory rate of dissipation is recorded. At the Engineers discretion the rate of dissipation maybe verified by a constant head permeability test using proprietary equipment to monitor and record the flow rate and the variation in water level within the borehole.

TESTING AND CLEANING SURFACE WATER DRAINS

1

Before completing of the road drainage part of the Works the Contractor shall systematically clean the whole road drainage system, in accordance with Section 8, Part 10, including gullies, connecting pipes and soakaways. The entire system shall be clear of debris and silts and in a sound working order.

2

Cast iron covers shall be freed from surfacing materials and pivot points shall be greased. The Contractor shall be responsible for cleaning up any silting of the surface water drainage system caused by other Contractors working within the Site and the approval of the Employer.

3

A CCTV survey shall be carried out of the completed system in accordance with Section 8, Part 10 of QCS.

17.9

TRENCH SOAKAWAYS

17.9.1

General

1

Trench soakaways shall be constructed in accordance with the dimensions and grades shown on the Drawings. The trench soakaway consists of a perforated pipe or geocellular units laid in a trench. A geotextile fabric lines the trench or surrounds the geocellular units, with the remaining voids being filled with single sized coarse aggregate.

2

Reinstatement of trench soakaways shall be in accordance with the Contract drawings.

17.9.2

General

1

Excavation for the trench shall be in accordance to the requirements of Part 3 of this Section.

17.9.3

Pipe

1

The pipe shall be a 300mm UPVC for installations outside the carriageway and 300mm ESVC for installations within the carriageway, perforated pipe supported on single-size coarse aggregate bedding. Pipe perforations shall be 10mm diameter in staggered rows around the circumference of the pipe with a pitch of 40degrees. The longitudinal spacing between each row of holes shall be 200mm.

2

The manufacture, distribution, laying and jointing of perforated pipes shall generally be in accordance with the requirements of Section 8.

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17.8

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17.9.4

Geotextile Fabric

1

Filter fabric material lining shall be non-woven geotextile manufactured from UV stabilised, high tenacity, virgin polypropylene fibres that have been both mechanically and thermally bonded and in accordance with Table 17.2.

2

The placing and laying of the material shall be in accordance with the manufacturer’s instructions and Part 15 of this specification.

3

The geotextile material shall not be left exposed to the sun for a period greater than 7 days before burying.

Unit

Mean Value (Applied (a) Tolerance )

kN/m

8.0 (-0.8) 60 (±20) 1500 (-150)

EN ISO 13433

mm

38 (+6)

EN ISO 12956

µm

75 (±20)

EN ISO 11058

l/m s

2

90 (-27)

EN 12224

%

>90

EN 12225

%

No loss

EN 14030

%

No loss

EN 12226

%

>90

mm

1.1

.l. l

. Test Method

rw

Table 17.2 Properties of Geotextile Material

Tensile Strength

EN ISO 10319

Tensile Elongation

ta

Property

%

EN ISO 12236

N

qa

EN ISO 10319

CBR Puncture Resistance

as

Cone Drop

se

Pore Size – Mean AOS

2

er

Permeability – (H50)

ov

Weathering 50MJ/m Exposure (1 month EU)

o

Microbiological resistance

et it

Resistance to acids & alkalis

m

Oxidation at 85 days (100 years) Thickness @ 2kPa Note:

(a)

EN ISO 9863-1

Applied tolerances are based on 95% Confidence limits

17.9.5

Single Sized Coarse Aggregate

1

The trench shall be filled by granular material, which shall infill the whole width of the trench between the undisturbed ground trench sides, or between the geocellular units and the undisturbed ground, as shown on the drawings. The granular material shall be laid and tamped in 150 mm layers using mechanical plate compactors. For geocellular unit trenches the backfill shall be brought up in even layers such that the backfill material does not differ by more than 150mm in level between sides.

QCS 2014

Section 06: Road Works Part 17: Road Drainage

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Where geotextile fabric is required to interface between the trench side walls and subgrade and the soakaway trench fill material, the width of the geotextile must include sufficient material to conform to trench perimeter irregularities and for a 150mm top overlap. When overlaps are required between rolls, the uphill roll should lap a minimum of 500mm over the downhill roll in order to provide a shingled effect. Care shall be exercised to prevent natural or fill soil from intermixing with the trench granular material. All contaminated granular fill shall be removed and replaced with clean material.

3

The granular material shall be clean, durable, sharp-angled fragments roughly cubical or pyramidal in shape, of un-weathered rock of uniform quality and meet the grading limits in Table 17.3. The materials source shall be approved by the Engineer based upon the properties of the materials in accordance with the testing requirements as per Table 17.4. No reactive carbonate rock or sources with indication of local ground water contamination shall be used.

100

qa

37.5 20

60 - 90 0.2 - 1 0

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5

5 - 30

as

14 10

.l. l

% passing by weight

ta

BS sieve size (mm)

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Table 17.3 Grading Limits for Granular Material

.

2

Catchpit Chambers

1

Catchpit chambers shall be constructed to the dimensions and at the spacing shown on the drawings.

2

Chambers shall consist of rectangular precast concrete sections with internal dimension 800 x 1500mm. All concrete works shall comply with the requirements of Section 5 of the specification. Concrete shall be Grade C50. Sulphate Resisting Cement shall be used. Chambers shall also conform in all respects to the requirements for surface water drainage manholes in Section 8.

3

All surfaces to be painted with an epoxy protective coating meeting the requirements of Section 5 Part 14 of the specification. The protective coating shall be factory applied to precast elements.

17.9.7

Road Crossings

1

Where the trench soakaway crosses a road then non-perforated pipe shall be used extending 1.0 meters beyond the road kerb line.

17.9.8

Geocellular Stormwater Attenuation / Soakaway Trenches

1

Loads on modular geocellular unitsThe permanent vertical loads to be carried by the units shall be determined by the designer

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17.9.6

(a)

Lateral loads

(b)

Maximum installation depth

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17.9.9

The maximum installation depth, to base of units, shall normally not exceed the height of Reinstatement above Trenches

1

Reinstatement material above the trenches shall be of suitable fill, cement bound granular material, foamed concrete pavement materials or asphalt, or as appropriate in accordance with the Contract drawings, and shall be constructed in accordance with QCS Section 6.

17.9.10 Testing On completion of each length of trench soakaway the Contractor shall carry out an infiltration test. The test shall be carried between completed catchpit chambers. The 2 No. upstream outlet pipes within the catchpit chamber shall be sealed and the chamber filled with water to a minimum depth of 1.5 metres. The depth of water shall be recorded each hour for the first twelve hours of the test and subsequently at time intervals as directed by the Engineer.

2

The Contractor shall record the results of the test on a standard proforma and present these to the Engineer on completion.

17.10

GEOCELLULAR TANKS

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1

Geocellular units used to form storm water attenuation tanks and soakaway tanks shall be in accordance with clause 14.9.8.

Locations for geocellular tanks

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17.10.2 Geocellular Tank Arrangement

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1

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17.10.1 Geocellular Units

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Geocellular tanks made up of geocellular units are suitable for installation in the following locations:

2

o

The vehicular access to the tank shall be restricted so as to exclude large vehicles, in excess of the design vehicle load, from the area above the tank.

m

(b)

Public open spaces: beneath landscaped areas and paths. The landscaping scheme for the park shall be considered when assessing the loads upon the tank.

et it

(a)

Loads on modular geocellular units The design of tanks constructed using modular geocellular units shall:(a)

take account of all applied loads, including accidental loading

(b)

be based on appropriate laboratory tests

(c)

use appropriate factors of safety

(d)

analyse all appropriate limit states (or failure modes)

The determination of the loads to be carried by the geocellular units shall be determined in accordance with the requirements of BD 31/01. 3

Permanent loads.

4

Accidental loads

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The risk of accidental loading occurring shall be assessed in the design process. Public parks may be occasionally inadvertently trafficked by HGVs and landscaped area can be used to park cars. Hard paved area shall be assumed liable to support such occasional accidental loading and geocellular tanks shall be designed to support accidental loading without risk of collapse.

Location

Risk

Landscaped area in public park

Specialist vehicles used for maintenance of geocellular tank and any separation system upstream of the tank Illegal parking of private vehicles Movement of delivery vehicles to kiosks in parks

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Large vehicles used for routine maintenance within park

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Specialist vehicles used for erection / maintenance of lighting systems

ta

Erection of marquees / tents / stages / portable cabins for public events

qa

Large vehicles delivering equipment for public events Cranes for installation of equipment

as

Generators used for public events Planned parking of private vehicles during public events

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Access for emergency vehicles – fire engines

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If the tank has not been designed to carry accidental loading then special precautions may be required to prevent it occurring. In public parks, the area above a tank shall be fenced off or have other barriers / landscaping to prevent vehicle access. Warning signs shall be provided to state that there is an area with limited load bearing capacity and restricted access for vehicles.

5

m

The location of the tank and any loading restrictions shall be clearly identified in the operation and maintenance manual for any facility. Lateral loads The lateral loads on the units due to earth and water pressure shall be assessed and allowed for by the designer in accordance with the requirements for the design of retaining walls given in BS 8002:1994. 6

Flotation or uplift Where the tank system is located below the water table, the uplift force shall be resisted by the dead weight of fill above the tank. Other surcharges that are not permanent shall not be included in the assessment. The minimum factor of safety against flotation shall be 1.25.

7

Minimum cover The minimum cover to units shall be as follows:

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Landscaped areas: a minimum of 1.0m to allow for suitable planting over the tank. The design of landscaping should be undertaken at the same time as the design of the tank so that the impact of tree roots can be considered. Trees should not be located closer than the canopy width at mature height from the tank. Trees should not be planted directly over a tank or in such a position where maintenance work would require the removal of the tree. 8

Maximum installation depth The maximum installation depth, to base of units, shall normally not exceed the height of three units, plus the cover as assessed in Sub-Clause 15. Limit state design

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END OF PART

ta

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Modular geocellular tanks shall be designed as structural components, using limit state structural design theory in accordance with Section 4.1 of CIRIA Report C680 and BD 31/01. The design philosophy shall follow the requirements for geotechnical design practice as described in Eurocode 7 (BS EN 1997-1:2004).

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Section 06: Road Works Part 18: Geosynthetics

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18

GEOSYNTHETICS ........................................................................................ 2

18.1

GENERAL REQUIREMENTS FOR ALL GEOSYNTHETICS ........................ 2

18.1.1 18.1.2 18.1.3 18.1.4 18.1.5

Scope References Submittals Quality Assurance Guarantees and Warranties

18.2

REQUIREMENTS FOR GEOTEXTILES ....................................................... 4

2 2 3 3 4

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18.3

.

18.2.1 General Requirements 18.2.2 Drainage Applications 18.2.3 Earthworks Applications

4 5 6

GEOGRIDS ................................................................................................... 7

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18.3.1 General Requirements for Geogrids 18.3.2 Material Requirements for Geogrids 18.3.3 Installation of Geogrids

7 8 9

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18

GEOSYNTHETICS

18.1

GENERAL REQUIREMENTS FOR ALL GEOSYNTHETICS

18.1.1

Scope

1

This part of the specification covers the use of geotextiles and geogrids for the;

(b)

reinforcement of embankment foundations over soft or weak soils

(c)

reinforcement of steep earthwork fills

(d)

reinforcement of retaining walls and bridge abutments

(e)

repairs to earthworks embankment failures and landslides

(f)

for erosion control of slopes

(g)

for subsoil and sub-base drainage.

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Related Sections and Parts: This Section Part 3 Part 4 Section 8,

.

reinforcement of unbound aggregates for roads, hard standing and airfield pavements

Earthworks Unbound Pavement Materials Drainage Works

as

2

(a)

References

1

The following Standards and other documents are referred to in this part:

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ASTM D 751 ...............Test Methods for Coated Fabrics ASTM D 5034 .............Test Method for Breaking Strength and Elongation of Textile Fabrics (Grab Test) ASTM D 5035 .............Test Method for Breaking Strength and Elongation of Textile Fabrics (Strip Method) ASTM D 4533 .............Test Method for Trapezoidal Tearing Strength of Geotextiles BS 8006......................Code of practice for strengthened/reinforced soils and other fills BS 2782......................Method of testing plastics BS 3502......................Symbols for plastics and rubber materials BS 4618......................Recommendations for the presentation of plastic design data BS EN ISO 10321 ......Geosynthetics BS EN ISO 10319 ......Geosynthetics DIN 54307 ..................CBR Test DIN 53854 ..................Weight Test DIN 53855 ..................Thickness Test ISO 9001 ....................Quality Management and Quality Assurance Standards Published Document (PD) 6533, Guide to Methods for Assessing the Durability of Geotextiles, British Standards Institute.

QCS 2014

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Page 3

18.1.3

Submittals

1

The manufacturer shall submit comprehensive test results for the geosynthetic for the designated tests, which shall clearly indicate whether the values are mean values measured in current production or minimum values which the property does not fall below.

2

The manufacturer’s submittal shall clearly state: (a)

the type of material, (whether a polyethylene, propylene or other)

(b)

its structure whether (a monofilament, multifilament or other)

(c)

the element of manufacture by one or combination of the following processes:

.

Heat bonding. Chemical resin bonding Mechanical bonding.

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(i) (ii) (iii)

If the Contractor wishes to propose a material that has been tested to alternative standards, the Contractor shall submit correlation tests showing the comparable values of the two test methods. These test results shall be comprehensive giving full details of the sample conditioning, preparation, method of test and criteria for assessment.

4

The manufacturer shall submit comprehensive information of previous applications of the material in similar conditions and environments. This information shall include the project name, contract details, type/grade of material used, quantity of material used, name of the contract, client, consultant, and main contractor.

18.1.4

Quality Assurance

1

The geotextile shall be supplied by a manufacturer who is certified to the ISO 9001. The Contractor shall submit to the Engineer a copy of the ISO 9001 certificate that clearly states the scope of the certification.

2

The geotextile shall be supplied by a manufacturer who provides technical assistance on the suitability for the application and installation for the material. For the initial use of the material on site, the Contractor shall arrange for the technical representative of the manufacturer to be present to demonstrate the correct use of the material.

3

Where feasible the jointing of geosynthetics shall be as prefabricated joints manufactured under factory controlled conditions. Joints made during the execution of the work shall be kept to a minimum.

4

Joints shall be tested by the same test methods used for the main material.

5

All joints used in permanent structures designed to carry loads shall be tested in accordance with BS EN ISO 10319 Part 1 or BS EN ISO 10321.

6

In situations where relatively small tensions are developed and, if permitted by the Engineer overlapping joints may be used. These joints shall not be used in the primary tensile direction of reinforced soil structures but can be in secondary tensile directions only.

7

Joints where geotextiles are sewn together shall be with one of the methods showing in figure 5 of BS8006. These joints shall meet the performance characteristics shown in Table 8 BS8006.

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QCS 2014

Section 06: Road Works Part 18: Geosynthetics

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Prior to delivery of the material to site the Contractor shall submit a sample of a sawn joint.

9

Bodkin joints shall have sufficient cross sectional area and strength to avoid excessive deformation. A bodkin joint shall not be so large so as to distort the material causing stress concentrations, bodkin joints shall be pretensioned prior to loading to reduce joint displacement as the components lock together.

10

Any cuts, tears, splits and perforations to geosynthetics during installation shall be made good. The method of remedial work shall be prepared and proposed by the Contractor for approval by the Engineer.

11

The geosynthetics shall be suitable for use in the ambient soil temperature in the State of Qatar.

12

Geosynthetics that are able to ravel shall be heat treated or bonded with an adhesive tape at the cut. The proposed method of sealing the edges of geotextiles shall be proposed by the Contractor and shall fully identify the geotextile material, type of scene, stitch configuration, stitch density, sowing thread and sowing machine to be used.

18.1.5

Guarantees and Warranties

1

The Contractor shall submit a ten-year guarantee for the geotextile material and the workmanship. The guarantee shall be worded to reflect the required performance of the material and shall be approved by the Engineer.

18.2

REQUIREMENTS FOR GEOTEXTILES

18.2.1

General Requirements

1

All geotextiles shall be supplied in manageable roll or unit sizes and shall be robust enough to withstand handling and any treatment received during the installation process.

2

The geotextile shall comply with the minimum properties for geotextile serviceability in Table 18.1 below. The Engineer will direct as to the category that the geotextile shall meet; i.e., very high, high, moderate or low.

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8

Table 18.1 Minimum Properties for Geotextile Service Ability Property

Very High

High

Moderate

Low

Grab Strength ASTM D 5034

1200

800

600

400

Puncture Strength Modified ASTM D-751/3787, N

500

340

180

135

Burst Strength

3.0

2.0

1.5

1.0

Trapezoidal Tear ASTM D-4533

340

225

180

135

These are the minimum required values below which no test result on production material should fall.

QCS 2014

Page 5

The Engineer may require the Contractor to carry out tests to different standards, in addition to the test methods designated above or in the following clauses: the manufacturer’s recommendations strictly adhered to

concerning the installation process shall be

(b)

all geotextiles shall be suitable for use in the environmental conditions in the State of Qatar

(c)

geotextiles shall be resistant to deterioration on degradation from acids alkalis, bacteria, brackish or saline water. The manufacturer shall submit comprehensive results of tests carried out to demonstrate the durability of the materials under such conditions. These tests shall involve checking the strength properties of the material before and after prolonged exposure to typical groundwater conditions in the State of Qatar

(d)

all geotextiles shall be protected from direct sunlight by storing inside the building or covering with heavy tarpaulins. Geotextiles shall not be exposed to direct sunlight for a duration longer than 48 h

(e)

joints in Geotextiles shall be sewn where load transfer is required

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3

Section 06: Road Works Part 18: Geosynthetics

Drainage Applications

1

Geotextiles for drainage applications shall be needled polypropylene and meet the performance specifications given in Table 18.2. The performance shall be assessed based on regular tests on the production material. Unless a permitted variation is stated in Table 18.2, the mean test values shall meet the values in the Table.

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18.2.2

Table 18.2

o

Performance Specifications for Geotextiles for Drainage Applications International Classification According to CBR Test

2

3

4

4400

m

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1

CBR test (DIN 54307) mean value 10 %

780

1335

2695

mean value minus standard deviation 10 %

700

1200

2450

deformation %

30

50

60

65

longitudinal direction kN/m 10 %

3

7

12

25

longitudinal direction kN/m 10 %

3

8

14

35

Tensile strength (ASTM D 5035)

QCS 2014

Section 06: Road Works Part 18: Geosynthetics

Page 6

International Classification According to CBR Test

1

2

3

4

elongation at rupture %

35/45

50/60

45/55

90/65

Fall cone test hole diameter BS EN ISO 10319

50

32

18

6.5

Water permeability at 2 kPa mech. load 9 x 10

at 10 cm water column l/secm 30 % 2

-2

90

-2

13 x 10

-2

15 x 10

80

45

80

60

45

30

d 90%

110

85

65

40

100

140

250

500

0.6

0.95

1.5

3.4

as

d 50%

qa

ta

Pore size (unvibrated)

se

2

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Weight DIN 53854 g/m

-2

rw

.l. l

150

8 x 10

.

permeability coefficient cm/s

o

ov

Thickness DIN 53855 mm

The manufacturer shall clearly identify to which international classification category the geotextile conforms according to the CBR test.

3

The pore size of the geotextile shall be small enough to prevent the significant loss of soil particles from the retained soil, yet have adequate permeability to allow water transmission normal to the plain of the geotextile.

4

The manufacturer shall submit test results that demonstrate the ability of the geotextile to avoid clogging during water flow due to fine particles. Test results for the US Corps of Engineers gradient ratio test or similar type of test shall be submitted. The test shall be carried out using soil of the type where the geotextile is to be installed. Gradient ratios derived from the test shall be less than 3.

18.2.3

Earthworks Applications

1

Geotextiles for earthworks reinforcement or base use shall be woven polyester multi-filament or multi-filament fabrics with a high rupture strength and low axial strain. The geotextile shall have an adequate high tensile strength in all directions to resist loading imposed by uneven filling.

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QCS 2014

Section 06: Road Works Part 18: Geosynthetics

Page 7

The geotextile shall possess the strength for the required design life with minimal increase in strain over time. The average geotextile strain shall be limited to 5 %.

3

Where installed between a sub-base and the underlying soil, the geotextile shall prevent the granular material being pressed into the subsoil and also prevent an intrusion of fines from subgrade into the sub-base.

4

The water permeability of the geotextile shall prevent build up of water pressure under the separation layer. The short- and long-term permeability of the geotextile must be equal to or greater than that of the subsoil. The geotextile must not become blocked.

5

The geotextile shall possess high puncture resistance and a high tearing resistance.

6

Where used as base stabilisation for embankments the type of construction equipment used for spreading and compacting initial fill layers shall be suitable so as to avoid damage to the geotextile. The initial layer of fill placed on the geotextile shall be free from sharp angular or pointed material that may puncture the geotextile.

7

Trucks shall not be permitted to drive over the geotextile. The laying of the material shall be co-ordinated to ensure that trucks do not damage the material.

18.3

GEOGRIDS

18.3.1

General Requirements for Geogrids

1

The geogrid shall be identified as either uniaxial for single dimension loading or biaxial for two dimensional loading.

2

The design of all geotextiles or geogrid applications shall be based on an appropriate in soil temperature for the state of Qatar.

3

The type of geogrid to be used shall be as shown on the drawings or as described elsewhere in the contract documents.

4

The type of polymer used in the manufacture of the geogrid shall be clearly stated.

5

The design shall take into account any possible damage to the material during site installation and a factor shall be introduced into the design.

6

Prior to installing the geosynthetic the Contractor shall prepare a construction trial outside of the permanent works. The construction trial shall utilise similar ground conditions from materials and other factors as the permanent works.

7

If directed by the Engineer the Contractor shall arrange for geotechnical investigation to be carried out in the area where the geosynthetics are to be installed. The range and details of the tests and investigations to be performed shall be directed by the Engineer.

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QCS 2014

Section 06: Road Works Part 18: Geosynthetics

Page 8

Material Requirements for Geogrids

1

Geogrids shall be manufactured from a continuous sheet of polyethylene or polypropylene which is punched with a regular pattern of holes. The sheet shall be heated and stretched so that randomly orientated long chain molecules are drawn into an order and align state to increase tensile strength and tensile stiffness.

2

The bars or ribs of the geogrid transverse to the direction of primary loading shall provide a series of bearing points or anchors such that stress is transferred to the grid by surface friction and also interaction.

3

The ribs of the geogrid in both the longitudinal and transverse direction shall be manufactured to a near vertical face to provide good bearing surface for interlocking fill particles.

4

Geogrids shall be resistant to deterioration by aqueous solutions of acids, alkalis and salts, petrol, and diesel fuel.

5

Geogrids shall not be susceptible to hydrolysis, environmental stress, cracking or micro biological attack.

6

The manufacturer shall supply test results for load against strain for the material identifying all test conditions including strain rate and temperature of materials tested and test method.

7

The Contractor shall submit full technical details of the geogrid proposed for use in the works. These details shall include the following:

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18.3.2

grid dimensions

(b)

thickness of longitudinal and transverse ribs

(c)

strength of the material determined as stress strain, at strains of 2 and 5% both

(d)

transverse and longitudinally in accordance with BS EN ISO 10319

(e)

weight in kilograms per metre squared for material

(f)

the supplied roll of dimensions

ov

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the minimum amount of carbon black tested in accordance with BS 2782 Part 4

m

(g)

er

(a)

(h)

the approximate peak strain , expressed as a percentage

(i)

the creep of the material under load determined in accordance with BS EN ISO 10319 for strain shall not exceed 10%

(j)

the cross sectional shape of the ribs and of the rib joints.

All test results shall be expressed as a lower 95% conference limit in accordance with ISO 2602. 8

The Contractor shall submit test results for the durability of geogrids. Tests shall be in accordance with PD 6533, - Guide To Methods for Assessing the Durability of Geotextiles.

9

The Contractor shall submit laboratory test results for prolonged exposure tests at similar temperatures.

10

For each batch or delivery of the geosynthetic the Contractor shall submit the production quality control test results shall be clearly related to batches delivered to site.

QCS 2014

Section 06: Road Works Part 18: Geosynthetics

Page 9

Installation of Geogrids

1

Prior to placing geogrids the Contractor shall prepare a detailed method statement for the sequence of operations.

2

The methods employed shall ensure that the geosynthetic does not suffer deterioration during placing and that any joints are formed effectively.

3

The handling and placement and installation of geogrids shall be carried out strictly in accordance with the manufacturer’s recommendations.

4

Where the geogrid has been protected by a wrapping resistant to ultraviolet lights attack no further protection against sunlight is necessary.

5

For geogrids, jointing shall be by a bodkin whereby two overlapping sections are coupled together using a bar passed through the aperture of the grid. Joints shall be formed at the highest mechanical and durability efficiency possible.

6

If necessary the Contractor shall construct a temporary access road to the site location at a convenient location close to the works, the Contractor shall prepare a clean working platform in storage area to accommodate geosynthetic materials.

7

The geogrid shall extend across the full width of the embankment or area being treated in one continuous piece and no part bits of rolls shall be used. This shall be accommodated by increasing the lap lengths.

8

Prior to installation of the geogrid , the site shall be cleared in accordance with part 2 of this specification

9

Before placing geogrid any abrupt changes in ground profile should be levelled.

10

Any regulating layer of fill placed shall not impair the vertical hydraulic conductivity of the natural ground.

11

Geogrids supplied in rolls shall be supported at a minimum of 2 points to prevent excessive bending unless a central steel tube is used for support.

12

Site handling of geogrids shall ensure that damage to the product such as surface abrasions, splitting, notching or tearing is prevented.

13

The installation of the geogrid shall be consistent with the direction of major stress.

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18.3.3

END OF PART

QCS 2014

Section 06: Road Works Part 19: Miscellaneous

Page 1

19

MISCELLANEOUS ........................................................................................ 2

19.1

STONE PITCHING ........................................................................................ 2

19.1.1 19.1.2 19.1.3 19.1.4 19.1.5

Scope References Submittals Materials Installation

19.2

GABIONS & PROTECTION MATTRESS ...................................................... 3

19.2.1 19.2.2 19.2.3 19.2.4 19.2.5

Scope References General Requirements Specific Requirements for Gabions Specific Requirements for Protection Mattress

19.3

BOLLARDS .................................................................................................... 6

19.3.1 19.3.2 19.3.3 19.3.4

Scope References Concrete Bollards Steel Bollards

19.4

RUMBLE STRIPS .......................................................................................... 7

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3 3 4 5 5 6 6 6 7 7 7 7

SPEED CONTROL HUMPS .......................................................................... 8

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2 2 2 2 2

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Section 06: Road Works Part 19: Miscellaneous

Page 2

19

MISCELLANEOUS

19.1

STONE PITCHING

19.1.1

Scope

1

Stone pitching slope treatment shall consist of the placement and grouting of stone pitching on slopes at the designated locations or at the locations directed by the Engineer to the designated lines, grades, thickness and cross-sections or as directed by the Engineer.

2

Related Sections and Parts

19.1.2

References

1

The following standards are referred to in this Subpart:

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AASHTO T96 .............Resistance to Abrasion by Use of the Los Angeles Machine

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BS 812 Part 2 .............Testing Aggregates - physical properties BS 1881......................Methods of testing concrete Submittals

1

Samples of the stone to be used shall be submitted to and approved by the Engineer before any stone is placed. These samples shall be kept on site and used for reference purposes for the quality control of delivered material during the work.

19.1.4

Materials

1

Stone for pitching shall be hard, sound, durable, erosion resistant rock or cobbles.

2

The nominal weight of the stones shall be between 3 to 4 kg (corresponding to a size of about 240mm x 140mm x 100mm). The maximum weight of the stones shall be between 32 kg (corresponding to a size of about 420mm x 230mm x 200mm).

3

Tests for specific gravity and absorption, shall be determined in accordance with BS 812 part 2 Testing Aggregates - physical properties. The minimum apparent specific gravity shall be 2.5 and the maximum absorption shall be 3 %.

4

The stone shall not have an abrasion loss greater than 45 % when subjected to five hundred (500) revolutions in a Los Angeles Abrasion Machine in accordance with AASHTO T96.

5

The size and shape of the stones shall be such to allow for proper placement. The widths of the stone shall be not less than one and one-half times their respective thickness and lengths of not less than two times their respective widths.

19.1.5

Installation

1

The bed upon which the stones are to be placed shall be excavated to the designated grades and lines or as directed by the Engineer.

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19.1.3

QCS 2014

Section 06: Road Works Part 19: Miscellaneous

Page 3

Prior to commencing any stone pitching operations the Contractor shall prepare a trial laying of not less than 2 m by 2 m using the materials and methods proposed for the work. The trial laying shall establish the aesthetic appearance of the work and shall be used for comparison purposes for acceptance of the final work.

3

A footing trench shall be excavated along the toe of the slope as designated or as directed by the Engineer. All footing trenches and excavations shall be approved by the Engineer before placement of stones or concrete.

4

Subgrade or base shall be firm and well compacted and approved by the Engineer. A 50 mm thick layer of mortar shall be laid on the subgrade as bedding for the stones.

5

Stones shall be placed so as to provide a minimum number of voids; larger stones shall be placed in the footing trench and on the outside surface of the slope. The flattest face of the stone shall be laid uppermost parallel to the slope. Spaces between larger stones shall be filled with the smaller stones.

6

The surfaces of the stone shall be cleaned of adhering dirt and clay and shall be moistened immediately prior to grouting.

7

The space between stones of stone pitching shall be filled with mortar consisting of one part Portland cement and three parts of fine aggregate, and one-fifth part of hydrated lime with sufficient water to produce a workable mix as approved by the Engineer.

8

Sand and cement shall comply with the requirements of Section 5. The compressive strength of the mortar shall not be less than 15 MPa when tested in accordance with BS 1881 Part 108.

9

Immediately after placing, the mortar shall be spaded and rodded into place with suitable spades, trowels or other approved method. All the voids between stones shall be completely filled.

10

The exposed surface of the rocks shall project not less than 1 cm and not more than 4 cm above the mortar surface. The mortared stone pitching shall be cured by an approved method for a minimum period of four days. Immediately after the expiration of the curing period, the exposed surfaces shall be cleared of all curing mediums.

11

Joints will be provided at a maximum interval of 12 m. Joints shall comprise a gap in the stone pitching of 15 mm. The method of forming the gap shall be to the approval of the Engineer.

19.2

GABIONS & PROTECTION MATTRESS

19.2.1

Scope

1

This work shall consist of supplying, building and placing of stone-filled gabions or protection mattress as slope or watercourse channel protection.

2

Related Sections and Parts

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This Section Part 3

Earthworks

19.2.2

References

1

The following standards are referred to in this Subpart: BS EN 10244..............Testing zinc coatings on steel wire and for quality requirements

QCS 2014

Section 06: Road Works Part 19: Miscellaneous

Page 4

BS EN ISO 1461.........Hot dip galvanised coatings on iron and steel articles BS 1052......................Mild steel wire for general engineering purposes BS 1722 Part 16 .........Organic powder coating to be used as a plastics finish to components and mesh ASTM G152 and G153-----Practice for Operating Light-Exposure Apparatus (Carbon-Arc Type) With and Without Water for Exposure of Nonmetallic Materials. General Requirements

1

Gabion boxes and protection mattress shall be made of a hexagonal woven mesh of double twisted hot dip galvanised steel wire. The nominal mesh size shall be 80mm x 100mm. Details of type of mesh proposed for use shall be submitted to the Engineer for approval.

2

Wire shall be coated with a minimum thickness of 0.55 mm of dark green or black PVC complying with BS 1722 Part 16 Organic powder coating to be used as a plastics finish to components & mesh.

3

Wire shall be capable of resisting the effects of immersion in sea water, exposure to ultraviolet light and abrasion, when tested for a period not less than 3000 h in accordance with ASTM G152 and G153.

4

The cages of gabion panels and protection mattress panels shall be selvedged to prevent unravelling of the mesh. Steel wire core used for selvedges shall have a nominal diameter of not less than 3.0 mm. Lacing wire shall have a nominal diameter of not less than 2.2 mm for the wire core. Wire for selvedges and lacing shall otherwise comply with the same specification for the wire used in the mesh.

5

Non-metallic material such as extruded polypropylene for gabion boxes may be proposed, for the Engineer's approval. Samples and manufacturer's certificates shall accompany the proposal. The Contractor shall demonstrate that non-metallic materials are suitable for use in the climatic conditions of Qatar.

6

Gabion and protection mattress dimensions shall be as designated. A tolerance of 5 % on width and height, and 3 % on length shall be allowed.

7

Gabions and protection mattress shall have diaphragms at 1 m centres.

8

Wire used in the fabrication of the gabion and protection mattress shall be mild steel to BS 1052 having an average tensile strength, before coating, of 380 to 500 MPa. The core wire diameter shall be 3.0 mm before galvanising. Galvanising shall comply with BS EN 10244.

9

Non-metallic gabion and protection mattress cages of proprietary type shall be constructed according to the manufacturer's instructions.

10

All the fixing and binding wires shall be coated with PVC layer complying with BS 1722 Part 16.

11

All Gabions and mattresses shall be laid over a layer of geotextile membrane Grade 3000 at all times.

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19.2.3

QCS 2014

Section 06: Road Works Part 19: Miscellaneous

Page 5

19.2.4

Specific Requirements for Gabions

1

Stones for gabion filling shall be hard, sound, durable and highly resistant to erosion. The stone size distribution in each individual box shall be as shown in Table 16.1: Table 16.1 Stone Size Distribution of Gabions % of Total (by number)

80 - 125

7 maximum

125 - 200

88 maximum

200 - 250

5 maximum

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Gabions shall be placed and built to the designated lines, levels and patterns on a prepared horizontal foundation surface, excavated as required and compacted as directed by the Engineer.

3

Gabion cages shall be securely wired together at comers and cages, and where there is more than one course of gabions, the upper course cages shall be laced to the lower course. Before filling, the cage shall be in its permanent position and laced to adjoining previously filled cages.

4

Stones shall be packed by hand inside the cages as tight as practicable with the minimum of voids. Tie wires shall be fixed inside the compartments and the units tensioned in accordance with the manufacturer's instructions.

5

The cages shall be overfilled with stones to allow for subsequent settlement and the lid laced down with binding wire to the top of each of the four sides and to the top of the diaphragm panels.

19.2.5

Specific Requirements for Protection Mattress

1

The material shall be supplied as a large sheet with partition panels at 1 m centres to form a cellular structure with the sheet turned up to form the sides. A separate sheet shall form the lid.

2

The cages of protection mattress panels shall be selvedged to prevent unravelling of the mesh. Steel wire core used for selvedges shall have a nominal diameter of not less than 3.0 mm. Lacing wire shall have a nominal diameter of not less than 2.2 mm for the wire core. Wire for selvedges and lacing shall otherwise comply with the same specification for the wire used in the mesh.

3

Stones for protection mattress filling shall be hard, sound, durable and highly resistant to erosion.

4

The stone size distribution in each individual box shall be dependent on the design thickness of the mattress as shown on the contract drawings.

5

The protection mattress shall be a special type of rectangular gabion with a large plan area to thickness ratio that is divided into compartments by partition panels fixed to the base.

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Section 06: Road Works Part 19: Miscellaneous

Page 6

The thickness of the protection mattress, the installation slope and the panel size shall be as designated. The Contractor may elect to use a manufacturer’s standard size of mattress that is thicker than that designated.

7

Protection mattress shall be placed and built to the designated lines, levels and patterns on a prepared foundation surface, excavated as required and compacted as directed by the Engineer.

8

Protection mattress cages shall be securely wired together at comers and cages. Before filling, the cage shall be in its permanent position and laced to adjoining previously filled cages. Several assembled units should be placed in position and wired together at their edges with the wire passed continuously through each mesh in turn with a double turn at every second mesh.

9

Stones shall be packed by hand inside the cages as tight as practicable with the minimum of voids. Tie wires shall be fixed inside the compartments and the units tensioned in accordance with the manufacturer's instructions.

19.3

BOLLARDS

19.3.1

Scope

1

Short metal or precast concrete bollards for traffic control in roads or pedestrian areas.

2

Related Sections

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The following standard is referred to in this Part:

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1

The use of cast in-situ concrete bollards will not be permitted.

2

Precast concrete bollards shall be constructed with the dimensions and details shown in the drawings. The surface finish and colour of the bollards shall be as shown in the drawings, in the Project Specification, per the designated details or as directed by the Engineer.

3

All concrete and steel materials and procedures for the precast concrete bollards shall comply with the requirements of Section 5.

4

The minimum grade of concrete for bollards shall be C40. Bollards shall be constructed using OPC cement to BS EN 197-1.

5

The minimum cover to all embedded steel items in the bollards shall be 50mm with a tolerance of -0 mm and + 10 mm.

6

Where precast concrete bollards are specified the Contractor shall design the bollards such that the durability is ensured for a period of ten years. The Contractor shall submit a performance guarantee for the bollards for a period of ten years. The guarantee shall provide for the replacement of the bollard in the event of any deterioration due to exposure to the elements.

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QCS 2014

Section 06: Road Works Part 19: Miscellaneous

Page 7

The supplier shall verify this by a design submission covering the concrete mix design, special admixtures additives, cover to reinforcement type of reinforcement and protective coating. The engineer shall approve the material and design for the bollard based on the particular exposure of the location proposed for use.

8

Prior to production of the precast bollards the Contractor shall cast a trial bollard for approval by the Engineer.

19.3.4

Steel Bollards

1

Metal bollards shall be constructed of steel tube with the dimensions, details, wall thickness and height shown on the drawings or provided in the Project Specification.

2

The top of the bollard shall be ground free of any rough edges and fitted with a tight durable ultraviolet light resistant plastic top.

3

All metal parts shall be hot dipped galvanised to BS EN ISO 1461 after fabrication.

4

All metal parts shall also be painted to the colours and pattern as shown on the drawings or directed by the engineer. The paint system shall be compatible with the hot dipped galvanising and shall provide a service free life for five years.

5

Where designated, bollards shall be removable. This shall be achieved by casting a 4 mm

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thick PVC pipe sleeve into the pavement. The bollard shall be a tight fit into this sleeve. If so designated or directed by the Engineer a locking facility shall be incorporated with the removable bollard.

RUMBLE STRIPS

19.4.1

Scope

1

Rumble strips to provide warning to drivers of vehicles that accidentally stray out of the carriageway.

2

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19.4.2

Quality Assurance

1

The Contractor shall arrange for a trial installation of a rumble strip to demonstrate the methods and equipment to be used. Approval to proceed with the construction of the rumble strips will only be permitted after the Engineer has approved this trial in writing.

19.4.3

Construction

1

Rumble strips shall comprise of shallow formed depressions in the wearing course of the road shoulders. The depth, plan size and layout of the rumble strips shall be as designated or as directed by the Engineer.

2

Rumble strips shall be formed by one of the following methods: (a)

cold planing

QCS 2014

(b)

Section 06: Road Works Part 19: Miscellaneous

Page 8

Removal shutter boards.

Cold planing of indentations in the wearing course in the shoulder shall be carried out in accordance with the requirements of the cold planing of Part 5. Edges shall be square and true and free from any loose material.

4

Rumble strips may also be formed by the use of removable shutter boards. The boards shall be rigidly located on the base or binder course prior to laying the wearing course. The method of fixing the strip shall be subject to the approval of the Engineer. The laying of the wearing course shall be carried out in accordance with the requirements of Part 5. Care shall be taken to ensure full compaction of material around the edges of the shutter boards. The shutter boards shall be carefully removed not earlier than three days after the laying and compaction of the asphalt.

19.5

SPEED CONTROL HUMPS

19.5.1

Scope

1

Speed control humps to limit the speed of vehicles.

2

Related Parts

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General

1

Speed control humps shall only be installed at the locations designated on the project drawings or specified elsewhere within the contract documents.

2

All speed humps shall be identified by markings on the road surface. The layout of these road markings shall be as the Qatar traffic control manual or as shown on the project drawings or elsewhere in the contract documentation.

3

The profile of the speed hump shall be as shown on the project drawings.

4

The profile shall represent a smooth gradual rise in elevation.

5

Speed humps shall be constructed of the same asphalt mix design as the asphalt wearing course.

6

The use of prefabricated rubber section speed humps or steel checker plate filled with concrete speed humps is not permitted.

7

Speed humps shall be designated as one of two types; for low speed pedestrian areas and for high speed roads. Low speed pedestrian areas speed humps shall comprise of a ramp within elevated section constructed of interlocking concrete paving blocks.

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19.5.2

QCS 2014

Section 06: Road Works Part 19: Miscellaneous

Page 9

Construction of Speed Humps

1

The dimensions and construction details of speed hump shall be as shown on the drawings.

2

Prior to installation of the speed hump the surface of the wearing course shall be scabbled or abraded to a rough irregular finish to ensure bond with the speed hump. Tack coat shall be applied at the base.

3

Wearing course shall be hand laid for the speed hump. The wearing course shall be compacted and finished to a smooth profile.

4

All the asphalt work for the speed hump shall comply with the relevant clauses in part 5 of the specification. The final profile speed hump shall comply to the profile on the drawings to within  6mm.

5

Heavy traffic or construction plant shall not be permitted to drive over speed humps until 7 days after the construction unless the engineer permits otherwise.

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END OF PART

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19.5.3

QCS 2014

Section 06: Road Works Part 02: Site Clearance

Page 1

SITE CLEARANCE .................................................................................................. 2

2.1 2.1.1 2.1.2 2.1.3

GENERAL ............................................................................................................... 2 Scope of Work 2 References 2 Submittals 2

2.2

PROTECTION TO EXISTING SERVICES AND INSTALLATIONS.......................... 3

2.3

RECOVERY OF MATERIALS ................................................................................. 4

2.4

CLEARING AND GRUBBING .................................................................................. 4

2.5

REMOVAL OF STRUCTURES ................................................................................ 5

2.6

REMOVAL OF STREET FURNITURE ..................................................................... 6

2.7

REMOVAL OF FENCES .......................................................................................... 6

2.8 2.8.1 2.8.2 2.8.3 2.8.4

REMOVAL OF EXISTING PAVEMENTS ................................................................. 6 General Requirements 6 Cutting Back Pavement 6 Stockpiling Asphalt Pavement 7 Stockpile Site 7

2.9

MEASURES FOR STATUTORY UNDERTAKERS .................................................. 8

2.10 2.10.1 2.10.2 2.10.3 2.10.4 2.10.5 2.10.6 2.10.7 2.10.8 2.10.9 2.10.10

REMOVAL OR TREATMENT TO BURIED UTILITIES ............................................ 8 General 8 Underground Storage Tanks 8 Removal of Culverts 8 Abandoned Pipes and Culverts 9 Total Removal of Pipelines 9 Grouting of Pipelines 9 Plugging of Pipelines 10 Cut-off Walls and Capping Slabs 10 Manholes and Access Shafts 10 Drainage Inlets and Gullies 10

2.11

DISPOSAL OF MATERIALS.................................................................................. 10

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QCS 2014

Section 06: Road Works Part 02: Site Clearance

2

SITE CLEARANCE

2.1

GENERAL

2.1.1

Scope of Work

1

This Part includes:

Page 2

Excavating for, demolishing and removing wholly or in part and disposing of designated redundant pavements, fences, buildings, culverts, manholes, inlets, gullies, pipelines or any other obstructions.

(b)

Associated earthworks to uncover facilities to be demolished, removed or recovered and to backfill and compact all trenches, holes, pits or excavations resultant from demolition, removal and recovery works.

(c)

Recovering designated materials for storage and reuse.

(d)

Removing and, where required, recovery of designated water, gas and sewage pipelines and fittings and of underground cables.

(e)

Disposal of materials not recovered.

(f)

Removal of vegetation and surface boulders and rocks.

Part 3 Part 5 Part 11

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1

The following standards are referred to in this Part:

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BS 5228......................Code of practice for noise control on construction and demolition sites BS 6187......................Code of practice for demolition The Guide for Civil Users of Explosives in Qatar prepared by the former Ministry of Industry and Public Works. 2.1.3

Submittals

1

Where existing services are to remain and are in close proximity to the works the Contractor shall submit to the Engineer details of proposed measures to ensure that the existing services are kept in a safe and stable condition for the duration of the Works.

2

Structures and installations to be dismantled or demolished shall be surveyed by the Contractor to ascertain exposed constructional dimensions and details. The Contractor shall prepare sketches of the structures and installations and submit these to the Engineer. This information shall be used by the Engineer to confirm the scope of the dismantling or demolition and confirm materials or equipment to be recovered.

QCS 2014

Section 06: Road Works Part 02: Site Clearance

Page 3

The method of dismantling and demolition including the sequence of operations and any special procedural requirements shall be submitted to the Engineer for consideration not less than seven days before the work is due to begin. Demolition work shall be carried out in accordance with BS 6187, and the submittal shall include information demonstrating the Contractor’s proposed methods to attain compliance.

4

Before any blasting operation the Contractor shall submit a detailed method statement for the work. Blasting work shall be carried out in accordance with The Guide for Civil Users of Explosives in Qatar, prepared by the former Ministry of Industry and Public Works. Approvals for blasting work shall be obtained as per the requirements of part 3 of the specification for rock excavation.

5

The Contractor shall submit for approval his proposed method of grouting pipes to be abandoned.

6

Before commencing work on the construction of reinforced concrete cut-off walls and reinforced concrete capping slabs the Contractor shall submit details for the Engineer's approval.

2.2

PROTECTION TO EXISTING SERVICES AND INSTALLATIONS

1

The Contractor shall conduct his operations in such a manner as to avoid hazards to persons, property and vehicles. After work is started on any structure, work on that structure shall be continued to completion promptly and expeditiously.

2

Services to unused installations shall be safely disconnected before demolition. Notification of disconnection shall be given to the appropriate authorities.

3

Drains, manholes and gullies that are to remain shall be protected and kept clear of debris at all times. They shall be left clean and in working order.

4

Details of any underground caverns, chambers, wells or voids discovered during the demolition operation shall be reported to the Engineer. Dangerous openings shall be protected and illuminated.

5

Precautions shall be taken to prevent leakage or formation of flammable, explosive, unhealthy or environmentally hazardous gas or vapour.

6

Pits, drains and manholes shall be checked before entry to ensure that the atmosphere is fit for respiration.

7

The quantity of dust in the atmosphere shall be minimised by spraying the demolition works with water.

8

The recommendations of BS 5228: Part 2 shall be followed in minimising noise and vibration. Silencing devices on plant shall be fitted where practicable and ear defenders shall be provided for site personnel where noisy machinery is used.

9

The location of any survey stations shall be reported to the Engineer. The Engineer may require the Contractor to transfer existing survey stations to new locations and carry out a survey to verify the level and co-ordinates of the new survey stations.

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Section 06: Road Works Part 02: Site Clearance

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All existing structures, paving, services, fittings, and other features which are not to be demolished, dismantled, removed or otherwise dealt with shall be protected from damage by a means approved by the Engineer.

11

Adjacent structures shall be surveyed for movement, cracks or deformations before and after demolition. The definition of adjacent structures in this context will be decided by the Engineer dependent on the type of structure to be demolished and the method of demolition proposed by the Contractor and the risk of damaging adjacent property.

12

A photographic record of the adjacent structures before and after demolition shall be taken.

13

Where structures, paving, services, fittings or other features are damaged by the Contractor, they shall be made good to the satisfaction of the Engineer.

2.3

RECOVERY OF MATERIALS

1

Where required the Contractor shall recover designated materials without undue damage, carry out any required cleaning and shall deliver the recovered materials to locations designated by the Engineer and unload and place them into storage.

2

Where on-site reuse is designated recovered materials shall be stored on site before their incorporation in the Works.

3

Materials to be recovered shall be handled and stored in such a manner as to avoid any damage which will impair their reinstallation and reuse. Where the absence of care results in damage, the Contractor shall repair the damage at his expense. If repairs are deemed to be impracticable the Contractor shall provide replacements at his expense.

2.4

CLEARING AND GRUBBING

1

The Contractor shall excavate and remove surface material such as debris, windblown sand, vegetation and any other unsuitable material in the areas and to the thickness instructed by the Engineer. Clearing and grubbing shall be restricted to removal of surface material and debris and shall not include the excavation of natural ground unless directed by the Engineer.

2

The removed material shall be loaded and transported to an approved dumping area.

3

All surface objects, trees, stumps, roots and other protruding obstructions not designated to remain shall be grubbed and cleared as follows:

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(a)

In areas inside of the grading limits of cut and embankment areas, stumps and non perishable solid objects shall be cut off not less than one metre below the subgrade level in the area.

(b)

In areas outside of the grading limits of cut and embankment areas, stumps and nonperishable solid objects shall be cut off not less than 500 mm below finished ground level.

(c)

In areas to be rounded at the top of cut slopes, stumps shall be cut off flush with or below the surface of the final slope line.

(d)

Grubbing of pits and ditches will be required only to the depth necessitated by the proposed excavation within such areas.

QCS 2014

Section 06: Road Works Part 02: Site Clearance

Page 5

(e)

Except in areas to be excavated, stump holes and other holes from which obstructions are removed shall be backfilled with suitable material and compacted.

(f)

Where designated the Contractor shall carefully remove existing trees, plants or shrubs and carefully transport these to a location designated by the Engineer.

REMOVAL OF STRUCTURES

1

Unless otherwise directed the Contractor shall demolish and remove all buildings and structures within the limit of works limits together with all foundations and retaining walls, piers, partitions and columns down to a plane not less than one metre below the finished ground level or one metre below the subgrade level in the area.

2

Upon receipt of notification by the Engineer, the Contractor shall take over all responsibility of the building or buildings then acquired and vacant and shall proceed with the demolition and removal thereof.

3

All structures shall be neatly trimmed off and the reinforcement shall be cut or trimmed off close to the concrete and made safe; basement floor slabs shall be broken into pieces; excess debris and other foundations, concrete floor slabs, sidewalks, driveways, signs, sheds, garages, fences and other facilities shall be removed.

4

The Contractor shall arrange for the discontinuance and disconnection of any services to the structure or structures in accordance with the requirements of the agency concerned. The Contractor shall disconnect and properly seal in an approved manner any sewer outlets that serve any structure he is to remove. The Contractor shall keep the Engineer informed of his plans for the performance of any work in connection with the sealing off of such outlets in order that proper inspection can be provided at the time the work is performed.

5

Any additional small out-buildings or temporary structures even if not shown on the Drawings shall also be removed if directed by the Engineer.

6

Demolition and removal works shall be carried out mechanically or by hand as necessary in such a manner as to cause no undue damage to the public, property, vehicles, pavements, services and structures, and the Contractor shall provide temporary works for protection when necessary, in accordance with any special requirements of the concerned authorities.

7

Blasting or other operations necessary for the demolition and/or removal of facilities which may damage new construction shall be completed before placing the new work, unless otherwise directed by the Engineer.

8

In all cases the Contractor shall be responsible for all claims resulting from damage, of any nature, caused by carelessness or negligence on the part of the Contractor, his subcontractors or agents.

9

Demolition or removal operations for any particular facilities shall not be started until written approval is obtained from the Engineer.

10

Throughout the demolition period the Contractor shall provide and maintain sufficient and adequate temporary supports.

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2.5

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Section 06: Road Works Part 02: Site Clearance

Page 6

REMOVAL OF STREET FURNITURE

1

Where designated, street furniture shall be recovered, cleaned and either delivered to and placed into storage at the stores of the designated authority or set aside for re-erection as part of the Works, or shall be removed and disposed of.

2

The Works shall include the excavation, removal and disposal of all foundations.

3

Before proceeding with the removal of any of the above installations the Contractor shall contact the relevant authority and obtain approval.

4

The recovery of existing street lighting installations shall form part of the Works and shall be in accordance with the requirements of the Public Works Authority.

2.7

REMOVAL OF FENCES

1

Where designated, fencing, including all support posts, gates, other accessories and foundations shall be removed.

2

The Contractor shall provide suitable termination's for remaining fencing whether inside or outside the right-of-way limits.

3

Unless otherwise directed all fencing, posts, gates and other accessories shall remain the property of the Employer and shall be carefully dismantled and delivered to and place into storage on site or at the Employer's stores, the location of which shall be obtained from the Engineer. The supporting posts and supports shall be carefully cleaned of concrete, avoiding damage to the posts.

4

Foundations and sections of fencing which are designated unsuitable for recovery by the Engineer shall be disposed of.

2.8

REMOVAL OF EXISTING PAVEMENTS

2.8.1

General Requirements

1

On sections of redundant existing roadway (and detours and diversions that are no longer needed for traffic) the existing pavement structure together with all kerbs, kerb base and backing, sidewalk paving, edging or kerb to sidewalk paving including base and backing to same and other items shall be broken out and removed.

2

Non-asphaltic pavement, kerbs, kerb base and backing, gutters and other associated debris shall be disposed of unless such items are designated for recovery.

3

Where designated side drainage ditches and excavations shall be filled and the roadway rough graded to restore approximately the original contour of the ground or to produce natural, rounded slopes. After the rough grading is completed, the area of the old roadbed shall be scarified or ploughed to mix the remaining road material thoroughly with earth and then shall be harrowed and smoothed.

2.8.2

Cutting Back Pavement

1

The Contractor shall cut back all existing construction in such a manner to avoid damage to the construction which is to remain.

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2.6

QCS 2014

Section 06: Road Works Part 02: Site Clearance

Page 7

Any damage to the existing pavement and other work areas which are to remain shall be restored to the satisfaction of the Engineer.

3

The details and dimensions of the cutting back of the existing pavement construction shall be as designated subject to a minimum benching step of 300 mm between each pavement course.

4

The method of cutting back all existing construction shall be as approved by the Engineer.

5

Once cut back all pavement edges shall be suitably protected against damage from construction traffic. Any such damage shall be made good before proceeding with pavement construction.

2.8.3

Stockpiling Asphalt Pavement

1

During the recovery and stockpiling operations asphalt pavement containing soil or other debris shall be kept separate from recovered pavement which does not contain soil or other debris.

2

Existing pavement designated for recovery shall be removed and stockpiled by methods which will minimise losses and prevent it being contaminated with other materials. Especially, the Contractor shall ensure that the material is reasonably free of soil and other matter when it is stockpiled.

2.8.4

Stockpile Site

1

The Engineer may direct that removed asphalt or concrete pavement is stockpiled for possible future use and the Contractor will transport all removed asphalt or concrete pavement to the designated stockpile location.

2

The Contractor shall inform the Engineer at least seven (7) days before he is ready to commence stockpiling operations and obtain written approval from the Engineer.

3

If not previously protected, the Contractor shall provide a protective enclosure around the stockpile site to prevent unauthorised dumping by other Contractors and ensure that material is not removed without authorisation. The protective enclosure around the stockpile site shall include a suitable lockable gate for entry.

4

The Contractor shall assure responsibility for maintenance of the stockpile site during the time he is depositing and removing material from the stockpile.

5

Maintenance responsibility shall include but not be limited to:

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2

6

(a)

Furnishing plant when directed by the Engineer to spread the material and shape the stockpile as successive loads of salvaged material are delivered.

(b)

Ensuring by whatever means required that no unauthorised dumping is allowed.

(c)

Consolidating and reshaping of stockpile from time to time and when final operations are complete.

When directed by the Engineer the Contractor shall permit other contractors access to the stockpile site to deliver or remove materials.

QCS 2014

Section 06: Road Works Part 02: Site Clearance

Page 8

MEASURES FOR STATUTORY UNDERTAKERS

1

The Contractor shall take all measures required by any statutory undertaker, the management of other publicly owned services, or owners of privately owned services or supplies, for disconnection and proper sealing off of all redundant drains, services and supplies.

2

The Contractor shall observe and comply with all the safety regulations that are in force for work associated with various services.

3

Before commencing work on the removal or treatment to any utilities the Contractor shall contact the statutory undertakers and obtain their written approval.

4

The removal of overhead power lines shall be carried out by the QGEWC or by a specialist contractor approved by the QGEWC.

2.10

REMOVAL OR TREATMENT TO BURIED UTILITIES

2.10.1

General

1

Designated existing underground storage tanks, culverts, box culverts, pipelines, pipes, manholes, inlets, gullies and similar facilities for drainage or other designated utilities shall be totally or partially demolished as designated, all debris removed, the facility thoroughly cleaned out and the resultant void backfilled with suitable material (as defined in Section 6 Clause 3.3) and compacted.

2

Underground utilities, pits, chambers, cesspools and similar facilities shall be demolished to a depth of one metre below the finished subgrade level in the area, and shall be properly cleaned out to full depth and backfilled with approved compacted materials.

3

Where designated, manhole and access shaft covers and frames and drainage inlet covers and frames shall be carefully removed, cleaned and transported to and placed into storage at designated storage areas.

4

Materials not recovered for reuse shall be disposed of.

2.10.2

Underground Storage Tanks

1

Existing underground storage tanks on the site or under structures designated for removal shall be removed and disposed of by the Contractor. The Contractor shall take all necessary precautions during the removal and disposal of any fluid within the tanks and of the tanks themselves.

2.10.3

Removal of Culverts

1

Where the total demolition of a culvert is designated the culvert top slab, walls, base slab and all manhole shafts, shall be broken out and all debris removed and disposed of.

2

Where the partial demolition of the culvert is designated the top slab of the culvert shall be removed together with all manhole shafts. The side walls shall be broken out to the designated level or to a minimum of one metre below the subgrade level or the finished ground level in the area. The walls shall he neatly trimmed off and the reinforcement shall be cut or burned off close to the concrete.

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2.9

QCS 2014

Section 06: Road Works Part 02: Site Clearance

Page 9

2.10.4

Abandoned Pipes and Culverts

1

Pipes and culverts no longer required which are designated to be abandoned in place shall either be filled with grout or concrete, as designated by the Engineer.

2

All ends of abandoned pipes with a nominal diameter greater than 100 mm and less than 600 mm and all ends of abandoned culverts with a cross-sectional area of 1.0 m2 or less shall be plugged by either mass concrete or a reinforced blockwork wall. All ends of abandoned pipes with a nominal diameter of 600 mm or greater and all ends of abandoned culverts with a cross-sectional area greater than 1.0 m2 shall be provided with a cut-off wall as designated.

2.10.5

Total Removal of Pipelines

1

Where designated, pipelines, manholes and fittings together with any plain or reinforced concrete bed, haunch or surround shall be broken out, removed and disposed of.

2

Designated pipes and ring fittings to be reused shall be recovered in such a way as to leave them undamaged and suitable for reuse.

3

The method of taking apart the pipes and fittings shall be agreed with the Engineer before the start of the work.

4

Materials damaged in the process of recovery shall be repaired by the Contractor.

5

The pipes and fittings recovered shall have all extraneous material including concrete surround carefully removed, they shall then be thoroughly cleaned and delivered to the designated storage area and placed into storage.

2.10.6

Grouting of Pipelines

1

Where designated, abandoned-in-place pipelines 300 mm or less in diameter shall he completely filled with a sand-cement grout.

2

The cement, fine aggregate and water used for the grout shall comply with the requirements of section 5 of the Qatar Construction Specification. The sand used for the grout shall be a fine graded rounded sand that produces a free flowing grout.

3

The grout shall comprise of one part cement to two parts fine aggregate with enough water to produce a free flowing and pumpable mix. The use of admixtures to improve the flow and setting characteristics of the grout will be permitted subject to the prior approval of the Engineer.

4

Each end of the pipe shall be plugged. No grouting shall commence until the Engineer's approval has been obtained.

5

The Contractor may propose alternative methods of filling the pipe for the approval of the Engineer. The Engineer shall retain the right to designate certain pipes that shall be filled with grout irrespective of any approval to alternative methods of filling.

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QCS 2014

Section 06: Road Works Part 02: Site Clearance

Page 10

Plugging of Pipelines

1

Designated pipes shall be plugged by mass concrete as per section 5 of Qatar Construction Specification to a minimum of one metre lateral extent into the pipe.

2

The method of constructing the plug to ensure a solid watertight seal shall be approved by the Engineer.

2.10.8

Cut-off Walls and Capping Slabs

1

Where designated the Contractor shall construct a reinforced blockwork cut-off wall to box culverts and pipelines and a reinforced concrete capping slab to manholes and access shafts.

2

Reinforced blockwork cut-off walls shall extend beyond the edges of the pipe and shall be founded on a mass concrete of grade 20 as per section 5 of Qatar Construction Specification.

2.10.9

Manholes and Access Shafts

1

Unless otherwise designated, manholes and access shafts shall be broken out to a plane not less than one metre below the subgrade level or the finished ground level in the area or to immediately below the manhole and/or access shafts cover slab, whichever is the lower.

2

Manhole and access shaft walls shall be neatly trimmed off and reinforcement shall be cut or burned off close to the concrete and made safe.

3

Manholes and access shafts shall be cleaned out and all debris, sediment and refuse and other unsuitable material disposed of, and backfilled with approved compacted material.

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2.10.7

2.10.10 Drainage Inlets and Gullies

Unless shown otherwise, all redundant drainage inlets, gullies and similar facilities shall be broken out to full depth.

2.11

DISPOSAL OF MATERIALS

1

Materials removed but not recovered shall be disposed of in a lawful manner at approved dumping areas. The Contractor shall be responsible for obtaining the location of the dumping area as well as the necessary permits and approvals from the relevant authorities.

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END OF PART

QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 1

EARTHWORKS ....................................................................................................... 3

3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5

GENERAL ............................................................................................................... 3 Scope of Work 3 References 3 Definitions 4 Submittals 4 Quality Assurance 6

3.2

EARTHWORKS BY OTHERS ................................................................................. 6

3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6

MATERIALS ............................................................................................................ 6 General 6 Unsuitable Materials 7 Fill and Subgrade Materials 7 Rock Fill 8 Water 9 Performance Indicators 9

3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8

MAIN PLANT FOR EARTHWORKS ........................................................................ 9 General 9 Compaction Trials 10 Rotary Cultivators 10 Water Sprinklers 10 Bulldozers 10 Motor Graders 11 Shovel Tractors 11 Compacting Equipment 11

3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6

EXCAVATION GENERAL ..................................................................................... 12 Removal of Unsuitable Soil and Soft Spots 12 Excavating High Level Areas 12 Rock Excavation 13 Manual Excavation 13 Excavation for Pits and Trenches 14 Double Handling 14

3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 3.6.7 3.6.8 3.6.9

FILLING GENERAL ............................................................................................... 14 General 14 Filling Around Utilities 15 Fill Supplied by Qatar National Transport Organization (QNTO) 15 Contractors Imported Fill 15 Rock Fill 16 Compaction 17 Filling of Pits and Trenches 18 Work Over Sabkha 18 Trimming Side Slopes 19

3.7 3.7.1 3.7.2 3.7.3

STRUCTURE EXCAVATION AND FILLING .......................................................... 19 General 19 Excavation Supports 20 Dewatering 20

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QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 2

Excavation for Structures Use of Materials Cofferdams Backfill Adjacent to Structures

20 21 21 22

3.8 3.8.1 3.8.2 3.8.3

FORMATION PREPARATION............................................................................... 22 Scope 22 Protection 23 Rectification 23

3.9

TOPSOIL ............................................................................................................... 23

3.10 3.10.1 3.10.2 3.10.3 3.10.4 3.10.5

TESTING ............................................................................................................... 23 General 23 Testing Degree of Compaction 24 California Bearing Ratio 24 Testing Levels and Evenness of the Formation 25 Testing Formation Works after Completion 25

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3.7.4 3.7.5 3.7.6 3.7.7

QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 3

3

EARTHWORKS

3.1

GENERAL

3.1.1

Scope of Work

1

This Part includes all the earthworks required to construct and maintain the roadway facilities as follows:

(b)

Excavating selected material from the roadway and borrow pits for use as specified.

(c)

Placing and compacting of selected material.

(d)

Structure excavation.

(e)

Backfilling.

(f)

Supplying and placing topsoil (sweet soil).

(g)

Laying and compaction of fill for shallow embankments where additional slope protection measures are not required.

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Removing unsuitable materials.

Related Parts are as follows:

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(a)

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Drainage Works Earthworks Related to Buildings

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Section 8, Section 12,

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This Section Part 1, .............. General Part 2, .............. Site Clearance Part 4, .............. Unbound Pavement Materials Part 5, ............. Asphalt Works Part 6, ............. Concrete Road Pavements Part 19, ........... Miscellaneous

References

1

The following standards are referred to in this Part:

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3.1.2

ASTM D1556 .............Standard Test Method for Density and Unit Weight of Soil in Place by Sand-Cone Method ASTM D1557 .............Standard Test Methods for Laboratory Compaction Characteristics of 3 3 Soil Using Modified Effort (56,000 ft lbf/ft (2,700 kN m/m )) ASTM D4718 .............Standard Practice for Correction of Unit Weight and Water Content for Soils Containing Oversize Particles ASTM D1883 .............Standard Test Method for CBR (California Bearing Ratio) of Laboratory Compacted Soils ASTM D4318 ..............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils ASTM D6913 .............Standard Test Methods for Particle Size Distribution (Gradation) of soils using Sieve Analysis

QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 4

ASTM D4429 ..............Standard Test Method for (California Bearing Ratio) CBR of Soils in Place ASTM D4944 ..............Standard Test Method for Field Determination of Water (Moisture) Content of Soil by the Calcium Carbide Gas Pressure Tester ASTM D6938 ..............Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth) ASTM D1140 ..............Standard Test Method for Amount of Material in Soils Finer than No. 200 (75-μm) Sieve ASTM E1703 ..............Standard Test Method for Measuring Rut-Depth of Pavement Surfaces Using a Straightedge

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AASHTO T307 ..........Standard Method of Test for Determining the Resilient Modulus of Soils and Aggregate Materials

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BS 1377 - Part 3 ........Methods of test for Soils for Civil Engineering Purposes: Chemical and electro-chemical tests Definitions

1

LSA: Laboratories and Standardization Affairs – Ministry of Environment.

2

Suitable material: material which is acceptable in accordance with Clause 3.3.3.

3

Imported material: suitable material obtained from outside of the Site.

4

Optimum moisture content (OMC): the moisture content of soil at which a specified compaction effort will produce the maximum dry density when determined in accordance with ASTM D1557.

5

Maximum dry density (MDD): The dry density of soil obtained using a specified compaction effort at the optimum moisture content when determined in accordance with the modified compaction test ASTM D1557. Unit weight and moisture content of materials containing more than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.

6

Subgrade: the compacted existing ground or fill for 500mm beneath formation.

7

Formation: the completed earthworks level shaped in accordance with the Drawings in readiness to receive the sub-base.

3.1.4

Submittals

1

The Contractor shall submit to the Engineer for approval his proposals for the compaction of each type of material to be used in embankments detailing the type of plant, number of passes and maximum loose depth of layer.

2

The contractor shall submit to the Engineer for approval method statements for the following:

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3.1.3

(a)

Materials production, handling, storage, identification, marking and traceability to source of production.

(b)

Quality assurance and quality control plans for all construction activities.

(c)

Quality control testing plan.

QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 5

(d)

Equipment and its suitability to fulfill all construction activities to the required quality.

(e)

Personnel capability.

(f)

Safety and environment preservation measures.

Before commencing any structural excavation work greater than 1.5 m in depth, the Contractor shall submit to the Engineer for his review details of proposals for supporting excavated faces.

4

The proposals shall be submitted in the form of calculations and drawings which clearly indicate the extent of excavation at all points along the structure relative to adjacent properties, roads and services.

5

In the case of supported excavations the proposals shall, for the actual soil properties, comprise detailed drawings of the support system stating method of installation and showing support member materials, sizes, spacing and engineering calculations to validate the design of the above, including the maximum theoretical deflections of the support members. The support system shall be designed in such a manner that no support members extend through surfaces exposed in the finished construction and no shoring or bracing is placed under permanent structures.

6

The engineering calculations shall be in English and shall show lateral earth pressures for the full excavation depths, faces at various stages of support during installation and removal and concrete placement, the anticipated equipment loads, anchorage loads of any description, the maximum design loads to be carried by various members of the support system and strut preload forces.

7

If the structure support system proposed includes tie-back anchors, the Contractor's submittal drawings shall show the profile of the soil in which each anchor is to be installed, the design load for the full depth of the excavation, the maximum design and proof loads, surcharge loads of any description; equipment loads, forces at various stages, support during installation and removal, and the criteria proposed for deformations under proof loads.

8

In addition to the approval submittal, shop drawings of the support system are to be submitted. Where a proposed system of tie-back anchors projects onto adjoining property beyond the vertical projection of the designated limits of the Contract, the permission of the owner shall be obtained in writing and documentation of such permission shall be included in the submittal.

9

Complete working drawings showing the type of dewatering and groundwater control system proposed shall be submitted for review. The submittal drawings shall show the arrangement, location and depths of the proposed dewatering system if required. A complete description of the equipment and materials to be used and the procedure to be followed shall be shown together with the standby equipment, standby power supply, and the proposed location or locations of points of discharge of water. Details of methods of cofferdam construction shall be included in the submittal.

10

The method and the type of equipment to be used for advancing dewatering wellpoints shall be submitted for review.

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QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 6

Quality Assurance

1

The designs of the structure excavation support systems and the dewatering system shall be prepared by and signed by a professional engineer specializing in this type of design work.

2

Blasting work shall be carried out by a specialist company with the appropriate license as detailed in clause 3.5.3.

3.2

EARTHWORKS BY OTHERS

1

Where earthworks have been carried out by others before commencement of the Works, the Contractor shall carry out all tests he considers necessary to satisfy him that the work already executed complies with this specification.

2

Should the Contractor consider the result of the tests unsatisfactory he shall immediately provide full details of all such tests carried out for the Engineer's review as to the remedial work to be undertaken.

3

The Contractor will be deemed to have satisfied himself as to the adequacy of any previous earthworks when he proceeds with his own work, and he shall be responsible for repairs to or replacement of any defective layer or surface where such failure was due to a fault in the previously executed work which would have been revealed by normal testing procedures.

3.3

MATERIALS

3.3.1

General

1

All excavated material shall be the property of the Owner and shall not be removed from the Site without the written consent from the Owner.

2

Suitable and approved excavated material from any part of the Site shall be hauled and used for filling in any other section of the Site. The Contractor shall store such material when necessary until the need arises for its use in filling as required by the phases of construction, or as directed by the Engineer.

3

Where the amount of suitable material exceeds the amount of fill required for the Works, the Contractor shall dispose of the surplus material at designated locations. The Contractor shall off-load, spread, level, water and carry out other related operations at the disposal site as directed by the Engineer. The Contractor shall ensure that the disposal site has been approved by the Municipality concerned.

4

Any excavation greater than the net volume required for the Works in length or width, shall be made up with suitable compacted fill material at no cost to the Owner and subject to inspection and approval of the Engineer.

5

Any additional excavation to remove unsuitable material at or below the bottom of foundation level or construction layers shall be replaced with mass concrete.

6

Before using material resulting from excavation for filling, the Contractor shall carry out field and laboratory testing to establish the suitability of said material for filling work. Whenever such excavated material indicates a change in characteristics the Contractor shall carry out additional testing.

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3.1.5

QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 7

Where the contract provides for the supply of fill material by others the Contractor shall remain responsible for checking each load received to ensure that it is in accordance with the specification requirements and for rejecting unsuitable material. The Contractor shall be responsible for maintaining all records of deliveries and documentation relating to the quality of such material.

3.3.2

Unsuitable Materials

1

Unsuitable materials shall mean materials other than suitable materials and include; Material from marshes.

(b)

Tree and plant stumps.

(c)

Perishable material.

(d)

Deposits of sabkha with more than 5% water-soluble salts.

(e)

Material subject to spontaneous combustion.

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Fill and Subgrade Materials

1

The subgrade material and the material used for filling and compacting below the formation level of the roadway, sidewalks, hard shoulder, drainage ditches and other areas on site shall consist of material approved for filling resulting from the excavation works.

2

In the event that such material is unsuitable or insufficient, the Contractor shall obtain and use filling material from borrow pits.

3

This material shall be clean and free from any unsuitable material and complies with the requirements listed in Table 3.1.

4

The maximum particle size of fill material shall be 75 mm unless the material is classified as rock as per this part of the specification and the placing and compaction are carried out according to the requirements for rock fill.

5

Unit weight and moisture content of materials containing more than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.

6

When nuclear gauge is used for field density and moisture content testing, 3 readings shall be made at each test location within a radius of 2 meters. The average of the 3 readings is considered to be the density for that test location. Individual density readings shall not be less than the target relative density by more than 0.5%.

7

Recycled aggregate produced from excavating natural ground and from demolition wastes can be used for filling purposes provided that the specifications stated in Section 6 - Part 9 are complied.

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3.3.3

QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 8

Table 3.1 1 Fill and Subgrade Materials and Construction Specifications Parameter

Standard

Specification Limits

Percent passing the 75mm sieve

ASTM D6913

100%

Percent passing the 0.075mm sieve

ASTM D1140

30% max.

Liquid limit

ASTM D4318 Method A

30% max.

Plasticity Index

ASTM D4318

10 % max.

- Visible change in material

ASTM D6938

In Place Moisture 2 Content

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ASTM D4944

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ASTM D1556

Min. 95% of MDD

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ASTM D6938

Field Density

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2% max.

 2% of OMC

ASTM D4429

Acid soluble Chloride Content

BS 1377 Part 3

Acid soluble sulphate content

BS 1377 Part 3

3% max.

Organic Matter

BS 1377 Part 3

2% max.

15% min.

- 1 per 200 m layer

2

per

- 1 every 75m per lane per layer 1 per 2000 m

2

1 per 3000 m

3

2% max.

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In Place California Bearing Ratio (CBR)

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15% min. at 95% MDD

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ASTM D1883 (Soaked)

Swelling

Loose materials for testing and acceptance shall be sampled from the un-compacted in- place layer. During compaction.

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- Each Source

- 1 per 1000 m

California Bearing Ratio (CBR)

1

Minimum Frequency

Rock Fill

1

Rock shall be defined as any naturally formed solid matter encountered in excavation having 2 2 a crushing strength of not less than 7 N/mm when dry and not less than 4 N/mm after submergence in water for 24 hours.

2

This shall be determined on samples of 100 mm x 100 mm x 100 mm cubes obtained from

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3.3.4

the material (equivalent cores in lie u of cubes may be considered for testing at the discretion of the Engineer and the method of testing and acceptance criteria will be advised by the Engineer in such cases). 3

Individual masses of solid material found in excavation and weighing less than 500 kg shall not be considered as rock.

4

Any artificially formed solid matter such as block work or concrete shall not be considered as rock.

QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 9

The Contractor shall supply any equipment and labor necessary to obtain suitable samples and carry out testing of rock or suspected rock. The Engineer shall determine the location and quantity of samples necessary to determine the extent of the rock. These samples shall be taken in the presence of the Engineer.

6

In the event that the tests prove that the material is rock, the Engineer shall determine the extent of such material and shall instruct the Contractor accordingly.

3.3.5

Water

1

Potable or brackish water shall be used for all earthwork operations except that only potable water shall be used for compaction of backfill material within one meter from all surfaces of the structure and for the backfill of all service trenches.

2

Brackish water shall have a maximum total dissolved solids (TDS) of 5000 ppm, a maximum chloride content of 1500 ppm and a maximum sulphate content (as SO3) of 2000 ppm.

3.3.6

Performance Indicators

1

Upon the request of the Engineer, the following performance indicators shall be determined from loose in place materials for verification of the pavement structural design following the AASHTO Mechanistic-Empirical Pavement Design Guide:

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5

Resilient Modulus (MR) in accordance with AASHTO T307 at optimum moisture content and maximum density as per ASTM D1557.

(b)

Parameters and moduli required for determining the Permanent Deformation Potential in accordance with AASTHO Mechanistic Empirical Design Guide.

(c)

Parameters and moduli required for measuring the Fatigue Cracking Potential for stabilized and surface layers in accordance with AASHTO Mechanistic Empirical Design Guide.

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(a)

3

For performance testing, one sample shall be tested every 10,000 m , and for constructions 3 having less than 10,000 m volume, one sample shall be tested every 50% of the total volume.

3.4

MAIN PLANT FOR EARTHWORKS

3.4.1

General

1

The Contractor shall provide the Engineer with copies of catalogues, technical data and charts of the machinery to be used on site before the commencement of the work.

2

The Engineer will inspect the machinery and tools before the commencement of work. The machinery and tools used in carrying out earthworks and other related works for the road construction and in maintenance of the work shall be in good working condition, and the Contractor shall maintain them in such condition for the whole duration of the Work.

3

The Contractor shall use power screens equipped with clay reject screen with sufficient screen area and clay reject conveyor belt when processing subgrade materials. Static screens shall not be used to produce subgrade materials. Any deviations from this process must be approved by the Engineer.

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The Contractor shall supply an adequate type and number of machines and tools for the proper and timely execution of the Works. The number of machines shall not be limited to the types of equipment or recommended minimum number stipulated in the Contract Documents, which shall be used for guidance purposes only.

5

The Contract is awarded on the understanding that the actual numbers of machines and other plant will not be reduced below the numbers shown in the Contract.

6

No plant shall be removed from the site without the specific written approval of the Engineer.

3.4.2

Compaction Trials

1

Before commencing construction of the permanent works, unless otherwise agreed with the Engineer, the Contractor shall carry out compaction trial, after submitting a method statement, for each type of fill material and construction situation of the earthworks to establish an approved rolling/compaction procedure which shall then be used as a minimum requirement for the permanent works unless otherwise directed or agreed by the Engineer.

2

The compaction trials shall involve all procedures specified for the permanent works including testing and any equipment, processes or procedures as proposed by the Contractor which are not included as a part of these specifications. Compaction trials for each main type of material shall be carried out on areas having dimensions of approximately 50 meters by 10 meters.

3

Construction of the permanent works shall not commence until a compaction procedure has been approved in writing by the Engineer.

3.4.3

Rotary Cultivators

1

Rotary Cultivators shall have axles rotated by a powerful motor and be equipped with metal teeth or plates. They shall be designed in such a way as to ensure proper pulverization and mixing of soil. They must be equipped with apparatus to lift and lower the axles so as to be always to the required depth.

3.4.4

Water Sprinklers

1

Water sprinklers shall be borne by trucks with pneumatic tires and shall be equipped with a pressure pump and water sprinkling distribution equipment. The pump shall be powered in such a manner that the pump pressure will remain uniform regardless of variations in truck speed. The distributors shall be so designed as to allow sprinkling and adding of water to the soil uniformly and in controlled quantities and shall be equipped with an approved gauge to control the quantity of water added during operation. Special spray bar attachments shall be provided and used in order to sprinkle water on sloped sections. The activation of the water system shall be controlled from the cab by the driver.

3.4.5

Bulldozers

1

Bulldozers may be tracked or pneumatic-tire vehicles and shall be equipped with a blade for earth moving and levelling. Ripper attachments shall be provided when necessary. The blade level shall be hydraulically controlled to raise or lower it so that the work surface can be formed and adjusted as required.

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Motor Graders

1

Motor graders shall be pneumatic-tire and shall be equipped such that it is possible to lift, lower and adjust the angle of the blade as required to control the grading operation and to perform grading without making undulations.

3.4.7

Shovel Tractors

1

Shovel tractors shall be tractors equipped with a shovel for earth hauling or moving and may be either on tracks or on pneumatic tires. The shovel shall be hydraulically controlled to raise and lower it as required.

3.4.8

Compacting Equipment

1

Rolling compacting equipment shall consist of pneumatic-tire and steel wheeled rollers as described below:

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Pneumatic-tire rollers shall be equipped with tires of equal size and diameter which shall be uniformly inflated so that the air pressure of the tires shall not vary significantly, from one another. The wheels shall be spaced so that one pass will accomplish one complete coverage equal to the rolling width of the machine. There shall be a minimum of 6mm overlap between the tracks of the front and rear tracking wheels. Self-propelled, pneumatic-tire rollers shall have a minimum weight of 9 tons without ballast and a minimum weight of 18 tons with ballast.

(b)

Steel wheeled rollers shall be of the following types:

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(a)

Three-wheeled rollers shall be self-propelled and equipped with a reversing clutch, a differential drive and with adjustable scrapers to keep the wheel surface clean.

(ii)

Tandem rollers shall be self-propelled and equipped with reversing clutches and adjustable spring scrapers fitted to the driving and steering roller to scrape in both directions.

(iii)

Vibratory steel tandem rollers shall have the requirements of the foregoing steel tandem rollers with a static weight of at least 5000 kg and a vibrating frequency between 1500 and 2000 cycles per minute.

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(iv)

Single drum vibratory steel rollers shall be double axle, self-propelled units with the rear axle equipped with pneumatic flotation wheels, they shall have vibrating frequency capabilities between 1500 and 2000 cycles per minute.

2

Portable vibratory compaction rollers shall be double axle tandem single-drum self-propelled equipped with a vibrating element delivering an impact of not less than 1590 kg at a frequency of about 5000 cycles per minute. The roller shall be easily maneuvered, of adequate width and suitable for rolling ditches with their side slopes having grades of up to 1:3.

3

Hand plate compactors shall be capable of delivering an impact of between 750 to 1500 kilograms.

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EXCAVATION GENERAL

3.5.1

Removal of Unsuitable Soil and Soft Spots

1

If during the progress of the work the soil encountered has characteristics, as determined by tests conducted under the direction of the Engineer, that render it unsuitable for incorporation in the road embankment, the Contractor shall excavate and remove such unsuitable material to the extent directed by the Engineer.

2

Where contractor finds isolated soft spots during excavation, this material shall be removed to the extent directed by the Engineer.

3

No excavated suitable material shall be removed from the Site without the approval of the Engineer. Should the Contractor be permitted to remove suitable material to suit his operational procedure then he shall make good any consequent deficit of fill material arising therefrom.

4

Where the excavation reveals a combination of suitable and unsuitable material the excavation shall, unless otherwise agreed with the Engineer, be carried out in such a manner that the suitable materials are excavated separately for use in the Works without contamination by the unsuitable material.

5

The hauling of excavated material to areas of fill shall proceed only when sufficient spreading and compacting plant are operating at the place of deposition to ensure placing and compaction.

6

Unsuitable excavated material shall be removed and carted away to an approved dumping area after approval from the Engineer.

7

The Contractor shall replace this unsuitable material by other suitable surplus or imported material in layers not exceeding 150 mm compacted thickness to the density specified.

8

If the contractor considers in some situations it is impractical to replace unsuitable material with imported material he may elect to use granular material, which shall comply with the requirements of part 4 of this specification.

9

Granular material placed beneath water shall not require compaction, granular material placed above water shall be compacted and tested as per the requirements of part 4 of this specification.

10

If any solution cavities are found in lime stone material they shall be brought to the attention of the Engineer. The Engineer shall advise what treatment is to be carried out in such situations.

3.5.2

Excavating High Level Areas

1

The Contractor shall excavate high level areas in all materials including rock for the full width of the road construction down to the top of the required subgrade.

2

The Contractor shall then scarify a layer not less than 150 mm deep except that this requirement shall not apply where rock is present.

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3.5

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The soil shall be pulverized, watered as required, mixed, shaped and compacted to 95 % maximum dry density, as per ASTM D1557, to a depth of 150 mm. In all excavations the groundwater level shall be maintained at least 300 mm below the formation level during the works.

3.5.3

Rock Excavation

1

Excavation in rock shall be as defined in clause 3.3.4 of the specification.

2

Excavation in rock may be carried out by a tracked bulldozer and ripper or by the use of blasting with explosives or any other method approved by the Engineer.

3

Blasting using explosives shall only be permitted if authorized by the civil defense, police and any other statutory authority. The Contractor’s method statement shall be agreed before any blasting operation.

4

Blasting work shall be carried out in accordance with The Guide for Civil Users of Explosives in Qatar prepared by the former Ministry of Industry and Public Works.

5

For any blasting work involving the use of explosives the Contractor shall use a specialist company, licensed to carry out such work by the former Ministry of Industry and Public Works.

6

The specialist company shall possess the appropriate license for the required scope of work.

7

The purchase and delivery of each consignment of explosives for blasting work should be covered by a separate application for a possession license.

8

The transportation of explosives shall only be carried out after notification to the police and civil defense.

9

For each planned blasting operation the Contractor shall arrange for advance notification to be made to the police and civil defense authorities.

10

After it has been established that the excavated material is rock and after the area where such rock exists has been defined, the Contractor shall incorporate the rock in the embankment.

11

When excavated material contains more than 25 % of rock larger than 150 mm in greatest

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diameter the rock shall be crushed, pulverized and further broken down. The resultant material from the excavation shall be placed on the embankment in accordance with clause 3.6.5. 3.5.4

Manual Excavation

1

The Contractor shall excavate manually in the vicinity of all services, structures, and any other areas, and if necessary uncover them, all as directed by the Engineer.

2

The Contractor shall take all precautions to prevent damages to services, properties and persons, and any damage resulting from the negligence of the Contractor, his agents, or his employees. Any such damage shall be repaired by the Contractor at his own expense.

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Excavation for Pits and Trenches

1

All trenches and pits under roads shall, where possible, be excavated, backfilled and compacted before road construction commences.

2

The sides of the excavation shall be adequately supported at all times.

3

Trenches and pits shall be kept free of water.

4

In tidal and high water table areas the excavation shall be kept free from standing water at all times during construction.

5

Trenches for pipes or ducts shall be excavated to the levels and gradients indicated in the contract documents.

3.5.6

Double Handling

1

It shall be the Contractor’s responsibility to assess at the start of the contract the quantity of suitable material available from an excavation for use as fill material and the requirement for imported fill material.

2

The Contractor shall plan earthworks operations to minimize the handling of fill material and disruption due to dust and noise from transportation operations.

3

The Contractor shall not be entitled to any additional payment for double handling of any excavated material from the site for imported fill.

4

If it is necessary to double handle the material the Contractor shall take all measures to avoid degradation or contamination of fill material.

5

The Engineer may instruct that the tests to assess the properties of the fill material are taken at any point during the transportation, placing and compaction process.

3.6

FILLING GENERAL

3.6.1

General

1

Filling low-level areas shall be to the level of subgrade as designated. After completion of clearing and grubbing, the Contractor shall carry out the necessary levelling in order to control the thickness of the layers of fill.

2

The existing natural ground shall then be scarified in place to a minimum depth of 150 mm for the full width of the embankment except where the material is classified as rock. The scarified material shall be watered as required, thoroughly mixed, shaped and compacted to a minimum of 95 % maximum dry density.

3

Where an existing embankment is being widened, the existing embankment slope shall be trimmed and compacted into benches of minimum width 1m and depth 500mm before placing and compacting each layer of new embankment material unless otherwise directed by the Engineer to suit particular circumstances.

4

The Contractor shall not proceed with filling and compacting any subsequent layer before testing and securing the approval of the Engineer for the previous layer.

5

All fill material for a depth of 500 mm below the formation level must meet the requirements provided in clause 3.3.3.

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3.5.5

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Filling Around Utilities

1

Filling around culverts, storm water and sewerage pipes, utility and structures, and between building plot and footpath areas shall be done in accordance with the specific requirements of the relevant utility authority and the following additional requirements.

2

Filling for these areas shall be from surplus excavated material obtained on site and approved by the Engineer. In the case of insufficiency of such material then approved material shall be obtained from borrow pits and filled to the designated levels. The maximum size of particle allowed in the backfill within one meter of culverts, storm water and sewage pipes, utilities and structures shall be 25 mm.

3

The Contractor shall take every precaution to protect bridge columns and lighting equipment when filling between median barriers and any damage to these items arising from the filling works shall be repaired by the Contractor.

4

The Contractor shall agree the type of plant or equipment to be used with the Engineer before undertaking this work.

3.6.3

Fill Supplied by Qatar National Transport Organization (QNTO)

1

If instructed under the projects specification, fill will be imported from other sources using the Qatar National Transport Organization (QNTO).

2

It shall be the responsibility of the Contractor to monitor and control both the quality and the quantity of this imported fill.

3

The Contractor shall ensure that all delivery notes for such material are verified and authenticated and then collated for submission to the Engineer.

3.6.4

Contractors Imported Fill

1

The project specifications shall designate areas for the Contractor to obtain borrow material for use in the construction of the Works. It is the Contractor's responsibility to satisfy himself that there is sufficient borrow material of suitable types.

2

The Contractor may elect to use alternative sources of borrow material.

3

It shall be the Contractor's responsibility to obtain all permits or permission and make any payments that may be required in acquiring the rights to borrow material whether the Contractor uses the designated areas or elects to use alternative areas. The Contractor shall ensure that the source of all borrowed material has been approved by the Municipality concerned.

4

The Contractor shall obtain and supply to the Engineer representative samples from the borrow pits he intends to use. The Engineer will be afforded the opportunity to be present during the sampling operations.

5

The Contractor will carry out the necessary laboratory and, if required, field testing to establish the suitability of the material for filling work and will advise the Engineer of the results. The Engineer will advise the Contractor whether such material is acceptable and whether the borrow pit is an approved source of borrow material.

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3.6.2

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The Contractor will test samples of the approved borrow pits material actually being imported onto the site, and should such material fail to meet the requirements of these Specifications, approval to the use of the borrow pits will be withdrawn and the Contractor shall immediately cease importation from the borrow pits until such time as the Engineer may approve alternative sources of material from within the same borrow pits based on sampling and testing as specified above.

7

The Engineer will decide whether the material already imported from the concerned borrow pits can remain as placed on the site, or whether the Contractor shall remove and replace the said material at his own expense.

8

Overburden and any unsuitable top layers at the borrow pit shall be stripped and stockpiled to the satisfaction of the Engineer. Upon completion of excavation the Contractor shall replace the overburden and unsuitable material, smooth the surface and leave the area clean and tidy to the satisfaction of the Engineer.

9

The Contractor's haul and traffic arrangements will be subject to the Engineer's approval before the work may be commenced.

3.6.5

Rock Fill

1

Material consisting predominantly of rock fragments of such a size that it cannot be placed in layers of the thickness allowed without crushing, or further breaking down, may be placed in the embankment in layers not exceeding twice the average size of the larger fragments.

2

No layer of rock fill shall exceed 800 mm loose thickness.

3

Rock fill shall be placed and spread so that the largest boulders and fragments are evenly distributed, with the voids in-between completely filled with smaller fragments, sand or gravel, watered in if necessary.

4

Each layer shall be bladed and leveled by a track laying tractor.

5

Quality control tests will not normally be performed on this material but each layer must be approved in writing by the Engineer before the next is placed.

6

Embankment layers which consist of material that contains rock but also has sufficient compatible finer material other than rock shall be placed and compacted as for soil embankments. Quality control tests will be made wherever the Engineer determines they are feasible.

7

Compaction shall be carried out by a vibratory roller with the following minimum mass:

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Mass per Meter Width of Vibration Roll (kg/m)

Depth of Fill Layer ( mm )

Minimum number of Passes of the Roller on each Layer

2300 - 2900

400

5

2900 - 3600

500

5

3600 - 4300

600

5

4300 - 5000

700

5

>5000

800

5

QCS 2014

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Page 17

Compaction

1

The Contractor shall carry out the required compaction specified after grading and leveling the surface to be compacted. In areas to be filled, compaction shall include adding necessary soil, water and compacting the first layer in addition to subsequent layers up to the proposed levels.

2

In areas already excavated down to the required level, compaction shall include adding the necessary water, and compacting the surface, in accordance with the procedure outlined in paragraphs 3 to 12 below.

3

After carrying out the grading, leveling, scarifying and pulverizing of the soil layer the Contractor shall add the necessary amount of water to permeate the pulverized soil.

4

The soil shall then be thoroughly turned after each addition of water so as to achieve homogeneous moisture content in the whole thickness of the layer.

5

Before compacting, samples of the pulverized soil shall be tested using a 'Speedy Moisture Device' (ASTM D4944) or similar instrument to measure the moisture content. If the moisture content is not within  2 % of the optimum moisture content as determined by ASTM D1557,

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as

primarily leveled in order to commence earth compaction. After primary levelling referred to above, compaction shall be commenced by means of the approved rolling pattern.

7

Filling shall be in layers not exceeding 150 mm compacted thickness.

8

All areas including embankment roadway, medians, shoulders, sidewalks and verges shall be compacted to 95 % of Maximum Dry Density as determined by ASTM D1557 unless

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otherwise specified or directed by the Engineer. The rolling shall be carried out in the direction of the road axis until the soil reaches the required density. In crowned sections, rolling shall start from both edges of the road in the direction of the road axis. If the road is super elevated, rolling shall commence from the lower side and continue to the higher side. In order to compensate for the amount of water loss in evaporation during the course of compaction, additional quantities of water shall be added as required.

10

Each layer shall be levelled and rolled to achieve uniform compaction free from undulations, soft spots and depressions.

11

No layer shall be covered by the next layer until it has been tested, inspected and approved by the Engineer.

12

The Contractor shall be responsible for reinstatement to the satisfaction of the Engineer of any layer damaged or disturbed after compaction and approval, by any means or cause, before placing the next layer.

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Filling of Pits and Trenches

1

The bottom of all excavations shall be formed to the lines and levels shown on the drawings.

2

Any pockets of soft soil or loose rock in the bottom of pits and trenches shall be removed and the resulting cavities and any large fissures filled with suitable material and compacted to a minimum relative compaction of 95 % based on ASTM D1557.

3

Prior to proceeding with filling, the base of the excavation shall be compacted to a minimum relative compaction of 95 % based on ASTM D1557.

4

The full width of the compaction plant shall fit inside the surface area of the backfilling with sufficient space to permit adequate compaction. Under no circumstance shall compaction be carried out with plant straddling backfilled and existing surfaces.

5

Trenches and pits shall be backfilled in layers not exceeding 150 mm compacted thickness unless otherwise directed by the engineer.

3.6.8

Work Over Sabkha

1

Where the road embankment passes over Sabkha areas with a high water table the contractor shall take special precautions during the construction.

2

These precautions shall include but shall not be limited to the construction of suitable temporary haul roads for all construction plant operating in the area.

3

Haul roads shall be constructed using rock fill and geotextiles as necessary to ensure a safe stable surface.

4

The use of geotextiles and geosynthetics shall be in accordance with Part 15 when used for the permanent embankment.

5

If directed by the Engineer the Contractor shall construct embankments over Sabkha areas with a surcharge of excess material that shall remain in place till all appreciable settlement has stopped. The Contractor shall provide a means of monitoring the settlement. The Engineer shall decide when appreciable settlement has stopped.

6

Unless a specific treatment in using geotextiles or geosynthetics is described elsewhere in the contract, work over Sabkha shall comprise of initially stabilizing the existing Sabkha area by laying and rolling rock fill layer type 1 according to Table 3.2. This operation should be continued by adding and rolling type 1 rock fill layer with steel vibratory roller till the layer is completely stabilized.

7

A layer of geotextile fabric should be laid over the compacted type 1 pervious backfill.

8

A layer of 50mm pervious backfill type 2 according to Table 3.2 should be laid over the stabilized layer to protect the geotextile fabric.

9

Layer of 200mm thick rock fill type 1 should be laid over type 2 pervious backfill to receive the required road layers after the above operation.

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Table 3.2 Definition of Type 1 & 2 backfill materials Percentage Passing Size (mm) Type 2

152.0

Max.

-

125.0

85 - 100

-

100.0

75 - 90

-

50.0

45 - 65

-

37.5

35 - 55

-

19.0

20 - 35

100

12.5

10 - 25

95 – 100

9.5

5 - 20

70 – 100

4.75

-

0 – 55

2.36

-

0.075

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Type 1

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Trimming Side Slopes

1

Embankment side slopes shall be trimmed to the profiles and dimensions shown on the contract drawings.

2

The earthworks shall be trimmed to within  20 mm of the designated profile.

3

The side slopes shall be thoroughly compacted after trimming to ensure a hard surface.

4

Side slopes shall be tested for compaction in accordance with this part of the specification and the minimum density requirement shall be 95% of the maximum dry density as per ASTM D1557.

3.7

STRUCTURE EXCAVATION AND FILLING

3.7.1

General

1

In addition to the work specified, the Contractor shall include all operations necessary to excavate and backfill as required for the construction of any structure’s installations and utilities.

2

This work shall include necessary, pumping, dewatering, draining, sheeting, bracing, and the necessary supply and construction of cribs and cofferdams and their subsequent removal.

3

The Contractor shall take all necessary precautions, to the satisfaction of the Engineer, to prevent loss of natural cementation in the existing subsoil during, and as a consequence of, dewatering operations.

4

This work shall also include the furnishing and placing of approved foundation fill material or concrete to replace unsuitable material encountered below the foundation elevation of structures.

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3.6.9

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Excavation Supports

1

Battered excavation slopes greater than 1.5 m high shall not be used without the express written permission of the Engineer. Where such permission is not granted or where only a part of the overall depth of an excavation is permitted to be with battered slopes all faces of excavations greater than 1.5 m high shall be supported.

2

The Contractor shall submit his proposals for supporting excavated faces.

3

Before commencing any structural excavation work greater than 1.5 m in depth, the Contractor shall obtain the Engineer’s approval of his proposals for supporting excavated faces.

3.7.3

Dewatering

1

At locations where the excavation extends below the groundwater table, a dewatering system shall be provided. This will effectively reduce the hydrostatic pressure and lower the groundwater levels below excavation levels, as required for the safe and proper excavation of the work. It will result in obtaining a stable, dry subgrade for the execution of subsequent operations.

2

The Contractor shall design dewatering methods and settling basins so that no critical amounts of soil, sand or silt are removed during either the initial operations or the construction operations. Complete working drawings showing the type of dewatering and groundwater control system proposed shall be submitted to the Engineer for his review.

3

The Contractor's submitted drawings shall show the arrangement, location and depths of the proposed dewatering system if required. A complete description of the equipment and materials to be used and the procedure to be followed shall be shown, together with the standby equipment, standby power supply, and the proposed location or locations of points of discharge of water.

4

Any required dewatering system design shall also include the measures taken to prevent damage due to settlement of pavement, utilities, sewers, buildings and other structures outside the excavation but within the area affected by the dewatering procedures.

5

Dewatering shall not be terminated without the approval of the Engineer and in the case of structures retained by ground anchors dewatering shall not be terminated until the ground anchors have been stressed to the full working load and approved by the Engineer.

3.7.4

Excavation for Structures

1

The Contractor shall notify the Engineer sufficiently in advance of the beginning of any excavation so that cross-sectional elevations and measurements may be taken of the undisturbed ground.

2

Trenches or foundation pits for structures or structure footings shall be excavated to the designated lines and grades or elevations. They shall be of sufficient size to permit the placing of structures or structure footings of the full width and length shown. The designated elevations of the bottoms of footings shall be considered as approximate only and the Engineer may order, in writing, such changes in dimensions or elevations of footings as may be deemed necessary, to secure a satisfactory foundation.

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Boulders, logs, and any other unsuitable material encountered in excavations shall be removed from the site.

4

Unless otherwise designated structure excavation shall be carried out for a width of at least 500 mm beyond the horizontal outside limits of the foundation, footing, box culvert or structural member to which the excavation relates. Concrete blinding or sub-foundations are not to be considered as structure for the purpose of defining such excavation.

5

If during the progress of the work, loose or improperly compacted soil or such other material as the Engineer considers would be detrimental to load distribution of new foundations to the underlying soil is encountered below the structure foundation level such material shall be removed within the limits as directed by the Engineer.

6

The resulting void shall be backfilled with either blinding concrete or with suitable material compacted to a density not less than 95 % of the maximum dry density as per ASTM D1557.

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The Engineer shall specify the type of backfill to be employed at each location. After each excavation is completed, the Contractor shall notify the Engineer to that effect, and no footing, bedding material or pipe culvert shall be placed until the Engineer has approved the depth of excavation and the character of the material on which the foundations will bear.

8

All rock or other hard foundation material shall be cleaned of all loose material and cut to a firm surface, either level, stepped, or serrated as directed by the Engineer. All seams or crevices shall be cleaned and grouted. All loose and disintegrated rock and thin strata shall be removed. When the footing is to rest on material other than rock, excavation to final grade shall not be made until just before the footing is to be placed.

3.7.5

Use of Materials

1

All excavated material, so far as it is suitable, shall be used as backfill or roadway fill.

2

All excavated material shall be approved by the Engineer before being used as fill. All surplus excavated material and excavated material rejected by the Engineer for use on the site shall be removed from the site and disposed of in locations approved by the Engineer.

3

Where the Engineer designates a disposal location this shall be within a 50 km radius of the site of the Works.

3.7.6

Cofferdams

1

Suitable and practically watertight cofferdams shall be used wherever water-bearing strata are encountered above the elevation of the bottom of the excavation.

2

Cofferdams or cribs for foundation construction shall, in general, be carried well below the bottoms of the footings and shall be well braced and as nearly watertight as practicable. In general, the interior dimensions of cofferdams shall be such as to give sufficient clearance for the construction of forms and the inspection of their exteriors, and to permit pumping outside of the forms. Cofferdams or cribs which are tilted or moved laterally during the process of sinking shall be righted or enlarged so as to provide the necessary clearance.

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Section 06: Roadworks Part 03: Earthworks

Page 22

When conditions are encountered which, as determined by the Engineer, render it impracticable to dewater the foundation before placing the footing, the Engineer may require the construction of a concrete foundation seal of such dimensions as he may consider necessary, and of such thickness as to resist any possible uplift. The concrete for such a seal shall be placed as directed by the Engineer. The foundation shall then be dewatered and the footing placed.

4

If weighted cribs are employed and the weight is used to overcome partially the hydrostatic pressure acting against the bottom of the foundation seal, special anchorage's such as dowels or keys shall be provided to transfer the entire weight of the crib to the foundation seal. When a foundation seal is placed under water, the cofferdam shall be vented or ported at low water level as directed.

5

As an alternative to a cofferdam, the Contractor may propose a wellpoint dewatering system, for approval by the Engineer, to keep structural excavation works dry. Such proposal shall include, but not be limited to, sufficient calculations, sketches and drawings, to justify the wellpoint positions and lengths in addition to pumping capacity required. The use of a wellpoint dewatering system may not preclude the use of support or shoring within the excavation to provide adequate stability and safety to the satisfaction of the Engineer.

3.7.7

Backfill Adjacent to Structures

1

Excavated areas around structures shall be backfilled with suitable excavated materials or imported materials as approved by the Engineer. Backfill materials shall be placed in horizontal layers not over 150 mm in depth and compacted to a minimum of 95% of the maximum dry density obtained by ASTM D1557.

2

Material used for backfill adjacent to structures shall have a sulphate content of less than 2.5 g/L when tested in accordance with BS 1377.

3

Each layer shall be moistened or dried as required and thoroughly compacted as specified. The maximum size of particle allowed in the backfill within one meter of structures shall be 50 mm.

4

Backfill and embankment behind walls of any culvert shall not be placed until the top slab of the culvert has been placed and cured.

5

Backfill to culvert walls shall be carried out simultaneously behind opposite walls.

3.8

FORMATION PREPARATION

3.8.1

Scope

1

This work shall consist of the preparation of the graded formation upon which sub-base, base course or pavement materials are to be placed, all in accordance with these Specifications.

2

All subgrade shall be compacted to the previous requirements of these Specifications.

3

Preparation and surface treatment of the formation shall be carried out after all duct and pipe installations in the subgrade have been completed.

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QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 23

Any non-compliant subgrade material shall be excavated, replaced, and compacted to the required density.

3.8.2

Protection

1

Once prepared, the formation shall be maintained in the finished condition until the first succeeding course of sub-base, base, or asphalt pavement material has been placed.

2

The Contractor shall take all precautions necessary to protect the formation from damage: hauling over finished subgrade shall be limited to that which is essential for construction purposes.

3

Any equipment used for hauling over the prepared subgrade which in the opinion of the Engineer is causing undue damage to the prepared subgrade or to the underlying materials shall be removed from the Works at the request of the Engineer.

4

All cuts, ruts and breaks in the surface of the subgrade shall be repaired by the Contractor before placing any subsequent layer. The Contractor shall protect the prepared subgrade from both his own and public traffic.

5

The Contractor shall maintain the subgrade by blading and rolling as frequently as may be necessary to preserve the subgrade in a completely satisfactory condition.

3.8.3

Rectification

1

Any surface area of the formation which is too high shall be graded off, scarified and recompacted to the full depth of the affected layer.

2

Any surface area of the formation which is too low shall be scarified and corrected by the addition of subgrade material of the same classification and moisture content.

3

The Contractor shall carry out additional testing as required by the Engineer to ensure that the standard of compaction is satisfactory through the full depth of a layer or previously placed layers.

3.9

TOPSOIL

1

Topsoil (sweet soil) shall be fertile, free draining, non-toxic soil capable of sustaining healthy plant growth.

2

The material proposed for use as topsoil shall be approved by the Agricultural Department of the Ministry of Municipal Affairs and Agriculture.

3

Topsoil shall be loosely placed at the designated thickness.

3.10

TESTING

3.10.1

General

1

For verification of material, moisture content, compaction, thickness and other properties of the materials or workmanship the Engineer shall at all times have access to all portions of the works and sites. All sampling and testing of material and work shall be carried out under the direction of the Engineer.

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QCS 2014

Section 06: Roadworks Part 03: Earthworks

Page 24

The minimum frequency of testing shall follow the frequencies mentioned in Table 3.1 unless more frequent tests are shown elsewhere in the contract documents or directed by the Engineer. Other testing shall be carried out as directed by the Engineer.

3.10.2

Testing Degree of Compaction

1

Testing shall be done in accordance with ASTM methods of testing, or other approved equivalent test or designated procedure.

2

The density-in-place of earthworks layers shall be tested by the sand replacement method (ASTM D 1556) or nuclear method (ASTM D6938).

3

Nuclear density gauge testing should only be carried out by personnel who have approved user certification issued by the Ministry of Environment.

4

Each in-situ density nuclear gauge shall be calibrated and a calibration form issued. The Contractor shall maintain on site and with the instrument a copy of the Ministry of Environment safety and training manual for the use of nuclear density gauges.

5

When nuclear gauge is used for field density and moisture content testing, the density and moisture content for each material shall be verified by measurements in accordance with ASTM D1556 and ASTM D2216, respectively. The mean value of the replicate readings shall be used as the calibration point value for each material.

6

When determining the laboratory maximum dry density the method described in ASTM D1557 shall be applied.

7

No person or company will be permitted to determine in situ density by means of a nuclear type density measuring device without complying with the requirements of the Ministry of Environment. Refer to clause 1.5 of part 1 of this Section.

8

The density of any layer requiring compaction shall be determined in accordance with the specifications mentioned in Table 3.1.

9

If a layer does not conform to the required density, additional tests may be taken to determine the limits of the failing area, after which the Contractor shall rework the area until the specified density is obtained. The Contractor shall allow enough time in his daily work program to permit the performance and checking of the above tests, before he proceeds into any subsequent operations.

3.10.3

California Bearing Ratio

1

The soaked value of the California Bearing Ratio shall be determined on specimens compacted at the optimum moisture content and 95 % of the maximum dry density as per ASTM D1557 after soaking for 4 days in accordance with ASTM D1883. CBR value shall comply with the minimum requirement as per Qatar Highway Design Manual (QHDM).

2

The test surcharge to be used for the equivalent pavement thickness shall be designated by the Engineer.

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Section 06: Roadworks Part 03: Earthworks

Page 25

Testing Levels and Evenness of the Formation

1

The Engineer shall test the levels and evenness of the finished formation surface to ascertain compliance.

2

The Contractor shall make available to the Engineer a three-meter straight-edge and a crown template of sturdy and approved design and the necessary labor to assist in the checking operations.

3

When tested in accordance with ASTM E1703 by a three-meter straight-edge placed at right angles to, or parallel to, the road centerline or when tested by a crown template placed centrally at right angles to the road centerline, the maximum gap between the road formation surface and the testing edge shall not be greater than 20 mm. Measurements shall be carried out at maximum spacing of 50m of road length for each lane.

4

The subgrade shall be prepared to the levels shown on the contract drawings to a tolerance of between  15 mm and  20 mm when checked by a level instrument.

5

Variation in the falls to cross-sections of the road shall not exceed 0.4 %.

6

These tests shall be made at any point requested by the Engineer. In the event of any failure, the Contractor shall correct the unevenness of the surface and resubmit the area for approval by the Engineer.

3.10.5

Testing Formation Works after Completion

1

All completed works shall be inspected at any time as directed by the Engineer in order to verify the compliance of the executed work to the requirements of the contract as per requirement of Part 5 in Section 3.

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3.10.4

END OF PART

QCS 2014

Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 1

UNBOUND PAVEMENT MATERIALS ..................................................................... 2

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5

GENERAL ............................................................................................................... 2 Scope 2 References 2 Definitions 3 Submittals 3 Quality Assurance 4

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8

MATERIALS ............................................................................................................ 4 Sources of Materials 4 Storage and Handling of Materials 4 Inspection Testing and Control 5 Fine Aggregate 5 Coarse / Combined Aggregate 6 Recycled Aggregate 7 Water 8 Performance Indicators 8

4.3 4.3.1 4.3.2 4.3.3

MAIN EQUIPMENT ................................................................................................. 8 General 8 Paving Machines 9 Central Mixers 9

4.4

MIX DESIGNS ......................................................................................................... 9

4.5

SCREENING AND MIXING ..................................................................................... 9

4.6

SPREADING AND COMPACTION ........................................................................ 10

4.7

CORRECTIVE ACTION......................................................................................... 11

4.8

PROTECTION OF SURFACE ............................................................................... 11

4.9 4.9.1 4.9.2 4.9.3

TESTING ............................................................................................................... 12 General 12 Thickness 12 Evenness and Level 12

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Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 2

4

UNBOUND PAVEMENT MATERIALS

4.1

GENERAL

4.1.1

Scope

1

This Part includes materials, equipment and construction requirements for unbound layers (aggregate Subbase and Road Base courses).

2

Related Parts are: General Earthworks Asphalt Works

References

1

The following standards are referred to in this Part:

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Part 1 Part 3 Part 5

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ASTM C88 ..................Standard Test Method for Soundness of Aggregates by Use of Sodium Sulphate or Magnesium Sulphate

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ASTM C131 ................Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

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ASTM C136 ................Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

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ASTM C535 ................Standard Test Method for Resistance to Degradation of Large-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

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ASTM D1556 ..............Standard Test Method for Density and Unit Weight of Soil in Place by Sand-Cone Method ASTM D1557 ..............Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN-m/m3))

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ASTM D1883 ..............Standard Test Method for CBR (California Bearing Ratio) of Laboratory-Compacted Soils ASTM D2216 ..............Test Methods for Laboratory Determination of Water (Moisture) Content of Soil and Rock by Mass ASTM D2419 ..............Standard Test Method for Sand Equivalent Value of Soils and Fine Aggregate ASTM D4318 ..............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils ASTM D4429 ..............Standard Test Method for CBR (California Bearing Ratio) of Soils in Place ASTM D4791 ..............Standard Test Method for Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate ASTM D4944 ..............Standard Test Method for Field Determination of Water (Moisture) Content of Soil by the Calcium Carbide Gas Pressure Tester

QCS 2014

Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 3

ASTM D5821 ..............Standard Test Method for Determining the Percentage of Fractured Particles in Coarse Aggregate ASTM D6913 .............Standard Test Methods for Particle Size Distribution (Gradation) of Soils Using Sieve Analysis ASTM D6938 ..............Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth) ASTM E1703 ..............Standard Test Method for Measuring Rut-Depth of Pavement Surfaces Using a Straightedge AASHTO T307 ...........Standard Method of Test for Determining the Resilient Modulus of Soils and Aggregate Materials BS 1377 Part 3 ...........Methods of test for Soils for Civil Engineering Purposes: Chemical and electro-chemical tests Definitions

1

LSA: Laboratories and Standardization Affairs – Ministry of Environment.

2

Optimum moisture content (OMC): the moisture content of soil at which a specific compaction effort will produce the maximum dry density when determined in accordance with the ASTM D1557.

3

Maximum dry density (MDD): The dry density of soil obtained using a specified compaction effort at the optimum moisture content when determined in accordance with the modified compaction test ASTM D1557. Unit weight and moisture content of materials containing more than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.

4

Subgrade: the compacted existing ground or fill for 500mm beneath formation.

5

Formation: the compacted subgrade level shaped in readiness to receive the Subbase or Road Base courses.

6

Subbase: It is the layer between the subgrade and the Road Base. It consists of compacted selected granular materials.

7

Road Base: It is the layer directly beneath the asphalt course layers and above the subbase or subgrade layer. It consists of compacted selected materials. It can be untreated or treated with suitable stabilizing admixtures.

4.1.4

Submittals

1

The Contractor shall submit recent test results for the proposed sources of materials for all quality requirements of the Contract. The Contractor shall submit a test certificate that proves that the raw materials that are purchased/used comply with specifications. The testing may be performed by an approved private laboratory or by the laboratory associated with the plant itself.

2

The contractor shall submit to the Engineer for approval method statements for the following:

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4.1.3

(a)

Materials production, handling, storage, identification, marking and traceability to source of production.

(b)

Quality assurance and quality control plans for all construction activities.

QCS 2014

Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 4

(c)

Materials production, handling, storage, identification and marking, traceability to source of production.

(d)

Quality control testing plan.

(e)

Equipment and its suitability to fulfill all construction activities to the required quality.

(f)

Personnel capability.

(g)

Safety and environment preservation measures.

Quality Assurance

1

If requested the Contractor shall arrange for the Engineer to visit the source of the materials and jointly take samples for testing. The Contractor shall carry out testing as directed by the Engineer.

4.2

MATERIALS

4.2.1

Sources of Materials

1

The Contractor shall notify the Engineer of the proposed sources of materials. The Contractor shall ensure that the sources of all aggregates have been approved by the Municipality concerned.

2

The Engineer shall approve the sources before delivery of materials to the site.

3

Where a proposed source of material is not approved, the Contractor shall propose an alternative source of material.

4.2.2

Storage and Handling of Materials

1

Materials shall be so stored and handled as to assure the preservation of their quality and fitness for use in the works. Even after source approval has been given materials may again be inspected and tested before use in the work.

2

Stored material shall be located so as to facilitate prompt inspection.

3

All storage sites shall be restored to their original condition before acceptance of the Works.

4

Handling and stockpiling of aggregates shall at all times be such as to eliminate segregation or contamination of the various sizes. Stockpiles shall be kept flat, and the formation of high cone-shaped piles shall not be permitted. When conveyor belts are used for stockpiling aggregates the Engineer may require the use of baffled chutes or perforated chimneys.

5

When trucks are used to construct stockpiles, the stockpiles shall be constructed one layer at a time with trucks depositing their loads as close to the previous load as possible. The use of tractors or loaders to push material deposited at one location to another location in the stockpile shall not be allowed during the construction of the stockpile and their use shall be limited to levelling the deposited material only.

6

The Contractor shall take all necessary protection measures in the storage, handling and stockpiling of materials to prevent contamination of materials by dust. The measures that the Contractor proposes to take shall be subject to the approval of the Engineer.

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4.1.5

QCS 2014

Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 5

Inspection Testing and Control

1

Loose materials for testing and acceptance shall be sampled from the un-compacted in-place layer.

2

For verification of plant weights and measures, character of materials used in the preparation of the mixes, testing and other quality control requirements, the Engineer shall at all times be provided access to all portions of the mixing plant, aggregate plant, storage yards, crushers and other facilities used for producing and processing the materials of construction.

3

The Engineer shall have authority to take samples and perform tests on any material supplied to the site from any source whatsoever in order to establish compliance and to accept or reject as he deems necessary. Samples shall also be taken from completed work to determine compliance. The frequency of all sampling and testing shall be as designated by the Engineer.

4

The Contractor shall provide suitable facilities at the quarry or plants to carry out all necessary tests on the raw materials and mixes.

5

The Contractor shall arrange for obtaining specimens of materials and samples taken from stockpiles, including the provision of any necessary equipment and plant. This work shall be performed in the presence of the Engineer if so directed by the Engineer.

6

Materials that are not in compliance shall be rejected and removed immediately from the site of the works unless otherwise instructed by the Engineer.

7

Where defects in the materials or the completed work have been corrected, the Contractor shall not proceed with subsequent work until approval has been given by the Engineer.

4.2.4

Fine Aggregate

1

Fine aggregate (passing the 4.75 mm sieve) shall consist of crushed mineral aggregate and/or natural sand.

2

The fine aggregate shall be clean and free from clay-balls and other extraneous or detrimental materials.

3

Where the source of fine aggregate does not meet the requirements listed in Table 4.1, the Contractor may, with the Engineer's approval, add fine aggregate and filler to correct the gradation or to change the characteristics of the material passing the 0.425mm sieve so as to meet the requirements. Such additional material shall be added in a manner which ensures a completely homogeneous material.

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4.2.3

QCS 2014

Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 6

Table 4.1 Specifications of fine aggregates for Road Base and Subbase layers Specification Limits Parameter

Minimum Frequency

Standard Road Base

Subbase

Liquid Limit

ASTM D4318

25%max.

25% max.

Plasticity Index

ASTM D4318

6 % max.

6 % max.

- Each source - Visible change in material

ASTM D2419

35 min.

25 min.

Organic content

BS 1377 Part 3

0.5% max.

0.5% max.

- 1 test every 1000m

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Sand equivalent

Coarse / Combined Aggregate

1

Coarse aggregate (retained on the 4.75 mm sieve) shall consist of crushed stone or crushed gravel and shall be free from organic matter, clay and other extraneous or detrimental materials.

2

The required properties of coarse aggregates for Road Base and Subbase layers are listed in Table 4.2.

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Table 4.2 Specifications of coarse aggregates for Road Base and Subbase layers Standard

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Parameter

Fractured Faces

ASTM D5821

Specification Limits Road Base

Subbase

50% min.

50% min. - Each source

ASTM D4791

10% max.

15% max.

Loss by Abrasion

ASTM C131 ASTM C535

30% max.

40% max.

ASTM C88

15% max.

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Flat and Elongated Particles (5:1)

Soundness (5 cycles by MgSO4)

Minimum Frequency

- Visible change in material - 1 test every 3000m

3

20% max.

3

Loose materials for testing and acceptance shall be sampled from the un-compacted inplace layer.

4

The required properties of combined aggregate for Road Base and Subbase layers are listed in Table 4.3.

5

Unit weight and moisture content of materials containing more than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.

QCS 2014

Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 7

When nuclear gauge is used for field density and moisture content testing, 3 readings shall be made at each test location within a radius of 2 meters. The average of the 3 readings is considered to be the density for that test location. Individual density readings shall not be less than the target relative density by more than 0.5%.

7

When nuclear gauge is used for field density and moisture content testing, the density and moisture content for each material shall be verified by measurements in accordance with ASTM D1556 and ASTM D2216, respectively. The mean value of the replicate readings shall be used as the calibration point value for each material.

8

In case abnormally high relative density values are encountered, it will be required to reevaluate the related field and laboratory density values.

9

Gradation requirements of combined aggregate for Road Base and Subbase layers are listed in Table 4.4.

4.2.6

Recycled Aggregate

1

Recycled aggregate produced from excavating natural ground and from demolition wastes can be used in subgrade and subbase layers provided that the specifications stated in Section 6 - Part 9 are complied.

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Table 4.3

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Specifications of combined aggregates for Road Base and Subbase layers

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Standard

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Specification Limits

Parameter

Minimum Frequency

Road Base

Subbase

3

2.05 Mg/m min.

2.15 Mg/m min.

ASTM D1557

Gradation

ASTM D6913

Table 4.4

Table 4.4

ASTM D1883 (Soaked)

80% min.

70% min.

Swelling

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ASTM D6938

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Field Density

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California Bearing Ratio (CBR)

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Maximum Dry Density

In Place Moisture 2 Content

ASTM D1556 ASTM D6938 ASTM D4944

- Each source. - Visible change in material - 1 test per 1000m

0.5% max.

1.0% max.

100% of MDD

100% of MDD

- 1 per 200 m per layer

 1.5% of OMC

 2% of OMC

- 1 every 75m per lane per layer 1 per 2000 m

2

1 per 3000 m

3

2

In Place California Bearing Ratio (CBR)

ASTM D4429

80% min.

70% min.

Acid soluble Chloride Content

BS 1377 Part 3

2% max.

2% max.

Acid soluble content

BS 1377 Part 3

sulphate

3

3% max.

3% max.

1

Loose materials for testing and acceptance shall be sampled from the un-compacted in- place layer.

2

During compaction.

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QCS 2014

Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 8

Table 4.4 Gradation limits for Road Base and Subbase layers Road Base

Subbase

50.0 mm

100

100

37.5 mm

95 – 100

90 – 100

19.0 mm

70 – 92

70 – 90

9.5 mm

50 – 70

45 - 75

4.75 mm

35 – 55

30 – 60

0.600 mm

12 – 25

10 – 30

0.075 mm

0–8

0 – 12

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Water

1

Sea, brackish or saline water shall not be used in the mixing, spreading and compacting operations for Road Base / Subbase layers.

4.2.8

Performance Indicators

1

Upon the request of the Engineer, the following performance related indicators shall be determined from loose in place materials for verification of the pavement structural design following the AASHTO Mechanistic-Empirical Pavement Design Guide:

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4.2.7

Resilient Modulus (MR) in accordance with AASHTO T307 at optimum moisture content and maximum density as per ASTM D1557.

(b)

Parameters and moduli required for determining the Permanent Deformation Potential in accordance with AASTHO Mechanistic Empirical Design Guide.

(c)

Parameters and moduli required for measuring the Fatigue Cracking Potential for stabilized and surface layers in accordance with AASHTO Mechanistic Empirical Design Guide.

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(a)

3

2

For performance testing, one sample shall be tested every 10,000 m , and for constructions 3 having less than 10,000 m volume, one sample shall be tested every 50% of the total volume.

4.3

MAIN EQUIPMENT

4.3.1

General

1

Unless otherwise stipulated herein the provisions of Section 6, Part 3 (Earthworks), in respect of the main machinery and tools used in earthworks construction, shall be adhered to, subject to the modifications and additions in this clause.

2

The Contractor shall not be allowed to use any equipment or plant before obtaining the approval of the Engineer, and the Contractor shall undertake sound technical methods in operation and to engage skilled and trained operators, mechanics and labor to carry out the works.

QCS 2014

Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 9

The Engineer shall have the right to stop the use of any equipment or plant which he deems to be inferior to the quality required and to instruct the removal of such equipment and to have it replaced by suitable equipment or to alter the method of operation at any time he so desires.

4

The Contractor shall immediately comply with such instructions without being entitled to any indemnities or extensions as a result of such instructions.

5

The Engineer shall have the right to expel any operators, mechanics or labor and to instruct suitable replacement thereof at any time he deems such action is necessary.

4.3.2

Paving Machines

1

Paving machines shall be self-propelled and shall be capable of spreading the Subbase and Road Base materials in one operation so as to make it ready for compaction with minimum shaping.

2

The paving machines shall be provided with a screed that strikes off and distributes the material to the required width and level.

3

The width of each spread shall not be less than a traffic lane wide.

4

The screed shall be adjustable to the required width being laid.

5

Screed action includes any practical motion that produces a finished surface texture of uniform appearance.

4.3.3

Central Mixers

1

A central mixing plant shall be either of an approved drum or pugmill type with a moisture control system so that the material may be spread without further mixing or processing.

2

Means shall be provided for regulating the flow of material to the mixer. The various feeds shall be calibrated to allow adjustments to the mix design to be carried out.

4.4

MIX DESIGNS

1

Aggregate Subbase and Road Base courses shall consist of crushed mineral aggregates or natural mineral aggregates of the designated gradation and thickness.

2

The maximum dry density and the optimum moisture content of the material shall be ascertained as per the test procedure given in ASTM D1557 and this shall be used to assess the degree of compaction of the mix after rolling.

3

The pavement layer designated as sub-base may be substituted by any of the materials designated to be laid on it subject to the approval of the Engineer.

4.5

SCREENING AND MIXING

1

Screening shall be required for the materials used in Subbase and Road Base courses to ensure that the designated gradation is attained.

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QCS 2014

Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 10

Screens shall be of the size and number required to remove oversize aggregate and to separate the materials into two or more fractions so that they may be combined to meet the required gradation.

3

A central mixing plant shall be used for the mixing of materials.

4

Mixing of separate materials on the roadway by motor grader will not be permitted.

4.6

SPREADING AND COMPACTION

1

Before commencing the construction of the Subbase and Road Base courses, a written approval for the Engineer must be obtained that the subgrade is in compliance.

2

The optimum moisture content of the material shall be noted from the mix design and the actual moisture content determined at the plant after mixing.

3

If the natural moisture content is less than the optimum moisture content, the necessary amount of water must be added to obtain the optimum content.

4

Allowance shall be made for the quantity of moisture which may be lost by evaporation in the process of raking, levelling and compacting, depending on atmospheric temperature.

5

The compacted layer shall have moisture content within  1.5% of the optimum moisture

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content for Road Base layers and within  2% for Subbase layers. The moisture content shall be uniform in all parts of the section where the work is being carried out and in the various depths of the layer thickness.

7

Subbase and Road Base courses shall be laid by a paving machine with a spreader box.

8

Loose samples of materials for testing and acceptance shall be obtained from behind the paving machine upon the approval of the Engineer.

9

Compaction shall start immediately the material has been laid and as per the approved rolling pattern.

10

Work on the Subbase and Road Base courses shall not be permitted during rainy weather.

11

Material shall be spread to a thickness that would result in layers not more than 150 mm thick after compaction. Where the finished compacted thickness exceeds 150 mm placing shall be executed in composite layers each layer not exceeding 150 mm in compacted thickness as directed by the Engineer.

12

The course shall not be rolled when the underlying material is soft or yielding or when the rolling causes a wave-like motion in this course.

13

When the rolling develops irregularities, the irregular surface shall be loosened, then refilled with the same kind of material as used in constructing the course and again rolled.

14

Along places inaccessible to rollers, the Subbase and Road Base courses material shall be tamped thoroughly with suitable mechanical tampers to achieve the required density and finish.

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15

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Page 11

Rolling must continue until a relative density of not less than 100 % of the maximum dry density has been obtained as determined by the moisture-density relationship in ASTM D1557. Care shall be taken so that layers already compacted under the layer being executed are not damaged, or that the formation is not damaged.

17

This aspect must be given special attention in places where rolling equipment makes turns to change direction.

18

Any such damage resulting in mixing the various layers constituting the different subgrades, Subbase and Road Base courses shall be carefully made good by the Contractor at his own expense and to the satisfaction of the Engineer.

4.7

CORRECTIVE ACTION

1

Any material that fails to meet test requirements shall either be reworked or removed and replaced and then retested to check for compliance.

2

Any soft spots, irregularities or depressions that develop in the surface of the Subbase or Road Base courses, shall either be corrected by loosening the surface of such areas and adding further material, or by removing the material in such areas and replacing with further approved material.

3

In the event of heave occurring during compaction, caused either by excessive build-up of pore water pressure or the groundwater table being sufficiently high to affect construction techniques, either of the following procedures shall be adopted subject to the approval of the Engineer:

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Sufficient time shall be allowed to elapse enabling the excess pore water to dissipate before further construction or compaction is carried out

(b)

The affected material shall be removed, and approved alternative construction layers substituted.

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(a)

For correction of low density or incorrect level, the top 75 mm shall be scarified, reshaped with material added or removed as necessary and re-compacted to the designated requirement. The area treated shall not be less than 30 metres long and 2 metres wide or such area determined by the Engineer as necessary to attain compliance.

5

Where the surface of the sub-base is covered in a very thin smooth skin composed of fine particles cemented together acting as a barrier to the prime coat the top 75 mm shall be scarified, reshaped, watered if necessary, and re-compacted prior to the application of prime coat.

6

The Contractor shall carry out additional testing if required by the Engineer to ensure that the standard of compaction is satisfactory through the full depth of the layer.

4.8

PROTECTION OF SURFACE

1

The Contractor shall protect the Subbase and Road Base courses so that it shall be maintained sound during work progress, after its completion and before receiving the bituminous layers or before laying the surface overlay thereon.

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Page 12

Any damage caused to the layer if exposed to traffic or natural conditions resulting in damage to its surface shall be made good at the expense of the Contractor and to the satisfaction of the Engineer.

3

The Engineer has the right to stop all hauling over completed or partially completed Subbase and Road Base courses when in his opinion such hauling is causing damage.

4

Following the completion of the Subbase or Road Base courses the Contractor shall perform all maintenance work necessary to keep the course in a condition for priming.

4.9

TESTING

4.9.1

General

1

Loose materials for testing and acceptance shall be sampled from the un-compacted in-place layer.

2

All testing shall be conducted in accordance with ASTM, AASHTO and BS standards listed in section 4.2.

3

Testing frequency for the properties of Subbase or Road Base layers are listed in Tables 4.1, 4.2 and 4.3.

4

At any stage in the mixing, transportation, spreading or compaction process, the Engineer may instruct that these tests are carried out.

5

Before the application of any prime coat or any other paving course, the aggregate Subbase or Road Base courses shall have been tested for compliance with the requirements of this clause on testing and approved by the Engineer.

4.9.2

Thickness

1

The thickness of the material shall be derived from checking the level by dipping from string lines stretched across the roadway between pins or kerbs. Unless agreed otherwise with the Engineer dipping shall be carried out at intervals of not less than 10m.

2

The thickness of the material shall be measured at the location where the material is removed from the roadway for gradation analysis.

3

Wherever the thickness of compacted aggregate Subbase or Road Base courses is found to vary from the thickness specified in the project drawings or specification by more than 10 %

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the area involved shall be satisfactorily corrected to provide the required thickness constructed to the designated grade level. 4.9.3

Evenness and Level

1

The final surfaces of the Subbase or Road Base courses shall be tested by means of a 3 meter long straight edge in accordance with ASTM E1703 and no rises or depressions in excess of 10 mm shall appear in the surface. Measurements shall be carried out at maximum spacing of 30m of road length for each lane.

QCS 2014

Section 06: Roadworks Part 04: Unbound Pavement Materials

Page 13

2

The finished surface shall also be checked by dips or spot levels and shall be constructed to the designated grade levels to within  10 mm.

3

Where these requirements are not met, the Contractor shall determine the full extent of the area which is out of tolerance and shall make good the surface of the course by scarifying to a minimum depth of 75 mm or 4 times the maximum particle size, whichever is greater, reshaping by adding or removing material as necessary, adding water if necessary and recompacting.

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END OF PART

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 1

ASPHALT WORKS.................................................................................................. 3

5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5

GENERAL ............................................................................................................... 3 Scope 3 References 3 Definitions 7 Submittals 7 Quality Assurance 8

5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.9 5.2.10

MATERIALS ............................................................................................................ 8 Unacceptable Materials 8 Fine Aggregate 9 Coarse Aggregate 9 Recycled Aggregate 10 Mineral Filler 10 Asphalt Binder 11 Prime Coat 13 Tack Coat 13 Delivery, Storage and Handling 13 Inspection and Control 14

5.3 5.3.1 5.3.2 5.3.3

MARSHALL MIX DESIGN ..................................................................................... 14 General 14 Marshall Mix Design Criteria 15 Quality Control Testing 17

5.4

DENSE BITUMEN MACADAM .............................................................................. 20

5.5

SUPERPAVE MIX DESIGN ................................................................................... 22

5.6

PERFORMANCE EVALUATION OF ASPHALT CONCRETE ................................ 24

5.7 5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 5.7.6 5.7.7 5.7.8 5.7.9 5.7.10

DELIVERY, SPREADING AND FINISHING ........................................................... 25 Delivery of Mixes 25 Spreading and Finishing 25 Compaction of Mixes 26 Transverse Joints 27 Longitudinal Joints 28 Paving Edges 28 Breakdown Rolling 28 Intermediate Rolling 29 Finish Rolling 29 Protection of Laid Courses 29

5.8

COLD PLANING .................................................................................................... 29

5.9 5.9.1 5.9.2 5.9.3 5.9.4 5.9.5

PRIME COAT ........................................................................................................ 30 General 30 Equipment Required 30 Surface Preparation 30 Application 30 Maintenance and Traffic 31

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Section 06: Roadworks Part 05: Asphalt Works

Page 2

TACK COAT .......................................................................................................... 31 General 31 Equipment Required 31 Surface Preparation 32 Application 32 Maintenance and Traffic 32

5.11 5.11.1 5.11.2 5.11.3

THICKNESS AND LEVEL...................................................................................... 32 Thickness 32 Transverse Evenness 33 Evenness and Rideability 33

5.12

PAVEMENT EVALUATION TECHNIQUES ........................................................... 35

5.13 5.13.1 5.13.2 5.13.3 5.13.4 5.13.5 5.13.6

PRODUCTION OF ASPHALT CONCRETE COURSES ........................................ 35 Weather Limitations 35 Equipment Required 35 Survey and Preparation 35 Heating of Asphalt Binder 36 Heating of Mineral Aggregate 36 Proportioning and Mixing 36

5.14

HAULING EQUIPMENT......................................................................................... 37

5.15 5.15.1 5.15.2 5.15.3

OTHER EQUIPMENT ............................................................................................ 37 Spreading and Finishing Equipment 37 Rolling Equipment 38 Liquid Asphalt Distributor 39

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5.10 5.10.1 5.10.2 5.10.3 5.10.4 5.10.5

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APPENDIX .......................................................................................................................... 40

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 3

5

ASPHALT WORKS

5.1

GENERAL

5.1.1

Scope

1

Materials, equipment, and construction of bituminous paving works including prime coating and tack coating.

2

Related Parts

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Part 1, ............. General Part 3, ............. Earthworks Part 4, ............. Unbound Pavement Materials. References

1

The following standards and other documents are referred to in this Part:

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ASTM C40 ..................Standard Test Method for Organic Impurities in Fine Aggregates for Concrete

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ASTM C50 ..................Standard Practice for Sampling, Sample Preparation, Packing and Marking of Lime and Limestone Products ASTM C51 ..................Terminology Relating to Lime and Limestone (as used by the industry)

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ASTM C88 .................Standard Test Method for Soundness of Aggregates by Use of Sodium Sulphate or Magnesium Sulphate

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ASTM C117 ................Standard Test Method for Materials Finer than 75-μm (No. 200) Sieve in Mineral Aggregates by Washing

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ASTM C127 ...............Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate

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ASTM C128 ...............Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Fine Aggregate

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ASTM C131 ...............Standard Test Method for Resistance to Degradation of Small Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine ASTM C136 ...............Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates ASTM C142 ...............Standard Test Method for Clay Lumps and Friable Particles in Aggregates ASTM C150 ................Specifications for Portland Cement ASTM C535 ...............Standard Test Method for Resistance to Degradation of Large Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine ASTM D5 ....................Standard Test Method for Penetration of Bituminous Materials ASTM D6 ....................Standard Test Method for Loss on Heating of Oil and Asphaltic Compounds ASTM D36 ..................Standard Test Method for Softening Point of Bitumen (Ring-and-Ball Apparatus)

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 4

ASTM D75 .................Standard Practice for Sampling Aggregates ASTM D92 .................Standard Test Method for Flash and Fire Points by Cleveland Open Cup Tester ASTM D113 ................Standard Test Method for Ductility of Bituminous Materials ASTM D140 ...............Standard Practice for Sampling Bituminous Materials ASTM D242 ................Standard Specification for Mineral Filler for Bituminous Paving Mixtures ASTM D402 ................Standard Test Method (Bituminous) Products

for

Distillation

of

Cutback

Asphaltic

ASTM D546 ................Standard Test Method for Sieve Analysis of Mineral Filler for Bituminous Paving Mixtures

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ASTM D946 ...............Standard Specification for Penetration Graded Asphalt Cement for Use in Pavement Construction ASTM D977 ................Standard Specification for Emulsified Asphalt

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ASTM D979 ................Standard Practice for Sampling Bituminous Paving Mixtures

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ASTM D995-95...........Standard Specification for Mixing Plants for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures

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ASTM D1188: ............Standard Test Method for Bulk Specific Gravity and Density of Compacted Bituminous Mixtures Using Coated Samples ASTM D2027 ..............Standard Specification for Cutback Asphalt (Medium-Curing Type)

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ASTM D2041 .............Standard Test Method for Theoretical Maximum Specific Gravity and Density of Bituminous Paving Mixtures

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ASTM D2042 ..............Standard Test Method for Solubility of Asphalt Materials in Trichloroethylene

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ASTM D2172 .............Standard Test Methods for Quantitative Extraction of Bitumen from Bituminous Paving Mixtures

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ASTM D2419 .............Standard Test Method for Sand Equivalent Value of Soils and Fine Aggregate

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ASTM D2726 .............Standard Test Method for Bulk Specific Gravity and Density of Non Absorptive Compacted Bituminous Mixtures

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ASTM D2872 .............. Standard Test Method for Effect of Heat and Air on a Moving Film of Asphalt (Rolling Thin Film Oven Test) ASTM D2950 ..............Standard Test Method for Density of Bituminous Concrete in Place by Nuclear Methods ASTM D2995 ..............Standard Practice for Estimating Application Rate of Bituminous Distributors ASTM D3319 ..............Standard Practice for the Accelerated Polishing of Aggregates Using the British Wheel ASTM D3549 ..............Standard Test Method for Thickness or Height of Compacted Bituminous Paving Mixture Specimens ASTM D4318 .............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils ASTM D4402 .............Standard Test Method for Viscosity Determination of Asphalt at Elevated Temperatures Using a Rotational Viscometer ASTM D4791 .............Standard Test Method for Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 5

ASTM D5361 ..............Standard Practice for Sampling Compacted Bituminous Mixtures for Laboratory Testing ASTM D5444 ..............Standard Test Method for Mechanical Size Analysis of Extracted Aggregate ASTM D5546 .............Standard Test Method for Solubility of Asphalt Binders in Toluene by Centrifuge ASTM D5581 ..............Standard Test Method for Resistance to Plastic Flow of Bituminous Mixtures Using Marshall Apparatus (6 inch-Diameter Specimen) ASTM D5821 .............Standard Test Method for Determining the Percentage of Fractured Particles in Coarse Aggregate ASTM D6307 ..............Standard Test Method for Asphalt Content of Hot-Mix Asphalt by Ignition Method

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ASTM D6373 ..............Standard Specification for Performance Graded Asphalt Binder

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ASTM D6521 .............Standard Practice for Accelerated Aging of Asphalt Binder Using a Pressurized Aging Vessel (PAV)

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ASTM D6648 .............Standard Test Method for Determining the Flexural Creep Stiffness of Asphalt Binder Using the Bending Beam Rheometer (BBR)

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ASTM D6723 ..............Standard Test Method for Determining the Fracture Properties of Asphalt Binder in Direct Tension (DT)

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ASTM D6926 .............Standard Practice for Preparation of Bituminous Specimens Using Marshall Apparatus

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ASTM D6927 ..............Standard Test Method for Marshall Stability and Flow of Bituminous Mixtures

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ASTM D6931 ..............Standard Test Method for Indirect Tensile (IDT) Strength of Bituminous Mixtures

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ASTM D7173 .............Standard Practice for Determining the Separation Tendency of Polymer from Polymer Modified Asphalt

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ASTM D7175 .............Standard Test Method for Determining the Rheological Properties of Asphalt Binder Using a Dynamic Shear Rheometer

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ASTM D7405 .............Standard Test Method for Multiple Stress Creep and Recovery (MSCR) of Asphalt Binder Using a Dynamic Shear Rheometer

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ASTM E11 .................Standard Specification for Woven Wire Test Sieve Cloth and Test Sieves ASTM E274 ................Standard Test Method for Skid Resistance of Paved Surfaces Using a Full-Scale Tire ASTM E303 ................Standard Test Method for Measuring Surface Frictional Properties Using the British Pendulum Tester ASTM E950................. Standard Test Method for Measuring the Longitudinal Profile of Travelled Surfaces with an Accelerometer Established Inertial Profiling Reference ASTM E965 ................Standard Test Method for Measuring Pavement Macrotexture Depth Using a Volumetric Technique ASTM E1926............... Standard Practice for Computing International Roughness Index of Roads from Longitudinal Profile Measurements AASHTO M82.............Standard Specification for Cutback Asphalt (Medium-Curing Type)

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 6

AASHTO M92.............Standard Specification for Wire-Cloth Sieves for Testing Purposes AASHTO M140...........Standard Specification for Emulsified Asphalt AASHTO M208...........Standard Specification for Cationic Emulsified Asphalt (ASTM D239702) AASHTO M320...........Standard Specification for Performance-Graded Asphalt Binder AASHTO M332...........Standard Specification for Performance-Graded Asphalt Binder Using Multiple Stress Creep Recovery (MSCR) Test, Single User Digital Publication AASHTO R28 .............Standard Practice for Accelerated Aging of Asphalt Binder Using a Pressurized Aging Vessel (PAV)

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AASHTO T48 .............Standard Method of Test for Flash and Fire Points by Cleveland Open Cup

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AASHTO T240 ...........Standard Method of Test for Effect of Heat and Air on a Moving Film of Asphalt Binder (Rolling Thin-Film Oven Test)

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AASHTO T313 ...........Standard Method of Test for Determining the Flexural Creep Stiffness of Asphalt Binder Using the Bending Beam Rheometer (BBR)

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AASHTO T283 ........... Standard Method of Test for Resistance of Compacted Asphalt Mixtures to Moisture-Induced Damage

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AASHTO T314 ...........Standard Method of Test for Determining the Fracture Properties of Asphalt Binder in Direct Tension (DT)

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AASHTO T315 ...........Standard Method of Test for Determining the Rheological Properties of Asphalt Binder Using a Dynamic Shear Rheometer (DSR) AASHTO T316 ...........Standard Method of Test for Viscosity Determination of Asphalt Binder Using Rotational Viscometer

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AASHTO T350 ...........Standard Method of Test for Multiple Stress Creep Recovery (MSCR) Test of Asphalt Binder Using a Dynamic Shear Rheometer (DSR)

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AASHTO PP60 ........... Standard Practice for Preparation of Cylindrical Performance Test Specimens Using the Superpave Gyratory Compactor (SGC) AASHTO PP61 .......... Standard Practice for Developing Dynamic Modulus Master Curves for Hot Mix Asphalt (HMA) Using the Asphalt Mixture Performance Tester (AMPT) AASHTO TP79 .......... Standard Method of Test for Determining the Dynamic Modulus and Flow Number for Hot Mix Asphalt (HMA) Using the Asphalt Mixture Performance Tester (AMPT) BS 812-110 ................Testing aggregates Methods for determination of aggregate crushing value (ACV) BS 1377 Part 3 ...........Methods of test for Soils for Civil Engineering Purposes: Chemical and electro-chemical tests BS EN 12697-13 ........Bituminous mixtures. Test methods for hot mix asphalt. Temperature measurement

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 7

Definitions

1

LSA: Laboratories and Standardization Affairs – Ministry of Environment.

2

Base Course: One or more bituminous layers beneath Wearing Course and above the unbound Road Base Layer. It usually consists of a mixture of aggregates and bituminous materials and functions as a structural portion of pavement.

3

Wearing Course: Top surface bituminous course, which resists skidding, traffic abrasion, and the disintegrating effects of climate.

5.1.4

Submittals

1

The Contractor shall submit for approval a proposed Job Mix Formula (JMF) together with all applicable design data at least one month before beginning the work. The JMF shall give a combined gradation showing a single definite percentage passing each sieve as well as a percentage of each material to be used in the mix. The JMF shall also establish the mixing and compaction temperature values and a compaction reference density. The Engineer will test samples of the materials proposed for use in order to check their quality and to check the proposed mix design. The Contractor shall report all the values obtained in the laboratory design and shall submit these together with a copy of the plotted curves resulting from the tests in an approved form to the Engineer. The Engineer may require verification of the submitted design before giving approval. The Engineer shall approve the optimum binder content based upon the design values submitted by the Contractor and shall notify the Contractor of the value. No asphalt works will be allowed to commence before the Contractor receives written approval from the Engineer for his JMF.

2

The asphalt mix design submission shall include a copy of valid calibration certificates from a calibration service agency approved by the Laboratories and Standardization Affairs (LSA) for the batching plant and the relevant laboratory equipment such as but not limited to balances, proving rings, and load devices. Approval certificates for mix designs will not be issued if the above requirements have not been complied with.

3

Based on the Engineer request, the Contractor shall submit the pertinent certifications of materials, equipment, plants, personnel and processes in relation to the project. Certificates must be issued by a competent authority approved by the Engineer.

4

The contractor shall submit to the Engineer for approval method statements for the following:

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5.1.3

(a)

Bituminous and asphalt materials production, storage, transportation, identification and marking procedure and traceability to source of production.

(b)

Quality assurance and quality control plans for laying, compaction and all construction activities.

(c)

Quality control testing plan.

(d)

Equipment and its suitability to fulfil all construction activities to the required quality.

(e)

Personnel capability.

(f)

Safety and environment preservation measures.

The Contractor shall provide the Engineer with a complete report on the origin and composition of all stone and/or gravel aggregates to be used in the work (Aggregate Resources Report). All materials shall comply with the specified requirements for the various aggregates.

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 8

Delivery of materials produced from commercial manufacturing process shall be accompanied by the manufacturer’s certification and test reports from local approved laboratory showing the materials compliance with the specification for which it is stipulated.

7

After receiving the approval of specific sources of material the Contractor cannot change these sources without prior written approval of the Engineer.

5.1.5

Quality Assurance

1

The Contractor shall notify the Engineer of the sources of materials and the Engineer shall approve the sources. All materials shall be tested and approved before use.

2

Where the quality of material from a source of material does not comply with the designated requirements, the Contractor shall furnish material that does comply from other sources. Delivery of materials produced from commercial manufacturing processes shall be accompanied by the manufacturer's certification and test report showing that the materials comply with the designated requirements.

3

No change shall be permitted in the source of any of the materials until the technical submissions listed in the specification have been made and approved by the Engineer.

4

All processed materials shall be tested and approved before being stored at the site or incorporated in the works and may be inspected and tested at any time during the progress of their preparation and use. Questionable materials, pending laboratory testing subsequent approval shall not be unloaded and incorporated with materials previously approved and

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accepted.

It is the full responsibility of both the asphalt mixture producer and the Contractor to obtain a certificate which proves that the asphalt binder complies with the specifications. Furthermore, both the asphalt mixture producer and the Contractor shall perform all the required tests in an approved private laboratory to make sure that the asphalt binder being purchased complies with the specifications. The LSA will, at any time, take samples from the asphalt mixtures producer’s plants and test them as part of its quality practice.

5.2

MATERIALS

5.2.1

Unacceptable Materials

1

Materials that do not conform to the designated requirements shall be rejected and immediately removed from the site of the works unless otherwise instructed by the Engineer. No rejected material, the defects of which have been corrected, shall be used until approval has been given by the Engineer.

2

Bituminous paving courses shall consist of coarse aggregate, fine aggregate, filler material, and bitumen binder. Mixture of two different types of rocks, e.g. igneous and sedimentary having different engineering properties shall not be permitted.

3

During execution of works, variations in the specific gravity of any individual fraction of aggregates used in the asphalt mixes by more than 1% shall cause the Engineer to request for evaluation of aggregates consistency and compliance and/or mix design validation.

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Section 06: Roadworks Part 05: Asphalt Works

Page 9

Fine Aggregate

1

Fine aggregate is that portion of the mineral aggregate passing the 2.36mm ASTM sieve for the Marshall mix design and passing the 4.75mm sieve for the Superpave mix design.

2

Fine aggregate shall consist of crushed hard durable rock and shall be of such gradation that when combined with other aggregates in proper proportions, the resultant mixture will meet the required gradation. Fine aggregate shall be non-plastic and chemically stable.

3

The source of natural fine aggregate is considered to be the crusher site at which it is produced. Crushed fine aggregate shall be produced by crushing clean coarse aggregate and shall not be thin, flaky or elongated. Sampling of fine aggregate shall be in accordance with ASTM D75.

4

Fine aggregate shall be clean and free from organic matter, clay, cemented particles and other extraneous or detrimental materials.

5

Unless permitted elsewhere in the contract, the aggregate type for wearing course shall be Gabbro. The aggregate type for Base Course shall be either Gabbro or Limestone.

6

The Contractor shall ensure that the sources of all fine aggregates have been approved by the Municipality concerned.

7

The specifications of fine aggregates for asphalt mixtures are listed in Table 5.1.

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Table 5.1 Fine Aggregate Specifications for Marshall Mixes Standard

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Parameter Plasticity index Sand equivalent value

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ASTM D 4318

Specification Limits 4% max.

Minimum Frequency

(stockpile)

Non Plastic (hot bins) 45% min.

- Each source

ASTM C88

18% max.

Acid soluble chloride content

- Visible change in material

BS 1377 Part 3

0.1% max.

Acid soluble sulphate content

BS 1377 Part 3

0.5% max.

Clay lumps and friable particles

ASTM C142

None

Organic Impurities

ASTM C40

No Impurities

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ASTM D2419

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Soundness by magnesium sulphate

- 1 test every 2000m

3

5.2.3

Coarse Aggregate

1

Coarse aggregate is that portion of the mineral aggregate retained on the 2.36mm ASTM sieve for the Marshall mix design and retained on the 4.75mm ASTM sieve for the Superpave mix design. Coarse aggregate shall consist of crushed natural stones and gravel. Crushed particles shall be cubic and angular in shape and shall not be thin, flaky or elongated. The gradation shall be such that when combined with other aggregate fraction in proper proportions, the resultant mixture will meet the required gradation.

2

The source of crushed aggregate is considered to be the crushing site from which it is produced. Sampling of coarse aggregate shall be in accordance with ASTM D75.

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 10

Coarse aggregate shall be clean and free from organic matter, clay, cemented particles and other extraneous or detrimental material.

4

The specifications of coarse and combined aggregates for asphalt mixtures are listed in Table 5.2.

5

Unless permitted elsewhere in the contract, the aggregate type for wearing course shall be Gabbro. The aggregate type for Base Course shall be either Gabbro or Limestone.

6

If directed by the Engineer, the polished stone value (PSV) should be determined for wearing course aggregates of main lane as per ASTM D3319. The PSV shall not be less than 45.

5.2.4

Recycled Aggregate

1

Recycled aggregate produced from excavating natural ground can be used in asphalt mixtures for temporary roads and for roads, which serve agricultural areas provided that the specifications stated in Section 6 - Part 9 are complied.

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Water absorption Aggregate Crushing Value (ACV)

100% min.

85% min.

85% min.

85% min.

ASTM D4791

15 % max.

15% max.

10 % max.

- Visible change in material

ASTM C88

15 % max.

15% max.

10 % max.

- 1 test every 3 2000m

30% max.

30% max.

25% max.

2.0% max.

2.0% max.

1.5% max.

25 % max.

25 % max.

20% max.

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ASTM C131 ASTM C535 ASTM C127 BS 812 Part 110

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Los Angeles Abrasion

100% min.

- Each source

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Flat and Elongated Particles (5:1) Soundness (5 cycles by MgSO4)

100% min.

Minimum Frequency

Table 5.7, Job Mix gradation and Table 5.10 tolerances

ASTM C136

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Gradation (Combined)

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One or more Fractured ASTM D5821 Faces 1 Two or more Fractured ASTM D5821 Faces

Specification Limits Base Course Base Course Wearing (Class A) (Class B) Course

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Standard

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Parameter

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Table 5.2 Coarse and Combined Aggregate Specifications for Marshall Mixes

Higher values can be recommended by the engineer based on the design ESAL.

5.2.5

Mineral Filler

1

Mineral filler when separately supplied from an external source shall consist of finely ground mineral matter in accordance with ASTM D242 such as rock dust, hydrated lime, cement or other material which can satisfy the Engineer will produce asphalt mixes of at least equal quality. It shall be free from organic substances and clay, shall be thoroughly dry and free from agglomerations, shall be non-plastic and shall meet the grading requirements shown in Table 5.3.

2

Hydrated lime shall conform to the definitions given in ASTM C51. Sampling, packaging and marking of hydrated lime shall be in accordance with ASTM C50. Storage and use of the hydrated lime shall at all times be such as to protect the material from the weather.

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 11

Table 5.3 ASTM Sieve

% Mass Passing

600 µm

100

300 µm

95 - 100

150 µm

90 – 100

75 µm

70 – 100

The grading of mineral filler shall be carried out in accordance with ASTM D546.

4

When cement is used as mineral filler, it shall meet the requirements of ASTM C150.

5.2.6

Asphalt Binder

1

The asphalt binder specified for use in the asphalt mixes shall be either of the following:

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Penetration grade 60-70: This binder type shall be graded in accordance with ASTM D946. The 60-70 binder specifications are listed in Table 5.4. Sampling shall be in accordance with ASTM D140. The 60-70 penetration graded binder is generally equivalent to PG 64-10 performance graded binder.

(b)

PG 76-10: Based on the Engineer approval, the PG76-10 binder can be used in asphalt mixes. This binder type shall be a polymer-modified binder (PMB) meeting AASHTO M320 and ASTM D6373 specifications in addition to separation test criteria as listed in Table 5.5. Sampling shall be in accordance with ASTM D140.

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(a)

Prior to the commencement of the mix design, the Contractor shall provide a certificate indicating conformance of binder with the specifications stated above. This certificate shall be obtained from an approved laboratory.

3

The asphalt binder shall be prepared by the refining of petroleum and shall be uniform in character. Blending of asphalt binders from different refineries will be permitted only with the written approval of the Engineer.

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Table 5.4 Specifications of Bitumen Penetration Grade 60 – 70 60 – 70 Pen Parameter Standard Minimum Frequency Min. Max. Penetration (0.1 mm) at 25C - Each source ASTM D5 60 70 -100g, 5 Sec - Visible change in material Softening Point Ring & Ball - 1 test per 75t of asphalt ASTM D36 46 Apparatus, C binder per layer Flash Point, Cleveland Open Cup, C

ASTM D92

230

-

Ductility at 25 C, cm

ASTM D113

100

-

Solubility Trichloroethylene, %

ASTM D2042

99

-

Loss on heating, %

ASTM D6

-

0.2

Penetration of Residue of original after TFOT, %

ASTM D5

52

-

ASTM D113

50

-

Ductility of Residue after TFOT at 25 C, 5cm/min, cm

- Each source - Visible change in material - 1 test per 450t of asphalt binder per layer

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Section 06: Roadworks Part 05: Asphalt Works

Page 12

Table 5.5 Specifications of Performance Graded Binders / Polymer Modified Binders (PMB) Standard Specification AASHTO ASTM Tests on Original Binder Average 7 days maximum pavement < 76 o design temperature, ( C) Minimum pavement design >-10 o temperature,( C) o Flash Point Temperature, Minimum ( C) T48 D92 230 Rotational Viscosity, Maximum 3 Pa.s, T316 D4402 135 o Test Temperature ( C) Dynamic Shear, G*/sinδ, Minimum, 1.00 T315 D7175 76 o kPa , Test Temperature ( C) at 10 rad/s Solubility, min, % T44 D5546 99 1 Separation Test: Absolute Difference o D7173 20 between G* @ 76 C and 10 rad/s of Top and Bottom Specimens, Maximum, % Requirements of the Rolling Thin Film Oven Residue ( T240 / D2872) Mass Loss, Maximum, Percent T240 D2872 1 Dynamic Shear, G*/sinδ, Minimum, 2.20 T315 D7175 76 o kPa , Test Temperature ( C) at 10 rad/s Pressure Aging Vessel Residue (D6521 / R28) o PAV Aging Temperature , ( C) R28 D6521 110 Dynamic Shear, G*.sinδ, Maximum 5000 T315 D7175 37 o kPa , Test Temperature ( C) at 10 rad/s Creep Stiffness, S, Maximum 300 MPa and m-value, Minimum 0.300 at 60 T313 D6648 0 o seconds , Test Temperature ( C) 2 Direct Tension , Failure Strain, Minimum, T314 D6723 0 1.0% (loading rate of 1.0 mm/min),Test o Temperature( C)

Minimum Frequency

Parameter

- Each source - Visible change in material

- Each source - Visible change in material - 1 test per 450t of asphalt binder per layer

2

Absolute Difference = Abs(100x(top-bottom)/top). If the creep stiffness is below 300 MPa, the direct tension test is not required. If the creep stiffness is between 300 and 600 MPa, the direct tension failure strain requirement can be used in lieu of the creep stiffness requirement. The m-value requirement must be satisfied both cases.

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- 1 test per 450t of asphalt binder per layer

4

Based on the Engineer approval, when bitumen grades PG76-10 H, V or E are specified for heavy, very heavy, and extra heavy loading, the bitumen shall meet the requirements of AASHTO M332 and will be required to indicate elastic response in percent recovery when tested in accordance with AASHTO T350 / ASTM D7405.

5

Binders modified using Crumb Rubber and other binders containing particulate materials, which are graded according to AASHTO M320 and/or AASHTO M332, shall not include particles with longest dimensions of more than 250μm. In addition, the requirements listed in Table 5.5 shall be satisfied.

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Section 06: Roadworks Part 05: Asphalt Works

Page 13

Prime Coat

1

Liquid asphalt for use as prime coat shall be MC-70 medium curing cutback asphalt in accordance with ASTM D2027 or AASHTO M82.

2

The prime coat shall be a cutback consisting of a 60/70 penetration grade bitumen and kerosene. The residue from the distillation test, carried out to 360 C in accordance with ASTM D402, shall be a minimum of 55 % (by volume), as determined by the difference method. Sampling shall be in accordance with ASTM D140. One sample shall be tested every 5 tons.

5.2.8

Tack Coat

1

Emulsified asphalt for use as tack coat in asphalt works may be CSS 1h or CRS-2 cationic emulsified asphalt in accordance with AASHTO M 208 or SS 1h anionic emulsified asphalt in accordance with ASTM D977 or AASHTO M140 unless otherwise designated.

2

Emulsified asphalt shall be of the slow-setting cationic or anionic type of the CSS-1h or SS1h grades respectively and shall conform to the designated requirements. Sampling shall be in accordance with ASTM D140. One sample shall be tested every 5 tons.

5.2.9

Delivery, Storage and Handling

1

Materials shall be so stored and handled as to assure the preservation of their quality and fitness for use. Materials, even though approved before storage or handling, may again be inspected and tested before use in the Works.

2

Stored material shall be located so as to facilitate their prompt inspection. All storage locations on land not owned by the Contractor shall be restored to their original condition at the Contractor's expense.

3

Handling and stockpiling of aggregates shall at all times be such as to eliminate segregation or contamination of the various sizes and to prevent contamination of materials by dust. Stockpiles shall be kept flat and the formation of high cone-shaped piles shall not be permitted. When conveyor belts are used for stockpiling aggregates, the Engineer may require the use of baffle-chutes or perforated chimneys.

4

Where trucks are used to construct stockpiles, the stockpiles shall be constructed one layer at a time with trucks depositing their loads as close to the previous load as possible. The use of tractors or loaders to push material deposited at one location to another location in the stockpile shall not be allowed during the construction of the stockpile, and their use shall be limited to levelling the deposited material only.

5

Stockpiles of aggregate located at permanent asphalt plant sites shall be separated by bin walls and shall be constructed on asphalt or concrete floors. Stockpile locations and procedures at temporary asphalt plant sites shall be as approved by the Engineer.

6

Intermediate storage of hydrated lime and commercial mineral filler for equipment feeding the asphalt plant shall be silos of adequate size to ensure a minimum of one day's continuous operation.

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5.2.7

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 14

Inspection and Control

1

For verification of weights and measures, character of materials and determination of temperatures used in the preparation of the asphalt mixes, the Engineer shall at all times have access to all portions of the mixing plant, aggregate plant, storage yards, crushers and other facilities used for producing and processing the materials of construction.

2

The Engineer shall have authority to instruct sampling and testing of any material supplied to the site from any source whatsoever in order to establish their compliance and to accept or reject as he deems necessary. Samples shall also be taken from completed work to determine compliance. The frequency of all sampling and testing shall be as designated.

3

The Contractor shall arrange for obtaining specimens of materials, asphalt mixes and samples cut from the paving courses after compaction, including the provision of necessary equipment and plant for obtaining these specimens and samples. This work shall be performed in the presence of the Engineer. The Engineer shall take possession of the samples upon their removal from the roadway unless the Contractor is authorised otherwise

4

In particular, the Contractor shall provide a portable coring machine and bits for taking 150 mm diameter full depth cores of all bituminous paving courses. The coring machine shall be available to the Engineer upon request.

5

In addition to the foregoing, one set of three laboratory compacted specimens and one uncompacted coated sample for each mix type and mixer plant for each day’s production, shall be delivered to LSA no later than 12 hours after compaction of the specimens together with the mix type and project details.

6

Upon the first erection of the batching plant and at least once every three months thereafter, the plant shall be calibrated by a calibration service organisation approved by the LSA.

5.3

MARSHALL MIX DESIGN

5.3.1

General

1

The types of bituminous paving mixes shall be as designated on the project drawings or in the contract documents.

2

The LSA shall act as the engineer for the approval of asphalt mix designs and materials submitted by the Contractor.

3

The contractor shall prepare the mix design with all necessary supporting documentation which shall include the results of the Contractor’s own laboratory procedures.

4

The Contractor shall carry out a trial batching and trial laying of the particular mix design.

5

The testing and sampling of the mix design by the LSA will take place for both the laboratory verification and the trial batching and laying.

6

Based on the results of the trial batching and laying the contractor may be required to make amendments to the mix design. Providing the mix design conforms to the specification the mix shall be approved by the LSA.

7

The LSA shall issue a certification for the job standard mix to the Contractor.

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5.2.10

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 15

The approved Job Mix Formula may be amended as a result of experience in the execution and performance of the permanent asphalt works. Such an amendment may be submitted by the Contractor for the Engineer's approval in which case the Contractor shall submit full details of the proposed amendment together with such data as is necessary to support his submittal. Amendment may also be directed by the Engineer.

9

Approval by the Engineer of the Job Mix Formula or amendments thereto shall in no way relieve the Contractor of his obligations under the Contract, and the Contractor shall be responsible for the soundness of the asphalt paving mixes and the satisfactory execution and performance of the asphalt paving courses.

5.3.2

Marshall Mix Design Criteria

1

The Asphalt Institute MS-2 “Mix Design Methods for Asphalt Concrete and Other Hot-Mix Types” shall be used in designing the bituminous mixtures using Marshall design method.

2

The recommended compacted layer thicknesses are shown in Table 5.6.

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80 to 100 mm

60 to 80 mm

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Base Course (Class B)

Wearing Course(WC) 45 to 55 mm

When tested according to ASTM C136, the combined mineral aggregate shall conform to Table 5.7 for asphalt concrete mixes.

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Base Course (Class A)

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Table 5.6 Recommended Compacted Layer Thicknesses

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Table 5.7 Combined Aggregate Gradation for Asphalt Concrete Marshall Design Mixes

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ASTM Sieve Size

m

37.5 mm 25.0 mm 19.0 mm 12.5 mm 9.5 mm 4.75 mm 2.36 mm 0.850 mm 0.425 mm 0.180 mm 0.075 mm

4

Percentage Passing (By Weight)

Base Course (Class A) 100 80 - 100 62 - 92 45 - 75 30 - 55 20 - 40 15 - 30 10 - 226 - 15 2-8

Base Course (Class B) 100 80 - 100 63 - 85 57 - 77 40 - 60 25 - 45 15 - 30 10 - 22 6 - 15 2-8

Wearing Course 100 86-100 69 - 87 58 - 78 40 - 60 25 - 45 15 - 30 10 - 22 6 - 15 2-8

The "Laboratory Designed Mixture" for all types of bituminous coated courses shall comply with the requirements given in Table 5.8. Note that any deviation from these requirements shall be approved by LSA.

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 16

Table 5.8 Design Criteria for Marshall Design Mixes Base Course (Class A)

Aggregate Properties

Flow (mm) Marshall Quotient (Stability/Flow) (kN/mm)

75

75

75

3.2 – 4.4

3.4 – 4.4

3.4 – 4.4

9.5 min.

9.5 min.

11.5 min.

2 to 4

2 to 4

2 to 4

4.75 min.

4.75 min.

4.75 min.

4 to 8

4.5 to 8

Voids in Mix (Air Voids) (%) Voids in Mineral Aggregate VMA (%)

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3.2 min.

50 to 75

75 min. 0.8 to 1.5

50 to 75

ta

50 to 70

Voids in Marshall Specimen at 400 Blows per face at optimum binder content (%) Retained Stability (%) (Filler/Binder) Ratio

5 to 8

Table No.5.9

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Voids Filled with Asphalt VFA (%)

.

Stability minimum (kN)

Table 5.7

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Aggregate Grading Number of Compaction blows at each end of specimen (see paragraph 5) Binder Content (% of total mix) inclusive of tolerances

Base Course Wearing Course (Class B) Tables 5.1 and 5.2

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Parameter

3.4 min.

4.0 min.

75 min. 0.8 to 1.5

75 min. 0.75 to 1.35

Note: Relevant ASTM standards shall be used for testing.

Base Course (Class B) and Wearing Course samples shall be prepared and tested using Marshall apparatus in accordance with ASTM D6926 and ASTM D6927, respectively, while Base Course (Class A) samples shall be prepared and tested in accordance with ASTM D5581. However, based on the Engineer approval, samples having aggregate sizes larger than 25mm can be prepared and tested according to ASTM D6926 and ASTM D6927 by substituting all aggregate sizes over 25mm with an equal weight of aggregate sizes in the next lower grading sizes.

6

Upon the request of the Engineer, the Tensile Strength Ratio (TSR) in accordance with ASTM D6931 shall be obtained for the mix for quality control purposes. The TSR acceptance limits shall be determined at mix design stage and approved by the Engineer.

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Table 5.9 Minimum Percent Voids in Mineral Aggregate (VMA) Minimum VMA, Percent Nominal Maximum 1, 2 Particle Size (mm) 1.18 2.36 4.75 9.5 12.5 19.0 25.0 37.5 50 63

Design Air Voids, Percent 3.0 21.5 19.0 16.0 14.0 13.0 12.0 11.0 10.0 9.5 9.0

4.0 22.5 20.0 17.0 15.0 14.0 13.0 12.0 11.0 10.5 10.0

3

5.0 23.5 21.0 18.0 16.0 15.0 14.0 13.0 12.0 11.5 11.0

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 17

1

Standard Specification for Wire Cloth Sieves for Testing Purposes, ASTM E11 (AASHTO M92). The nominal maximum particle size larger than the first sieve to retain more than 10 percent. 3 Interpolate minimum voids in the mineral aggregate (VMA) for design air voids values between those listed. 2

7

After the Job Mix Formula has been established and approved, all mixes furnished shall conform thereto within the following tolerances: Table 5.10

Base Course (Class A)

Base Course (Class B)

Wearing Courses

Aggregate retained on 4.75mm sieve or larger

 5%

 4%

 4%

Aggregate passing 4.75mm sieve and retained on 850m sieve

 4%

 3%

 3%

Aggregate passing 850m sieve and retained on 75m sieve

 3%

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Job Mix Tolerances For Field Mixtures

 2%

 2%

 1.0%

 1.0%

 0.2%

 0.2%

Binder Content

 0.3%

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 1.5%

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Aggregate passing 75m sieve

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Description

The ‘Job Standard Mix Density’ shall be obtained by making six standard Marshall specimens from samples of the approved ‘Job Standard Mixture’ determining the bulk specific gravity of each and comparing them with the mean value of the six. Any individual result which differs from the mean by more than 0.015 shall be rejected, and provided that not more than two results are so rejected the mean of the remaining result shall be designated the ‘Job Standard Mixture Density’. The absolute density shall be considered as the theoretical specific gravity calculated in accordance with ASTM D2041.

5.3.3

Quality Control Testing

1

The Contractor shall submit a testing plan to the Engineer for approval that demonstrates how he shall prove compliance with the requirements for compaction, mix composition, level, evenness and all other requirements of Section 6. Each lot shall be approved by the Engineer before placing any subsequent asphalt concrete course. In cases where the asphalt course is laid in more than one layer, each layer shall be tested and approved before placing the subsequent asphalt concrete layer.

2

In addition to the following requirements one set of three laboratory-compacted specimens and one uncompacted coated sample for each mix type and mixer plant for each day’s production shall be delivered to the LSA no later than 12 h after compaction of the specimens. Details of compaction date, time and temperature of mix shall be provided with the specimens together with mix type and project details.

3

The Contractor shall cut samples from each completed asphalt course during the progress of the work and before final acceptance as directed by the Engineer. The Engineer shall determine the location of the samples.

4

When testing for compaction at joints the edge of the core shall not be more than 50 mm or less than 25 mm from the joint.

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QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 18

Compacted samples shall be taken by coring in accordance with ASTM D5361, for testing by an approved laboratory. The core diameter shall be 150 mm. where the Contractor fails to provide cores as required by the Engineer, the Engineer may arrange for the taking of cores on behalf of the Contractor at his cost. Samples shall be taken of the asphalt mix for the full depth of the course. A sample shall comprise a pair of adjacent cores and the average density of these shall be the density of the sample.

6

Whenever deficiencies are noted in loose mix samples or core samples, the Engineer may direct the taking of additional cores at the Contractor's expense in order to define the area of pavement involved.

7

Hot asphalt mix of the same type shall be placed and compacted in holes left by sampling. The mixture shall be compacted to the percentage compaction required for the layer using a vibrating hammer.

8

Quality control testing of the asphalt mixtures during construction shall follow the frequencies shown in Table 5.12 for Marshall Mixtures:

9

Base Course (Class B) and Wearing Course samples shall be prepared and tested using Marshall apparatus in accordance with ASTM D6926 and ASTM D6927, respectively, while Base Course (Class A) samples shall be prepared and tested in accordance with ASTM D5581. However, based on the Engineer approval, samples having aggregate sizes larger than 25mm can be prepared and tested according to ASTM D6926 and ASTM D6927 by substituting all aggregate sizes over 25mm with an equal weight of aggregate sizes in the next lower grading sizes.

10

Upon the request of the Engineer, the Tensile Strength Ratio (TSR) in accordance with ASTM D6931 shall be tested for quality control purposes. The TSR acceptance limits shall be based on the mix design obtained limits approved by the Engineer.

11

If it appears from the analysis of samples of loose mix or cores that the asphalt content or aggregate gradation are beyond the permissible tolerances specified for the Job Mix Formula (established for each respective asphalt course mix) and that, such variation affects the characteristics of the asphalt mix conformity to the designated requirements is concerned, this shall be considered a major defect in the work. The portion of the asphalt course represented by these samples shall be rejected.

12

The density of the compacted mixes shall be related to the daily Marshall density determined by making minimum four Marshall specimens from samples collected from behind the paver. The density of each sample shall be determined and compared with the mean value. Any 3 individual result, which varies from the mean by more than 0.015gm/cm shall be rejected. The daily Marshall density shall not differ from the Job Mix Design Density by more than 1.0%.

13

The field density, as determined from each core sample and related to the daily Marshall Density, obtained as shown above, shall be as follows:

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Table 5.11 Layer

Relative Density (%)

Base Course Wearing Course

97 – 101.8 98 – 101.8

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Section 06: Roadworks Part 05: Asphalt Works

Page 19

14

The finished road surface shall be inspected visually techniques and if directed by the Engineer the structural ability of the pavement in terms of layer modulus shall be assessed by using the Falling Weight Deflectometer (FWD) and Light weight Deflectometer (LWD).

15

For safety purposes the pavement surface friction shall be measured by the pendulum portable tester or locked wheel tester in accordance with ASTM E303. Table 5.12 Quality Control Testing of the Marshall Mixtures Item / Parameter

Standard

Specification Limits

Aggregate conformance

Minimum Frequency

Sections 5.2.1, 5.2.2 and 5.2.3 Section 5.2.5

Every 300t

Section 5.2.7

Tack Coat conformance

Section 5.2.8

Asphalt Binder conformance

Section 5.2.6

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Prime Coat conformance

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Mineral Filler conformance

2

Rate of application for Tack Coat

ASTM D2995

Sampling of bituminous mixtures

ASTM D979

BS EN 12697 Part 13

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ASTM D2726 3 ASTM D1188

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Daily Bulk density (See paragraph 12)

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Binder content

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Gradation of extracted aggregates

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Marshall Stability, Flow and Stability/Flow Ratio

Voids in mineral aggregate (VMA) Voids filled with asphalt (VFA) Voids in Mix (Air Voids) (%) Voids in Marshall Specimen at 400 Blows per face at optimum binder content (%) (Filler/Binder) Ratio

In-place air voids

-

 10 C of JMF temperature in truck  135 C min. at paver  120 C min. prior rolling 1.0% of Job Standard Density Table 5.7, Job Mix gradation and Table 5.10 tolerances Job Mix value with Table 5.10 tolerances

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Temperature of bituminous mixture

0.45 – 0.75 kg/m at 60 – 85 C 2 0.15 – 0.38 kg/m at 10 – 60 C

ta

ASTM D2995

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Rate of application for Prime Coat

ASTM D5444 ASTM C117

ASTM D2172 ASTM D6307 ASTM D6927 4 ASTM D5581 ASTM C127 ASTM C128 2 ASTM D2726 3 ASTM D1188 ASTM D2041 2 ASTM D2726 3 ASTM D1188

Table 5.8 Table 5.9

Table 5.8

2

- 1 per 250 m - 1 every 75m per lane Test based

Each truck

Daily

- Each source - Visible change in material - 1 test per 300t per layer for Base Course - 1 test per 150t per layer for Wearing Course

ASTM D2172 ASTM D6307 ASTM C136 ASTM D2041 2 ASTM D2726 3 ASTM D1188

5 – 8%

- 1 test per 600t per layer for Base Course - 1 test per 300t per layer for Wearing Course

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Item / Parameter Retained Stability (%) (Paragraph 16) Field density (nuclear gauge) Field density (2 cores)

5

Page 20

Standard

Specification Limits

ASTM D6927 4 ASTM D5581

75 min.

ASTM D2950

Table 5.11

ASTM D5361 2 ASTM D2726 3 ASTM D1188 ASTM D5361 ASTM D3549

5

Thickness

Minimum Frequency 1 test per 3000t per layer At 50m intervals in alternate wheel tracks - 1 test per 200t per layer for Base Course - 1 test per 100t per layer for Wearing Course

Table 5.11 Section 5.11.1

Evenness of surface

Section 5.11.2 & 5.11.3

1

As per polymer manufacturer recommendation and mix design for polymer modified binders If water absorption ≤ 2% 3 If water absorption > 2% 4 For samples containing more than 25mm size aggregates 5 For acceptance of in-situ compaction

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The Retained Stability is the percentage of the average stability of 3 samples conditioned for 24 hours at 60  1C water bath and the average stability of 3 samples conditioned for 4 hours in 60  1C air bath. These two sets of samples shall be prepared at the optimum binder content by applying 75 blows and kept at ambient temperature for 17 – 20 hours and shall have similar average densities.

17

Each day the produced mixes shall be tested for checking their compliance with the approved Job Standard Mix criteria. When unsatisfactory results or changed conditions make it necessary, a new job-standard following approval of new mix design shall be established.

5.4

DENSE BITUMEN MACADAM

1

The mix properties for Dense Bitumen Macadam are listed in Table 5.13.

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Table 5.13 Properties of Mix for Dense Bitumen Macadam

Parameter

Number of Compaction blows at each end of specimen

75

75

3.2 – 4.0

3.5 – 4.1

7.5

10.0

2-4

2–4

3.7

4.9

Voids in Mix (Air Voids) (%)

7 - 11

6–9

Voids in Mineral Aggregate VMA (%)

14 - 20

14 - 20

Binder Content (% of total mix) inclusive of tolerances

Stability minimum (kN) Flow (mm) Marshall Quotient (Stability/Flow) (kN/mm), min

2

Specification Limits Base Wearing Course Course

Voids Filled with Asphalt VFA (%)

47 - 60

48 - 60

Retained stability

75 min.

75 min.

When tested according to ASTM C136, the combined mineral aggregate shall conform to Tables 5.14, 5.15 and 5.16.

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Section 06: Roadworks Part 05: Asphalt Works

Page 21

Table 5.14 Aggregate Gradation for Dense Bitumen Macadam Road Base (Unbound) B.S Sieve (mm) 50.0 mm 37.5 mm 28.0 mm 14.0 mm 6.3 mm 3.35 mm 0.300 mm 0.075 mm

Aggregate, Crushed Rock or Gravel Percentage by mass passing 100 95 - 100 70 - 94 56 - 76 44 - 60 32 - 46 7 - 21 2- 8

Aggregate, Crushed Rock or Gravel Percentage by Mass Passing for Finished Thickness of Base Course

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70 - 90 mm 100 95 - 100 71 - 95 58 - 82 44 - 60 32 - 46 7 - 21 2 - 8

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50.0 37.5 28.0 20.0 14.0 10.0 6.3 3.35 0.300 0.075

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80 - 100 mm 100 95 - 100 70 - 94 56 - 76 44 - 60 32 - 46 7 - 21 2 - 8

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B.S Sieve (mm)

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Table 5.15 Aggregate Gradation for Dense Bitumen Macadam Asphalt Base Course

50 - 70 mm 100 95 - 100 65 - 85 52 - 72 39 - 55 32 - 46 7 - 21 2 - 8

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Table 5.16 Aggregate Gradation for Dense Bitumen Macadam Asphalt Wearing Course

m

B.S Sieve (mm) 28.0 20.0 14.0 10.0 6.3 3.35 1.18 0.075

Aggregate, Crushed Rock or Gravel Percentage by Mass Passing for Finished Thickness of Wearing Course 50 - 60 mm 100 95 - 100 70 - 90 55 - 75 40 - 60 25 - 40 15 - 30 2 - 6

40 - 50 mm 100 95 - 100 70 - 90 45 - 65 30 - 45 15 - 30 2 - 6

30 - 40 mm 100 95 - 100 55 - 75 30 - 45 15 - 30 2 - 6

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Section 06: Roadworks Part 05: Asphalt Works

Page 22

SUPERPAVE MIX DESIGN

1

Based on the Engineer approval, the Superpave Mix Design Method can be used to design the asphalt mixtures for Wearing Course and Base Course layers. The design of the Superpave asphalt mixtures shall follow the method outlined in AASHTO R35 and SP-2 “Asphalt Institute Superpave Mix Design Method” in liaison with LSA.

2

The contractor shall prepare the mix design with all necessary supporting documentation which shall include materials production and handling specifications, plant quality procedures, construction quality control and quality assurance procedures, quality control tests, mix acceptance criteria and performance evaluation testing program. All documentations shall be submitted to LSA for review and approval.

3

Based on the Engineer approval, the PG76-10 binder can be used in asphalt mixes. This binder type shall be a polymer-modified binder (PMB) meeting AASHTO M320 and ASTM D6373 specifications and the criteria listed in Table 5.5.

4

Based on the Engineer approval, when bitumen grades PG76-10 H, V or E are specified for heavy, very heavy, and extra heavy loading, the bitumen shall meet the requirements of AASHTO M332 and will be required to indicate elastic response in percent recovery when tested in accordance with AASHTO T350.

5

Based on the Engineer approval, the guidelines shown in the Appendix can be used for the mix design. Note that software (ePAVE3) shall be validated prior use.

6

The recent editions of the references shown in the Appendix are recommended to be used for preparation of mix design and quality control schemes.

7

Table 5.17 can be used as a guide for sampling and testing frequency for quality control of Superpave mixtures.

8

Performance tests shown in Table 5.18 can be used to evaluate performance of Superpave asphalt concrete mixtures.

9

Before producing bituminous concrete mixtures, the Contractor shall submit in writing to the Engineer for approval, detailed information for each mix which he proposes to furnish. The information shall include, but not be limited to the following:

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5.5

(a)

Copy of mix certificate approval obtained from LSA and the mix design report.

(b)

The source(s) of the aggregate for each mix as well as the pertinent test data and a written certification that the aggregates conform to all of the quality requirements.

(c)

Type of Asphalt modifier intended to be used in the project along with the Certificate of Conformity of the modified asphalt binder to the required grade according to the Superpave Performance Based Grading System.

(d)

Pertinent test data on the type and properties of the aggregates, asphalt binder, modified asphalt binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.

(e)

The type and location of plant to be used for mixing each mix.

(f)

Any other support data and information special to the project (e.g. technical data sheets of a polymer in case it was used).

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

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Table 5.17 Sampling and Testing Frequency of Superpave Field Mixtures Item / Parameter Standard Specification Minimum Frequency Aggregate Conformance Sections 5.2.1, 5.2.2, 5.2.3 and Table 6 - Appendix Mineral Filler conformance Section 5.2.5 Every 300t Prime Coat conformance Section 5.2.7 Tack Coat conformance Section 5.2.8 Asphalt Binder conformance Section 5.2.6 2 0.45 – 0.75 kg/m 2 Rate of application for Prime Coat ASTM D2995 - 1 per 250 m at 60 – 85 C - 1 every 75m per 2 0.15 – 0.38 kg/m lane Rate of application for Tack Coat ASTM D2995 at 10 – 60 C Sampling of bituminous mixtures ASTM D979 Test based  ±10 C of JMF temperature in truck  Min. JMF compaction BS EN 12697 temperature +20 C at Temperature of bituminous mixture Each truck Part 13 paver  Min. JMF compaction temperature prior rolling (sec. 1.5.4 – Appendix) ASTM D2172 Binder content (%) JMF value ±0.40 ASTM D6307 Table 9 Gradation of extracted aggregates ASTM D5444 Appendix Effective Specific Gravity of ASTM D6857 - Each source; Gsb < Gse < Gsa Aggregates (Gse) ASTM D2041 - Visible change in ±1.5 Voids in mineral aggregate (VMA) AASHTO T312 material ASTM D6857 or 1 test per 500t per Voids in Mix (Va) ±1.3 ASTM D2041 layer for Base (Min 2 Gyratory specimens at Ndes) (Eq. 2) Course Density (% of Gmm) at Nmax Table 5 ASTM D2726 - 1 test per 250t per (Min 1 Gyratory specimens at Nmax) Appendix layer for Wearing ASTM D6857 / Course ASTM D2041 Table 5 Dust to binder ratio (P0.075 / Pbe) ASTM D2172 / Appendix ASTM D6307 ASTM D5444 Indirect tensile strength (IDT) ASTM D6931 IDT of JMF min. ASTM D6931 Sec. 1.5.8 Moisture Sensitivity (Retained IDT) Sec. 1.5.8 Weekly Appendix Appendix Dynamic Modulus at 10 Hz, 45 C, Min. 1920 MPa AASHTO PP60 0kPa confinement AASHTO TP79 Every 10,000t Flow Number (Fn) at 54.4 C, 600kPa Procedures A, B Min. 740 deviatory stress, and 0kPa AASHTO PP61 confinement ASTM D5361 - 1 test per 200t per In-place air voids 6 – 8% ASTM D2726 layer for Base Course; - 1 test per 100t per ASTM D5361 Thickness Section 5.11.1 layer for Wearing ASTM D3549 Course At 50m intervals in Field density (nuclear gauge) (%Gmm) ASTM D2950 92 – 94% alternate wheel tracks Evenness of surface Section 5.11.2 & 5.11.3

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5.6

PERFORMANCE EVALUATION OF ASPHALT CONCRETE

1

Based on the Engineer request, the asphalt mixture performance properties can be determined.

2

The performance properties of asphalt mixtures shall be measured for every asphalt concrete layer at least on the following frequencies: Prior asphalt laying on a laboratory prepared sample at the asphalt binder content specified in the JMF.

(b)

Asphalt mix sampled from behind the paver every 10000t of mix.

The purpose of the performance testing is to allow for pavement performance evaluation and verification of pavement structural design through the AASHTO Mechanistic-Empirical Pavement Design Guide. Performance models, references, test conditions are shown in table 5.18 below:

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(a)

Table 5.18

Test Reference

Test Conditions

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Performance Model

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Performance Models Criteria

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100X150mm cylindrical AASHTO PP60, sample under uniaxial Dynamic Modulus TP79 Procedure stress, zero confining Master Curve A, & PP61 pressure and sinusoidal deviator stress AASHTO PP60 100X150mm cylindrical & TP79 sample under triaxial Procedure B stress

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Rutting Model

Aging Model

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AASHTO T321

ASTM D7175

Applications / Use

The E* is used in mechanistic analysis to evaluate the structural responses of the asphalt concrete layers

To evaluate the rutting characteristics of the asphalt mixture in the form of a rutting model or Flow Number (FN)

64x50x380mm beam specimen is subjected to a 4-point bending with free rotation and horizontal translation at all load and reaction points

The initial flexural stiffness is measured at the 50th load cycle. Fatigue life or failure shall be defined as the number of cycles corresponding to 50% reduction in the initial stiffness.

Conduct asphalt binder A-VTS test in the Rheometer (DSR) to measure G* and  in accordance with ASTM D7175 at multiple temperatures

Viscosity-temperature relationship (A-VTS) of the asphalt binder is determined in order to assess the impact of binder aging on the E* property of the asphalt mix at various stages of the pavement life

Modelling methods adopted by Asphalt Institute and Shell or equivalent shall be used. The contractor shall submit a proposal includes performance modelling testing and interpretation procedures to the Engineer for approval.

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DELIVERY, SPREADING AND FINISHING

5.7.1

Delivery of Mixes

1

Sufficient plant capacity, haul vehicles and storage shall be provided so that adequate supplies of mixture are delivered to site to ensure that continuous paving can be achieved.

2

The dispatching of the hauling vehicles to the job site shall be so scheduled that all material delivered may be placed in daylight, unless the Engineer has approved the use of artificial light. Delivery of material shall be at a uniform rate and in an amount well within the capacity of the paving and compacting equipment.

3

All precautions shall be taken to protect the mix from the weather during transit and while waiting to discharge.

4

Hauling vehicles shall not be permitted to carry out tight turns on the laying surface.

5

The mixture at delivery to the paver shall be within 10 C of the Job Mix Formula temperature

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and above an absolute minimum temperature of 135 C. Material which has fallen below the

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minimum temperature of 135 C before discharge shall be rejected and immediately removed

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from site. Delivery temperature shall not exceed the maximum temperature specified for mixing at the plant Should a significant proportion of the mixture delivered to the paver fail to meet this requirement, or should cold lumps be found in the mixture, the Engineer shall order that paving operations be suspended until measures are taken, to the approval of the Engineer, to ensure compliance.

5.7.2

Spreading and Finishing

1

The Contractor shall prepare a paving plan and obtain approval of the Engineer to ensure adequate equipment and paving sequences.

2

Based on the approved paving plan and prior to the commencement of delivery of the mix the Contractor shall erect and maintain an approved reference guide wire for controlling the levels of the laid mix. The reference guide wire shall be supported at intervals of not more than 5m.

3

The mix shall be laid upon an approved surface and only when weather conditions are suitable and as designated. Upon arrival at the point of use, the asphalt mix shall be spread and struck off to the grade, elevation and cross-section shape intended, either over the entire width or over such partial width as may be required. If the material does not conform to the requirements, it shall not be used and shall be discarded.

4

The laid material shall be compacted as soon as rolling can be effected without causing undue displacement and while the temperature does not fall below 120 C for unmodified

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asphalt mixes. Materials still uncompacted and below this temperature shall be rejected. 5

The compaction temperature for the laid polymer-modified asphalt binder mixes shall be selected based on one of the following: (a)

As specified in the JMF.

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(b) 6

Section 06: Roadworks Part 05: Asphalt Works

Page 26

As established from the trial section.

The Contractor shall supply accurate calibrated thermometers suitable for measuring the inner and surface temperature of the material. The material temperature shall be checked immediately before rolling and at least every 30 minutes thereafter during forward progress. A record of these temperatures shall be passed to the Engineer at the end of each day’s work. While paving is in progress, the output of the batching plant shall be exclusively reserved for the operations and no mixture shall be supplied to other sites or projects.

8

If during laying, the paver is repeatedly delayed because of lack of mixture or if the paver stands at one location for more than thirty minutes (for any reason), a transverse joint shall be constructed. Paving shall not recommence until the Engineer is satisfied that paving will proceed uninterrupted and until at least four loaded vehicles have arrived at the paving site.

9

The asphalt course shall be constructed to proposed levels and shall be homogeneous, providing after compaction an even surface free from undulations, rises or depressions and within the tolerances stipulated.

10

In no case shall construction of a new asphalt concrete course begin until the previously laid course has been tested and approved.

11

When the same asphalt course is to be laid in more than one layer the second layer shall be placed as soon as practicable after the first layer has been finished, rolled and cooled, and the Engineer may at his discretion request cleaning of the first layer and the application of a tack coat thereon if he so deems necessary.

12

Transverse joints in succeeding layers shall be offset at least 2 m. Longitudinal joints shall be offset at least 300 mm.

13

The use of motor grader or hand spreading of the asphalt mix shall not be permitted except in places where it is impractical to use pavers and shall be only with the specific permission of the Engineer. The asphalt mix shall comply with all conditions regarding trueness of level, thickness, and homogeneity of the mix.

14

Automatic electronic screed controls shall be required on all pavers and shall be used with a 9 m long articulated averaging beam or grade wire control as approved by the Engineer.

5.7.3

Compaction of Mixes

1

At least three rollers shall be required at all times, one self-propelled pneumatic-tire and two self-propelled steel-wheeled. As many additional rollers shall be used by the Contractor as necessary to provide specified asphalt course density and surface characteristics in an orderly, efficient and continuous manner.

2

Before beginning construction of the permanent works, unless otherwise agreed with the Engineer, the Contractor shall carry out compaction trials for each type and thickness of asphalt course to establish an approved compaction procedure which shall then be used as a minimum requirement for the compaction of the permanent works unless otherwise directed or agreed by the Engineer.

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Section 06: Roadworks Part 05: Asphalt Works

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The compaction trials shall involve all procedures specified for the permanent works including testing as specified for the asphalt course under consideration and any equipment, processes or procedures proposed by the Contractor which are not designated. Construction of the permanent works shall not commence until a compaction procedure has been approved in writing by the Engineer. Such approval shall in no way relieve the Contractor of his responsibilities and obligations stipulated in the Contract.

4

Immediately after the asphalt mix has been spread and struck off, the surface shall be checked and any irregularities adjusted and then compacted thoroughly and uniformly by rolling.

5

To prevent adhesion of the mix to steel-wheeled rollers, the wheels shall be kept properly moistened but excess water shall not be permitted.

6

After the longitudinal joints and edges have been compacted, rolling shall start longitudinally at the sides of the road and shall gradually progress towards the centre. On super elevated sections, rolling shall begin on the low side and progress to the high side, overlapping on successive trips by at least one-half the width of tandem rollers and uniformly lapping each proceeding track. The rollers shall move at a slow but uniform speed with the drive wheels nearest the paver. The speed shall not exceed 4-5 km/h for steel-wheeled rollers or 8 km/h

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for Pneumatic-tire rollers. The operating speed shall be approved by the Engineer. The line of rolling shall not be changed suddenly or the direction of rolling reversed suddenly. If rolling causes displacement of the material, the affected areas shall be loosened at once with hand tools and restored to the original grade of the loose material before being rerolled. Heavy equipment or rollers shall not be permitted to stand on the finished surface before it has been compacted and has thoroughly cooled.

8

When paving in a single width, the first lane placed shall be rolled in the following order:

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Transverse joints.

(b)

Longitudinal joints.

(c)

Outside edge.

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Initial or breakdown rolling, beginning on the low side and progressing towards the high side.

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(e)

Intermediate rolling.

(f)

Final rolling.

1

When paving in echelon, 50 mm to 100 mm of the edge which the second paver is following shall be left unrolled. When paving in echelon the edges between the first and the second paver shall not be exposed more than 15 minutes nor 50m by distance without being rolled. Particular attention shall be given to the construction of the transverse and longitudinal joints in all courses.

5.7.4

Transverse Joints

1

Transverse joints shall be carefully constructed and thoroughly compacted to provide a smooth riding surface. Joints shall be checked with a straightedge to assure smoothness and true alignment. Joints shall be formed with a bulkhead, such as a board, to provide a straight line and vertical face.

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If the joint has been distorted by traffic or by other means, it shall be trimmed to line and the face shall be painted with thin coating of emulsified asphalt before the fresh material is placed against it. To obtain thorough compaction of these joints the material placed against the joint shall be tightly pushed against the vertical face with a steel-wheeled roller.

3

The roller shall be placed on the previously compacted material transversely so that not more than 150 mm of the rear rolling wheel rides on the edge of the joint. The roller shall be operated to pinch and press the mix into place at the transverse joint. The roller shall continue to roll along this line, shifting its position gradually across the joint, in 150 to 200 mm increments, until the joint has been rolled with the entire width of the roller wheel. Rolling shall be continued until a thoroughly compacted, neat joint is obtained.

5.7.5

Longitudinal Joints

1

Longitudinal joints shall be rolled directly behind the paving operations. The first lane placed shall be true to line and grade and have a vertical face. The material being placed in the abutting lane shall then be tightly pushed against the face of the previously placed lane. Rolling shall be done with a steel-wheeled roller.

2

The roller shall be shifted over onto the previously placed lane so that not more than 150 mm of the roller wheel rides on the edges of the newly laid lane. The rollers shall then be operated to pinch and press the fine material gradually across the joint. Rolling shall be continued until a thoroughly compacted, neat joint is obtained.

3

When the abutting lane is not placed in the same day, or the joint is distorted during the day's work by traffic or by other means, the edge of the lane shall be carefully trimmed to line, cleaned and painted with a thin coating of emulsified asphalt before the adjacent lane is placed.

4

The longitudinal joints in the surface course shall be along the same line as the traffic lane markers.

5.7.6

Paving Edges

1

The edges of the asphalt course shall be rolled concurrently with or immediately after rolling the longitudinal joint.

2

Care shall be exercised in consolidating the course along the entire length of the edges. Before it is compacted, the material along the unsupported edges shall be slightly elevated with hand tools. This will permit the full weight of the roller wheel to bear on the material to the extreme edges of the mat.

5.7.7

Breakdown Rolling

1

Breakdown rolling shall immediately follow the rolling of the longitudinal joints and edges. Rollers shall be operated as close to the paver as possible to obtain adequate density without causing undue displacement. In no case shall the mix temperature be allowed to drop below 120 C before breakdown rolling.

2

If the breakdown roller is steel wheeled, it shall be operated with the drive wheel nearest the finishing machine. Pneumatic-tire rollers may be used as breakdown rollers.

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Section 06: Roadworks Part 05: Asphalt Works

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Intermediate Rolling

1

Pneumatic-tire rollers or Steel wheeled rollers shall be used for the intermediate rolling.

2

The intermediate rolling shall follow the breakdown rolling as closely as possible and while the paving mix is still hot. Rollers shall be used continuously after the initial rolling until all of the mix placed has been thoroughly compacted. Turning of rollers on the hot paving mix which causes undue displacement shall not be permitted.

5.7.9

Finish Rolling

1

The finish rolling shall be performed with three-axle tandem rollers unless otherwise permitted by the Engineer. Finish rolling shall be accomplished while the material is still warm enough for the removal of roller marks.

2

All rolling operations shall be conducted in close sequence.

3

In places inaccessible for the operation of standard rollers as specified, compaction shall be performed by manual or mechanical tampers of such design as to give the desired density.

4

After final rolling, the smoothness, levels, crossfalls, density and thickness shall be checked and any irregularity of the surface exceeding the specified limits and any areas defective in texture, density or composition shall be corrected as directed by the Engineer, including removal and replacement as directed by the Engineer.

5.7.10

Protection of Laid Courses

1

Sections of the newly finished work shall be protected from traffic of any kind until the mix has been properly compacted and cooled. In no case shall traffic be permitted less than 24 h after completion of the asphalt course unless a shorter period is authorised by the Engineer.

5.8

COLD PLANING

1

The cold planing plant shall be to the approval of the Engineer.

2

Cold planing plant shall have sufficient power, traction and stability to maintain the required depth of cut and slope. The control of the depth of cut and the slope shall be by an automatic system based on reference wires.

3

Cold planing shall be carried out to straight crossfalls to the designated thickness. Planing shall be to a tolerance of  5 mm of the designated amount. The average thickness of

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5.7.8

planing achieved shall be at least the thickness designated. 4

In areas where there is severe deformation of the existing pavement, it may be necessary to vary the depth of planing.

5

Existing kerbs, gullies, manholes and other features shall not be disturbed by the planing process. This may require the use of smaller plant or removal by hand tools.

6

Any joints at the edge of planed areas shall be cut vertically and straight using asphalt saws.

7

Cold planing shall be carried out in a longitudinal direction.

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 30

After planing the prepared surface shall be thoroughly brushed and suction swept by mechanical means to the satisfaction of the Engineer. The surface shall be free from gouges, ridges, continuous grooves and shall have a reasonably uniform finish.

9

Cold planing shall be performed so that at the end of a day’s work the termination line does not present a hazard to traffic that may use the road.

10

Any cracks noted in the pavement shall be blown clean with compressed air. The Engineer will inspect the planed surface and may instruct that further work is carried out for treating cracks in the pavement.

5.9

PRIME COAT

5.9.1

General

1

The work shall consist of furnishing and applying liquid asphalt and blotter material, if required, to a previously prepared and approved subgrade or granular base/sub-base course as designated and to the full designated width.

2

Prime coat shall not be applied when the ambient temperature is less than 13 C nor during rain, fog, dust storms or other unsuitable weather.

5.9.2

Equipment Required

1

The equipment used by the Contractor shall include a liquid asphalt distributor as described in clause 5.17.3.

2

If the surface is covered in wind-blown dust or fine aggregate then a power broom shall be provided. The power broom shall be self-propelled and equipped with a cylindrical, rotating nylon bristle brush of not less than 760 mm in diameter and not less than 1800 mm in length. The brush shall be capable of being angled to the right and left with adjustable ground pressure. Where necessary for the proper preparation of the surface, motor graders, rollers and water trucks shall also be provided.

5.9.3

Surface Preparation

1

Immediately before applying the prime coat, all loose dirt, earth and other objectionable material shall be removed from the surface with a power broom of approved design and/or a power blower as required, and any ruts, soft spots or unacceptable irregularities in the surface shall be repaired in accordance with the instructions of the Engineer. If the Engineer so requires, the surface shall be lightly bladed and rolled immediately before the application of the prime coat, in which case brooming or blowing may not be required.

2

Priming will not be permitted when there is free water present on the surface.

5.9.4

Application

1

After preparing the road surface as above, the prime coat shall be applied by means of the distributor at the temperature and rate shown in Table 5.12. Hand-spraying of restricted, inaccessible areas is permitted, subject to the approval of the Engineer.

2

The surface of structures, kerbstones and other appurtenances adjacent to areas being treated shall be protected in such a manner as to prevent their being spattered or marred.

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The prime coat shall usually be applied to 1/3 or 1/2 of the road width at a time. When applied in two or more lanes, there shall be a slight overlap of asphalt material along adjoining edges of the lanes. It should be noted that no overlapping is allowed at the transverse joints and that thick paper shall be used at the joint to protect the previous application and the joining application shall begin on the paper. The paper used shall be removed and satisfactorily disposed of by the Contractor after use. Care shall be taken that the application of prime coat material at the junctions of spread is not in excess of the specified amount. Excess bituminous material shall be removed from the surface.

5.9.5

Maintenance and Traffic

1

Traffic shall not be permitted on the primed surface until the asphalt material has penetrated and dried and, in the judgement of the Engineer, will not be picked up under traffic. If it becomes necessary to permit traffic before that time, but in no case sooner than 48 hours after the application of the asphalt material, blotter material shall be applied as directed by the Engineer and traffic shall be permitted to use the lanes so treated.

2

Blotter material shall be spread from trucks operated backward so that the wheels will not travel in uncovered wet asphalt material. When applying blotter material to an asphalt treated lane that adjoins a lane that has not been treated, a strip at least 200 mm wide along the adjoining edge shall be left devoid of blotter material in order to permit an overlap of asphalt material.

3

The Contractor shall maintain the primed surface in good clean condition and before the application of the next course, any surface irregularities shall be corrected and all excessive blotter material, dirt or other objectionable materials shall be removed.

5.10

TACK COAT

5.10.1

General

1

This work shall consist of furnishing and applying diluted emulsified asphalt to a previously prepared Base or Wearing courses, to provide bond for a superimposed course to the full designated width.

2

Tack coat shall not be applied when the ambient temperature is less than 13C nor during rain, fog, dust storms or other unsuitable weather.

5.10.2

Equipment Required

1

The equipment used by the Contractor shall include liquid asphalt distributor as well as a power broom and a power blower. Power broom shall be self-propelled and equipped with a cylindrical, rotating nylon bristle Brush of not less than 760 mm in diameter and not less than 1800 mm in length. The brush shall be capable of being angled to the right and left with adjustable ground pressure. In addition, the Contractor shall supply and use efficient and approved equipment for diluting the emulsified asphalt with water.

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Section 06: Roadworks Part 05: Asphalt Works

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Surface Preparation

1

The full width of the surface to be treated shall be cleaned with a power broom or power blower to remove dust, dirt or other objectionable materials. All faulty or unsuitable patches, excess cracks or joint filler and all surplus bituminous material shall be corrected in accordance with the instructions of the Engineer. The surface shall be dry when treated.

5.10.4

Application

1

Immediately after cleaning the surface, the tack coat shall be applied by means of the distributor at the temperature and rate directed by the Engineer. Hand spraying of restricted, inaccessible areas is permitted, subject to the approval of the Engineer.

2

The diluted emulsion shall be applied at a rate shown in Table 5.12. The Contractor shall ensure that excessive application of tack coat is avoided.

3

The surface of structures, kerbstones and other fixed objects adjacent to areas being treated shall be protected in such a manner as to prevent their being spattered or marred.

5.10.5

Maintenance and Traffic

1

After application, the surface shall be allowed to dry until it is in a proper condition of tackiness to receive the superimposed course. Tack coat shall be applied only so far in advance of the superimposed course placement as is necessary to obtain this proper condition of tackiness.

2

Until the superimposed course is placed, the Contractor shall protect the tack coat from damage.

3

If the tack coat is unavoidably damaged by rain or dust, it shall be allowed to dry, shall be cleaned again by a power broom or power blower and, if required by the Engineer, a subsequent light application of tack applied to the surface. Where, in the opinion of the Engineer, a tack coat is not necessary between layers of freshly placed courses, he may give instructions in writing to omit the tack coat. Any cleaning required in these areas shall be carried out before the application of the next course.

5.11

THICKNESS AND LEVEL

5.11.1

Thickness

1

Cores shall be taken to determine the thickness of asphalt paving courses. As determined from each core, the thickness of a paving course shall not be less than that specified by more than 5 mm in the case of a single-layered construction. Furthermore, the thickness of the Wearing course shall not be less than that specified by more than 5 mm and the total thickness of all asphalt paving courses combined shall not be less than that specified by more than 10 mm.

2

In addition, the variations in the falls to cross sections of the road shall not vary from the required value by more than 0.3 %. Any asphalt paving course containing deviations or variations exceeding these tolerances shall be corrected or removed and replaced by the Contractor, in accordance with the instructions and to the satisfaction of the Engineer.

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Section 06: Roadworks Part 05: Asphalt Works

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Where any individual course is marginally out of tolerance on the low side, the Engineer may allow adjustment in the succeeding course to correct the overall thickness of the pavement.

4

The tolerances herein specified shall not invalidate the tolerances set forth for the evenness of surface of the asphalt paving course.

5

As directed by the engineer the laid thickness shall be checked by cutting test pits and/or using Ground Penetrating Radar (GPR) for the determination of the structural capacity of the pavement.

5.11.2

Transverse Evenness

1

The Engineer shall test the evenness of surface for each course of the various asphalt paving courses to determine compliance.

2

The Contractor shall put at the disposal of the Engineer a 3m long straight edge and a crown template of sturdy and approved design and enough labour to assist in the checking operations. The maximum allowable differences between the pavement surface and the straight edge shall be 3mm. Transverse measurements shall be carried out every 20m of road length for each lane.

3

Any layer containing deviations or variations exceeding the tolerances specified here shall be corrected or removed and replaced in accordance with the instructions of the Engineer and to his satisfaction.

5.11.3

Evenness and Rideability

1

Smoothness is a measure of the evenness and rideability of the pavement surface. It shall be measured on the driving surface of the completed pavement for all major roads before opening to the traffic.

2

Any section containing deviations or variations exceeding the criteria specified here or by the Engineer shall be corrected or removed and replaced in accordance with the instructions of the Engineer and to his satisfaction at the Contractor’s cost.

3

The minimum length of the rectification work undertaken shall be 100m.

4

All rectified segments shall be re-tested following the completion of rectification work at no additional cost to the client.

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(a)

Evenness

5

The evenness of the driving surface of road pavements shall be measured with a 3m rolling straight edge along any line or lines parallel to the center line of the pavement on sections of 300m selected by the Engineer, whether or not it is constructed in shorter lengths. Sections shorter than 300m forming part of a longer pavement shall be assessed using the number of irregularities for a 300m length prorated to the nearest whole number. Where the total length of pavement is less than 300m the measurements shall be taken in 75m lengths.

6

The number of deviations (from the bottom face of the straight edge) over the length of the section greater than or equal to 4mm shall be counted. None of the measured deviations shall exceed 6mm. The evenness of the driving surface of the tested section shall be within the relevant limits given in Table 5.19.

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Table 5.19 Evenness of Driving Surface

(b)

Section Length (m)

Allowed number of deviations ≥4mm

300

20

75

9

Rideability

For major roads the International Roughness Index (IRI) shall be used to monitor the roughness and condition of the pavement surface. The acceptable IRI for ride quality shall be decided by the Engineer.

8

The rideability of the driving surface of the completed pavement shall be measured in terms of the International Roughness Index (IRI) which shall be tested with a certified and calibrated Inertial Profiler meeting the requirements of ASTM E950–Class 1.

9

The testing method shall be in accordance with ASTM E950. The IRI shall be calculated according to ASTM E1926.

10

Calibration checks on the inertial profiler shall be conducted using test methods in accordance with the manufacturer’s recommendations, at the beginning of the day of operation and at any other time the operator may suspect changes of system performance since the last calibration.

11

Calibration checks on the inertial profiler and all other quality checks shall be submitted in a method statement to the Engineer for approval.

12

The selected measuring speed shall be the posted speed and within the range recommended by the manufacturer and shall remain nearly constant during testing, not to exceed +/-5 km/h of the selected speed.

13

The profiler system shall stabilize at the test speed prior to entering the test sections. This requires bringing the profiler vehicle to the desired test speed at least 100 m prior to the beginning of the test location. Any Features along the test section such as bridges, culverts, milepost or other pertinent information shall be identified. The test shall be conducted in the paving direction.

14

The start and end point of the test section shall be automatically identified by using a photo detector. The coordinates of the test section shall be identified by using a GPS.

15

Three runs of data collection (both wheel tracks in each lane) shall be conducted. The processing of the data for IRI shall include calculating the average IRI value of the three runs for the two wheel tracks. The processed data shall be reported on 25m and 400m subsections calculated using the Moving Average statistical method and applying a 250mm filtering.

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PAVEMENT EVALUATION TECHNIQUES

1

Pavement evaluation tests shall be carried out for the completed pavement structure at any point of the road as directed by the Engineer to assess the serviceability condition of the pavement and verify compliance with specifications.

2

Pavement evaluation methods can be grouped into two main categories, destructive and non-destructive.

3

The Contractor shall allow and provide all necessary arrangements for the execution of all pavement evaluation test required by the Engineer.

4

As directed by the Engineer the structural ability of the pavement in terms of load-deflection response and layer modulus shall be assessed by using the Falling Weight Deflectometer (FWD).

5

The pavement surface friction shall be measured based on the Engineer request using the portable pendulum tester (ASTM E303), locked wheel tester (ASTM E274) or the sand patch method (ASTM E965).

5.13

PRODUCTION OF ASPHALT CONCRETE COURSES

5.13.1

Weather Limitations

1

Production and spreading of asphalt Concrete mix shall not be permitted when the ambient temperature is less than 8 C, nor during rain, fog, dust-storms or other unsuitable weather.

5.13.2

Equipment Required

1

The equipment required for construction of the asphalt concrete courses shall include but not be limited to the equipment mentioned in Clauses 5.3 to 5.6 of this Part, together with such miscellaneous equipment and tools as required for the satisfactory preparation and performance of the work.

2

All equipment shall be checked, calibrated and approved by the Engineer before use. The equipment shall be satisfactorily maintained and shall be used in an approved manner.

3

Adequate equipment and labour shall be used so that there is continual production and distribution of the asphalt course being constructed.

5.13.3

Survey and Preparation

1

The area to be paved shall be true to line and grade and shall have a properly prepared surface before the start of paving operations.

2

When an asphalt concrete pavement course is to be placed on top of an existing pavement, the existing pavement surface shall be prepared as designated by the Engineer.

3

Priming or tacking of surfaces to be paved shall be carried out as designated.

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The surface of kerbs, vertical faces of existing pavements and all structures in actual contact with asphalt mixes shall be painted with a thin and complete coating of tack coat as instructed by the Engineer to provide a closely bonded, watertight joint.

5

All openings or structures in the road for water, drainage and other specified utilities shall be constructed and their positions and levels determined before the start of paving operations.

5.13.4

Heating of Asphalt Binder

1

The 60/70 penetration grade bitumen shall be heated to a temperature of between 150 to 165 degrees centigrade.

2

Bitumen of other penetration grade shall be heated to yield viscosity's in the range of 150 to 300 centistokes (175 to 150 seconds Saybolt-Furol) when delivered to the mixer, as determined from the Temperature Viscosity Chart of the product used.

3

Penetration Graded Asphalt Binders shall not be used if foaming occurs or shall it be heated above 175 C at any time.

4

Polymer-modified binder shall be heated to a temperature specified by the supplier.

5.13.5

Heating of Mineral Aggregate

1

When using 60/70 penetration grade asphalt binder the materials shall be thoroughly dried and heated so that their temperature is 165 to 180 degrees centigrade.

2

When using asphalt binder of other penetration grade the materials shall be thoroughly dried and heated so that their temperature is within ± 8 C of the temperature needed to satisfy the

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viscosity requirements of the asphalt cement. The moisture content of the heated and dried materials shall not exceed 1%.

4

The quantity of materials fed through the drier shall in all cases be held to an amount which can be thoroughly dried and heated within the limits specified.

5

The heated materials shall be screened into sizes such that they may be combined into a gradation meeting the requirements of the Job Mix Formula and the hot aggregate storage bins shall be such as to minimise segregation and loss of temperature of aggregate.

6

Hot bins shall be drawn and cleaned of material at the end of each day's operation.

5.13.6

Proportioning and Mixing

1

The heated ingredients together with the mineral filler and bitumen shall be combined in such a manner so as to produce a mixture which complies with the requirements of the Job Mix Formula. Plant settings, once established, shall not be changed without the approval of the Engineer.

2

Mineral filler, in a cool dry state, shall be proportioned into the mixer either with the aggregate or after the introduction of the bitumen to avoid loss of fines that may occur in dry mixing as a result of turbulence in the mixer.

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In batch type plants a dry mixing period of not less than four seconds shall precede the addition of the bitumen to the mix. Excess wet mixing shall be avoided. Wet mixing shall continue as long as it is necessary to obtain a thoroughly blended mix but shall not exceed 75 seconds nor be less than 30 seconds.

4

Once approved, mixing times shall not be altered unless so ordered or further approved by the Engineer.

5.14

HAULING EQUIPMENT

1

Vehicles used for the transport of aggregates or bituminous mix shall have tight, clean and smooth insulated metal bodies and shall be free from dust, screenings, petroleum oil and volatile or other mineral spirits which may affect the material being hauled. The vehicle metal bed shall, if required, be sprayed with a minimum amount of soapy water or lime solution to prevent the bituminous mix from adhering to the bed. After spraying, the truck shall be raised and thoroughly drained and no excess solution shall be permitted. Use of diesel or other solvents to spray in the truck bed is prohibited.

2

Provision shall be made for covering truck loads with canvas or other suitable material of such size that the bituminous mix is fully covered.

3

Any truck causing excessive segregation of material by its spring suspension or other contributing factors, or that shows oil leaks in detrimental amounts, or that causes undue delays, shall, upon the instruction of the Engineer, be removed from the work until such faults are corrected.

4

End dump trucks shall be equipped with chains on the tail gates for control when dumping the mix into the paving machine. Hauling trucks shall not be routed over wet or muddy access ways such that tires accumulate dirt that is deposited on the laying surface.

5

The Contractor shall provide an adequate number of trucks of such size, speed and condition to ensure orderly and continuous progress of the work all to the approval of the Engineer.

5.15

OTHER EQUIPMENT

5.15.1

Spreading and Finishing Equipment

1

The asphalt mixture shall be fed to the paver by end tipping of the truck or by means of a windrow elevator. The equipment for spreading and finishing the asphalt mixtures shall be of an approved mechanical, self-powered electronic controlled floating screed type, capable of spreading and finishing the mixture true to line, grade and required crown.

2

The pavers shall be self-propelled and equipped with hoppers and distributing screws of the reversing type to place the mixture uniformly in front of adjustable electronic controlled screeds. The pavers shall be so designed to allow a minimum paving width of 2 m, although paving in widths of less than 3 m will require the approval of the Engineer.

3

Pavers shall be equipped with such provisions and attachments to suit paving widths specified for road widening as well to as to suit paving on sloped sections. They shall be equipped with fast and efficient steering devices and shall have reverse as well as forward travelling speeds. The operational speed of the pavers shall be adjustable from 3 to 6 m/min in accordance with the instructions of the Engineer.

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The pavers shall employ mechanical devices as equalising runners, straight edge runners, evener arms or other compensating devices to maintain trueness of grade and to confine the edges of the pavement to true lines without the use of stationary side forms. The equipment shall include blending or joint levelling devices for smoothing and adjusting longitudinal joints between lanes. The assembly shall be designed and operated in such a manner that it will place the material at the required compacted thickness.

5

Electronic screeds shall include automatic feed controls to maintain a constant level of material along the full length of the screed, automatic grade control and automatic slope control. Unless waived by the engineer, on projects with smoothness (IRI) requirements, the paver shall carry minimum 9.0m long average beam equipped with an ultrasonic sensors capable of sensing a pavement section at several spatially separated spots. The automatic slope control shall be equipped with a proportioning manual override to enable smooth transition of changing slope rate. Automatic screed controls shall be approved by the Engineer before use.

6

Screeds shall be provided with devices for heating the screeds to the temperature required for the laying of the mixture without pulling or marring. Pavers shall also be provided with the standard attachable screed extensions. All screeds shall be of the vibrating type that permits material to be tamped into position.

7

The term "screed" includes any cutting, crowning or other physical action that is effective in producing a finished surface of the evenness and texture specified, without tearing, shoving, or gouging.

8

If, during construction, it is found that the spreading and finishing equipment in operation leaves in the pavement surface tracks or indented areas or other objectionable irregularities that are not satisfactorily corrected by scheduled operations, the use of such equipment shall be discontinued and other satisfactory spreading and finishing equipment shall be provided by the Contractor.

5.15.2

Rolling Equipment

1

Rolling equipment shall consist of vibratory steel-wheeled rollers, dead weight steel-wheeled rollers and pneumatic-tire rollers as required for proper compaction and finishing of the asphalt surface. Unless otherwise permitted, rollers shall be equipped with reversible or dual controls to allow operation both forward and backward with the operator always facing in the direction of movement.

2

Steel-wheeled rollers shall be two-axle tandem rollers or three-axle tandem rollers. These rollers shall be self-propelled and equipped with power units of not less than four cylinders and under working conditions shall develop contact pressures under the compression wheels of 45 to 65 kg/cm of width. Each two-axle roller shall have a minimum weight of 10,000 kg each and three-axle roller shall have a minimum weight of 13,000 kg. Vibrating steel-wheeled rollers shall have dual drums with a minimum weight of 7000 kg. Vibrating frequency shall be between 2000 and 3000 cycles per minute with individual controls for each tandem drum. Rollers shall be in good working condition and shall be equipped with a reversing clutch. Rollers shall be equipped with adjustable scrapers to keep the wheel surface clean and with efficient means of keeping them wet to prevent mixes from sticking. These surfaces shall have no flat areas or projections which will mark the surface of the asphalt courses. The three-axle rollers shall be equipped with a centre axle which may be operated either fixed or floating. The three-axle tandem roller shall be so constructed that when locked in a position

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for all treads to be in one plane, the roller wheels are held with such rigidity that, if either front or centre wheel is unsupported the other two wheels will not vary from the plane by more than 6 mm. All steel-wheeled rollers shall be in good condition and the Contractor shall furnish to the Engineer the manufacturer’s technical data for each roller and no roller shall be used except after approval of the Engineer. Pneumatic-tire rollers shall be self-propelled. The rollers shall be equipped with pneumatic tires of equal size and diameter which are capable of exerting varying average contact pressure. Pneumatic-tire rollers shall be in good condition and with enough ballast space to provide uniform wheel loading as may be required. The Contractor shall furnish to the Engineer charts or tabulations showing the contact areas and contact pressures for the full range of tire inflation pressures and for the full range of tire loading for each type and size compactor tire furnished and used in pneumatic-tire rollers. The total operating weight and tire pressure may be varied by the order of the Engineer to obtain contact pressures which will result in the required asphalt course density.

5.15.3

Liquid Asphalt Distributor

1

The liquid asphalt distributor truck shall be of the pressure type with insulated tanks. The use of gravity distributors will not be permitted. The distributor shall have pneumatic tires of such width and number that the load produced on the road surface shall not exceed 100 kg/cm tire width.

2

Spray bars shall have a minimum length of 2.4 m and shall be of the full circulating type. Spray bar extensions shall also be of the full circulating type. The spray bar shall be adjustable to maintain a constant height above the surface to be treated.

3

The spray bar nozzles shall be slotted and shall be of such design so as to provide a uniform unbroken spread of asphalt material on the surface. The valves shall be operated by levers so that one or all valves may be quickly opened or closed in one operation. The distributor shall be equipped with a hose and nozzle attachment to be used for spotting areas inaccessible to the distributor. The distributor and booster tanks shall be so maintained at all times as to prevent dripping of liquid asphalt material from any part of the equipment.

4

The distributor shall be equipped with devices and charts to provide for accurate and rapid determination and control of the amount of liquid asphalt material being applied and with a tachometer of the auxiliary wheel type reading speed in m/min. The spreading equipment shall be provided with a separate power unit for the pump or a variable displacement pump driven by a hydrostatic transmission so that a uniform application of liquid asphalt material, in 2 controlled amounts, may be made ranging from 0.15 to 5.0 kg/m . The distributor shall have satisfactory heating equipment and thermometers in order to provide the full range of application temperatures for the liquid asphalt material being used.

5

Before commencing the work and as required by the Engineer, the liquid asphalt distributor shall be checked and calibrated such that the rate of transverse spread or longitudinal spread shall not vary more than 10 % from the required rate of application.

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APPENDIX

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APPENDIX - ASPHALT WORKS........................................................................... 42

1.1

DEFINITIONS ........................................................................................................ 42

1.2

INTRODUCTION ................................................................................................... 44

1.3 1.3.2 1.3.3

SUPERPAVE DESIGN PARAMETERS ................................................................. 44 Traffic 44 Nominal Maximum Aggregate Size (NMAS) 45

1.4

SELECTION OF HMA PROPERTIES & REQUIREMENTS ................................... 46

1.5 1.5.2 1.5.3 1.5.4 1.5.5 1.5.6 1.5.7 1.5.8 1.5.9

OVERVIEW OF SUPERPAVE MIX DESIGN PROCESS....................................... 47 Step1: Selection of Materials 47 Step2: Selection of a Design Aggregate Structure (DAS) 48 Work Instructions of Step 2 Selection of DAS 50 Step 3: Selection of the Design Asphalt Content 51 Work Instruction of Step 3- Selection of DAC 52 Nmax and Ndes Verification 52 Step 4: Evaluation of the Strength and the Moisture Sensitivity of the Mixture 53 Work Instructions of Step 4 Evaluation of Strength and the Moisture Sensitivity 54

1.6 1.6.2 1.6.3

JOB MIX DESIGN PROPOSAL ............................................................................. 54 Acceptance of Job Mix Formula 55 Construction Quality Control: 56

1.7

REFERENCES ...................................................................................................... 57

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1

APPENDIX - ASPHALT WORKS

1.1

DEFINITIONS

1

Superpave: Is an abbreviation of Superior system consist the following steps:

Performing

Asphalt Pavement.

(a)

Performance-Based Asphalt Binder Grading System

(b)

Performance-Based Specifications of Materials & HMA.

(c)

Test methods and practices for material selection & mix design.

(d)

Performance prediction of HMA.

Superpave

Asphalt Binder Content (Pb): the percent by weight of asphalt binder in the total mixture.

3

Initial Trial Asphalt Binder (Pbi): the percent by weight of the asphalt binder in the total mixture for each trial blend in the selection of the Design Aggregate Structure (DAS).

4

Bulk Specific Gravity (G1, 2, to n; … Gsb, Gmb): the ratio of the weight in air of a unit volume of a permeable material (including both permeable and impermeable voids connected to the surface of the aggregate particle) at a stated temperature relative to the weight in air of an equal volume of gas-free distilled water at the stated temperature. This definition generally applies to individual aggregate stockpiles (Gl through Gn), the blended aggregate (Gsb, AASHTO T84, T85 and T100) or the compacted mix (Gmb, AASHTO T166 or T275).

5

Effective Binder Content (Pbe): the volume of the asphalt binder that is not absorbed into the aggregate but remains in the mixture to coat the aggregate particles.

6

Effective Specific Gravity (Gse): the ratio of the weight in air of a unit volume of a permeable material (excluding voids permeable to binder) at a stated temperature relative to the weight in air of an equal volume of gas-free distilled water at the stated temperature.

7

Maximum Specific Gravity (Gmm): the ratio of the weight of a given volume of voidless (Va=0) loose HMA at a stated temperature (usually 77 °F (25°C)) to a weight of an equal volume of gas-free distilled water at the same temperature (AASHTO T209).

8

Voids in Mineral Aggregate (VMA): It is the total space between the aggregate particles in the compacted paving mixture which includes 1) the air voids (Va) and 2) the effective binder volume . The VMA is defined as the volume of void space between the aggregate particles before adding the binder. Note: mineral aggregate is the aggregate which does not include any or organic material but it is the material that consists of minerals and compounds such as calcium, silicon, etc ….

9

Air Voids (Va): The total volume of the small pockets of air between the coated aggregate particles throughout a compacted paving mixture, expressed as percent of the bulk volume of the compacted paving mixture.

10

Voids Filled with Asphalt (VFA): the percentage portion of the volume of intergranular void space between the aggregate particles (i.e. VMA) that is occupied by the effective asphalt binder volume. It is expressed as the ratio of (VMA-Va) to the VMA.

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Volume of Absorbed Binder (Vba): the volume of binder absorbed into the aggregate (equal to the difference in aggregate volume when calculate with the bulk specific gravity and effective specific gravity).

12

Dust to Binder Ratio (P0.075/Pbe): ratio by weight of the percentage of the aggregate passing the 0.075 mm sieve (P200) to the effective binder content (Pbe).

13

Standard Axle: is 8.2 ton (18,000 lb) single axle with dual wheels; the center to center distance of dual wheels is 34.29 cm (13.5 in); the tire pressure is 0.517 MPa (75 psi).

14

ESAL's: is an abbreviation of Equivalent Single Axle Load. The equivalency factor is the number of repetition of the standard axle required to induce the same damage as the given axle. AASHTO Road Test has shown that an equivalent number of the standard axle can represent the damaging effect of the passage of an axle of any mass. This means that the ESAL is the number of applications of the standard axle that is equivalent in the damage to the pavement to an axle of any mass. The relationship is non-linear and is a fourth degree. For example, one application of a 16.2 ton single axle (36,000 lb twice as the standard axel) was found to cause damage equal to approximately sixteen applications of the standard axle; or one application of a 16.2 tons axle were required to cause the same damage or reduction in the pavement serviceability as sixteen applications of the standard axle. Also, one application of a 5.47 ton single axle (12,000 lb two thirds of the standard axel) was found to cause damage equal to approximately 0.2 applications of the standard axle; or five applications of a 5.47 tons axle were required to cause the same damage or reduction in the pavement serviceability as one applications of the standard axle.

15

Standard Sieves: Superpave standard sieve sizes are 50.0, 37.5, 25.0, 19.0, 12.5, 9.5, 4.75, 2.36, 1.18, 0.6, 0.3, 0.15 and 0.075 mm

16

Maximum Aggregate Size (MS): one standard size larger than the nominal maximum aggregate size (This definition applies only to Superpave mix design.)

17

Nominal maximum aggregate size (NMAS): one standard size larger than the first sieve that retains more than 10 percent of the aggregate (this definition applies only to Superpave mix design).

18

Nini, Ndes and Nmax: These are the number of gyrations of the gyratory compactor at three compaction levels simulating the construction traffic for N ini, the design traffic for Ndes and the maximum anticipated densification by the highest traffic for Nmax

19

Design Aggregate Structure (DAS): the aggregate blend meeting all Superpave requirements.

20

Design Asphalt Content (DAC): the percent by weight of the asphalt binder in the total mix selected at 4.0 % air voids in the mix meeting all Superpave requirements.

21

ePAVE3: is a user-friendly menu driven Excel program for the Superpave mix design system. It is a decision making program that includes all the computations, requirements and comparisons to design hot mix asphalt for a given project. ePAVE3 includes Superpave requirements based on the latest (to date) Asphalt Institute Superpave Mix Design – Superpave Series No. 2 (SP-2), third Edition 2001 and last edition of AASTO 2005 including M323 specification "Standard Practice for Designing Superpave HMA", and R35.

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Polymer: An organic substance that is originated from petroleum gases. It is the product of a complicated chemical process. The word “polymer” originally consists of two words “poly” which means numerous and “meros” which means parts; therefore, polymer means the substance with many parts. Polymers can be either copolymers or homopolymers. The most common polymers that are used to modify the asphalt binder for road applications are either “Elastomers” such as SBS or “Plastomers” such as EVA and Polyethylene.

23

Neat and Polymer Modified Binder (PMB): neat binder is a black or dark brown material produced from refining of petroleum oil in petroleum refineries. The polymer modified binder is a neat binder that has been modified by the addition of polymers. The purpose of blending polymer and other chemical substances is to improve the neat binder Rheological properties to achieve the Performance Grade (PG) requirements of Superpave grading system. This process is complicated and involves accurate control of the process parameters such as mixing mechanism, temperature, time, concentration and blending details

1.2

INTRODUCTION

1

This guide, which is based on ref. 1, should be considered as a guide to assist Engineers, consultants and contractors to design Hot-Mix Asphalt (HMA) using Superpave system. It is the contractor full responsibility to select the applicable parameters for his project in liaison with the Engineer and LSA. This system was developed using the last editions of the Asphalt institute “Superpave Mix Design”, 2001, and AASHTO, 2005.

1.3

SUPERPAVE DESIGN PARAMETERS

1

Before starting any HMA design using Superpave system for any project, the mixture and materials specifications and requirement must be identified. Superpave mix design system requires three parameters in order to design a mix. These Parameters are:

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Expected traffic volume in the project.

(b)

Nominal Maximum Aggregate Size (NMAS).

(c)

Location of the project.

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(a)

The contract documents shall specify and define the design parameters for the project. A brief description of the basic design parameters is given in the following sections.

1.3.2

Traffic

1

In Superpave, Traffic is defined as the total anticipated project level equivalent single axle load (ESALs) on the design lane for a period of 20 years. To simplify the design process, traffic class designations for each ESALs that appears in the Superpave system is specified herein. If the contract documents do not specify the ESALs applicable to the project, the Engineer can use the information provided in Table 1 to select the traffic classes needed to establish Superpave criteria.

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Table 1 ESAL and Traffic Designation Class Designation

ESALs Range

Applications

Less than 300,000

Agricultural roads with light traffic , local and city streets without trucks

L

Light

300,000 to 3 million

Agriculture, Feeder and collector roads

M

Medium

3 million to 10 million

Main roads and city streets

H

Heavy

10 million to 30 million

Highways and Expressway

Very Heavy

More than 30 million

Heavily trafficked highways, industrial areas ...

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VH

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Very Light

VL

Nominal Maximum Aggregate Size (NMAS)

1

Six Nominal Maximum Aggregate Sizes (NMAS) are identified in the Superpave system; these are 37.5, 25.0, 19.0, 12.5, 9.5 and, 4.75 mm as specified in Table 2.

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Table 2 SUAERPAVE Standard NMAS mixtures Maximum Size (MS)

37.5 mm

50.0 mm

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Nominal Maximum Size (NMAS)

37.5 mm

19.0 mm

25.0 mm

12.5 mm

19.0 mm

9.5 mm

12.5 mm

4.75 mm

9.5 mm

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25.0 mm

The selection of design NMAS for a specific layer is based on the general rule that the NMAS does not exceed half to one-third (1/2 to 1/3) the layer thickness. If the contract documents do not specify the NMAS for the project, the Engineer can use the above criteria and the information provided in Table 3 to select the NMAS of the project. Table3 Recommended NMAS for Different Layer Types Layer

Recommended NMAS

Sand Mix

4.75 mm

Wearing coarse

9.5 or 12.5 or 19.0 mm

Base coarse

25.0 or 37.5 mm

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1.4

SELECTION OF HMA PROPERTIES & REQUIREMENTS

1

Based on the specified design parameters (Traffic in ESAL, NMAS, geographic location of the project and location of required layer to be designed), the mixture properties and requirements can be selected. These properties include compaction level, which can be identified from Table 4 and the properties of HMA, which can be identified from Table 5. Table 4 Superpave Gyratory Compactive Effort (SGCE)

Ndes

Nmax

VL (< 0.3)

6

50

75

L (0.3 to 3)

7

75

M to H (3 to < 30)

8

100

VH (> 30)

9

.

Nini

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Gyrations

Traffic (ESAL, million)

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115

205

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125

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Table 5 Superpave Criteria for the Mixture Design

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Criteria

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Voids in the Mineral Aggregate (VMA %min) Important Note: mixtures with VMA greater than 2.0% above the minimum should be avoided.

Voids Filled with Asphalt, %

VL

Ninitial

< 91.5

L

M

< 90.5 96.0

Nmax

< 98.0

Nominal Maximum Size, mm

H < 89.0

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Required Density (% Gmm)

Traffic Class Designation (or ESAL, million)

37.5

11.0 %

25.0

12.0 %

19.0

13.0 %

12.5

14.0 %

9.5

15.0 %

4.75

16.0%

37.5

64-80

64-78

64-75

25.0

67-80

65-78

65-75

19.0

70-80

65-78

65-75

12.5

70-80

65-78

65-75

9.5

70-80

65-78

65-75

4.75

70-80

65-78

65-75

VH

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Page 47

Traffic Class Designation (or ESAL, million)

Criteria

VL

L

M

H

VH

Dust Proportion (DP) Ratio, if gradation line is above the PCS

For all NMAS DP = 0.6 - 1.2, for NMAS 4.75 DP = 0.9 - 2.0

Dust Proportion (DP) Ratio, if gradation line is below the PCS.

0.8 – 1.6

Average Indirect Tensile Strength of the Dry Set in the Moisture Sensitivity Evaluation, kPa

Report

OVERVIEW OF SUPERPAVE MIX DESIGN PROCESS

1

According to SP-2 and AASHTO R 35, there are four major steps in the volumetric mix design process. These steps consist of

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1.5

Material Selection, (Type of binder and aggregate).

(b)

Selection of Design Aggregate Structure (DAS).

(c)

Selection of Design Asphalt Content (DAC).

(d)

Evaluation of Strength and Moisture Sensitivity of the Mix.

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Step 4: Strength and Moisture Sensitivity Evaluation

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(a)

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Step 3: Selection of DAC

Step 2: Selection of DAS

Step 1: Selection of Materials (Binder, Aggregate and Modifiers)

2

ePAVE3 program should be used to assist in the preparation of the mix design and obtain the mix deign report summarizing the computations and test results. ePAVE3 mix design report shall be submitted to the Engineer for acceptance then to LSA for approval.

1.5.2

Step1: Selection of Materials

1

This process includes the selection of the asphalt binder PG (ABPG) and the aggregates that meet all Superpave criteria.

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The selection of ABPG necessitates an understanding of the climatic condition (e.g., temperature) in which the pavement will be constructed and operated. This includes both the average seven-day maximum high temperature and the single-day minimum low temperature for the last twenty years and the latitude for that particular geographic location.

3

To account for traffic volume and speed or both, adjustments should be made to the selected ABPG using AASHTO M332.

4

The requirements of the aggregate are selected based on the anticipated traffic and position of the layer within the pavement. The quality criteria for Superpave aggregates are summarized in Table 6. In order to be used in Superpave mixtures, the aggregate blends must meet two sets of criteria known as source properties and consensus properties. Source property requirements apply to each aggregate stockpile, but consensus properties apply to the combined blend of multiple stockpiles. The consensus properties are mandatory for all Superpave aggregate blends while; source properties are left to the contracts.

(b)

Coarse Aggregate Angularity, (CAA) Fine Aggregate Angularity, (FAA) Flat and Elongated Particles (F&E) Sand Equivalent, (SE)

ASTM D5821 AASHTO T304-Method A ASTM D4791 AASHTO T176

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i. ii. iii. iv.

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Consensus Properties (Superpave Requirements):

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Source Properties (QCS Requirements):

AASHTO T96 AASHTO T104 AASHTO T112

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Toughness Soundness Clay lumps & friable particles Others.

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QCS General Specifications, source properties are considered specific to the geology of a particular region and the experience with local materials.

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Table 6 Superpave Criteria for Aggregate Consensus Properties

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Traffic Class Designation (or ESAL, million)

Layer Depth, mm

Property

H(10to 100 mm

50

45

45

40

40

SE, % min

10

10

10

10

-

F&E, % max

m

VH(>30)

CAA, % min. FAA, % min.

Note: CAA values (X/Y) denotes that X% of the coarse aggregate has one fractured face and Y% has two or more fractured faces

1.5.3

Step2: Selection of a Design Aggregate Structure (DAS)

1

Once a group of aggregates has been identified, these aggregates are combined at different percentages to produce at least three distinct blends conforming to Superpave gradation requirements presented in Table 7 according to designed NMAS.

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Table 7 Aggregate Gradation Requirements – Control Points Nominal Maximum Aggregate Size, mm - Control Point (Percent Passing) Sieve Size

25.0 mm

Min.

Max.

50.0 mm

100

-

37.5 mm

90

25.0 mm

Min.

19.0 mm

Max.

Min.

Max.

12.5 mm Min.

9.5 mm

Max.

Min.

Max.

4.75 mm Min.

Max.

-

-

-

-

-

-

-

-

-

100

100

-

-

-

-

-

-

-

-

-

-

90

90

100

100

-

-

-

-

-

-

-

19.0 mm

-

-

-

90

90

100

100

-

-

-

-

-

12.5 mm

-

-

-

-

-

90

90

100

100

-

100

-

9.5 mm

-

-

-

-

-

-

-

90

4.75 mm

-

-

-

-

-

-

-

-

2.36 mm

15

41

19

45

23

49

28

1.18

-

-

-

-

-

-

-

0.075 mm

0

6

1

7

2

8

2

.l. l

.

-

100

95

100

-

90

90

100

58

32

67

-

-

-

-

-

30

60

10

2

10

6

12

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90

Primary Control Sieve (PCS) shown in Table 8 can be used to determine if the nominated blend is fine or coarse gradation. If the gradation line passes below the PCS, it is considered as coarse graded and it is considered fine gradation if the line passes above the PCS.

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37.5 mm

12.5mm

19mm

25mm

37.5 mm

Nominal Maximum Size

2.36mm

2.36mm

4.75mm

4.75mm

9.5mm

Primary Control Sieve Size

47%

47%

40%

47%

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9.5mm

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Table 8 Gradation Classification - PCS Control Points

39%

%Passing PCS

Typically, three blends are developed ranging from the coarse to the fine side of the Superpave control points for a given nominal maximum size (note: control points and PCS differ for different NMAS). After selecting a blend (i.e. from the three trial blends), the aggregate consensuses properties must be confirmed to meeting Superpave criteria by actual testing.

4

The most difficult part of designing an aggregate structure is the creation of the VMA necessary to meet the volumetric criteria. The procedure is typically a trial and error process; however, there are some general guidelines that will assist in obtaining the VMA. The following recommendations may be tried to increase VMA:

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(a)

Move the gradation away from the maximum density line;

(b)

Use highly angular particles;

(c)

Use particles with a rough surface texture;

(d)

Reduce the percent of natural sand and use more percent of the crushed sand;

(e)

Reduce the amount of P200 used in the HMA; and

QCS 2014

(f)

Section 06: Roadworks Part 05: Asphalt Works

Page 50

Use S-shaped gradation curve.

5

A good design aggregate structure is one that is economical and meets Superpave volumetric criteria.

1.5.4

Work Instructions of Step 2 Selection of DAS

1

To select the design aggregate structure, do the following: Obtain representative hot bin specimens from the plant.

(b)

Determine the consensus properties, water absorption, bulk and apparent specific gravities for each aggregate fraction.

(c)

Grade the specimens using Superpave standard sieve set.

(d)

Input the values from two and three into ePAVE3 or combine manually. to develop three blends that meet the Superpave criteria (i.e. within the control points for the design NMAS)

(e)

Estimate the initial trial asphalt binder content using ePAVE3 or by using formulas presented in ASSHTO R35.

(f)

For unmodified asphalt binders, determine the mixing and compacting temperature for the proposed asphalt binder as follows:

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(a)

Measure the rotational viscosity using AASHTO T316 or ASTM D4402 at 135 C and 165 C.

(ii)

Input the measured viscosities into ePAVE3. ePAVE3 will generate the viscositytemperature relationship.

(iii)

From the graph, determine:

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(i)

The mixing temperature at a rotational viscosity of 0.17 ± 0.02 Pa.s.

3

The compaction temperature at a rotational viscosity of 0.28 ± 0.03 Pa.s.

For modified asphalt binders, determine the mixing and compaction temperature in accordance with one of the methods presented in NCHRP 648.

(h)

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(g)

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2

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Prepare enough hot mix to make two 150 mm (or 100 mm) gyratory specimens and two specimens to measure the Maximum Specific Gravity (Gmm) for each blend at the estimated initial trial asphalt content. Note: small specimen size of 100 mm is used for mixes having NMAS of 19.0 mm or below.

(i)

Leave the mix in the oven for two hours at the compaction temperature then compact two 150.0 mm (or 100 mm) specimens for each blend using the Superpave Gyratory Compactor (SGC) to Ndes according to AASHTO T312 (minimum number of specimens is six).

(j)

For the specimens that were compacted to Ndes, measure the bulk specific gravity (Gmb), and obtain the specimen height at Nini and Ndes from the gyratory compactor that is automatically recording the specimen height for each gyration.

(k)

Measure the Maximum Specific Gravity (Gmm) for two specimens for each blend according to ASSHTO T209.

(l)

Input the measured values into ePAVE3. ePAVE3 will perform the computations, display results, and check them against the criteria of the project.

QCS 2014

(m)

Section 06: Roadworks Part 05: Asphalt Works

Page 51

Check the results given by ePAVE3 for the three blends and select the most conforming blend as the DAS; in case none of the three blends meets Superpave criteria, repeat the design by developing additional aggregate blends from the same source ; if the criteria is not met change the sources.

Preparation of the binder and aggregate mixtures for the gyratory compactor (SGC) should be timed such that a minimum of 20 minutes is allowed between batches. Batched specimens should be conditioned in a closed draft oven for a minimum of 2 hours ± 5 minutes prior to compacting them in the SGC. Refer to AASHTO R30 for more details. The short time oven aging is performed to permit time for the aggregate to absorb the binder. All specimens including those for SGC and maximum specific gravity tests, should be cured the same amount of time.

1.5.5

Step 3: Selection of the Design Asphalt Content

1

The selected aggregate blend (DAS) will then be mixed with four different proportions of the binder as follows:

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2

Estimated asphalt binder content corrected to give 4.0% air voids.

(b)

Estimated asphalt binder content corrected to give 4.0% air voids minus 0.5 %.

(c)

Estimated asphalt binder content corrected to give 4.0% air voids plus 0.5 %.

(d)

Estimated asphalt binder content corrected to give 4.0% air voids plus 1.0 %.

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(a)

A sufficient amount of the proposed aggregate blend will need to be prepared to permit two specimens to be compacted in the SGC according to Superpave system for gyrations equal (Ndes), and the maximum specific gravity to be determined at each of the four binder contents.

3

Preparation of the binder and aggregate mixtures for the SGC specimens should be timed such that a minimum of 20 minutes is allowed between batches. Batched specimens should be conditioned in a closed draft oven for a minimum of 2 hours ± 5 minutes prior to compacting them in the SGC. Refer to AASHTO R30 for more details. The short time oven aging is performed to permit time for the aggregate to absorb the binder. All specimens including those for SGC and maximum specific gravity tests, should be cured the same amount of time.

4

The procedure used for design in the laboratory will need to closely match the field conditions at the time of construction. Failure to consistently test the materials at the same time interval may result in a highly erratic all specific gravity values and possibly failure to achieve the required VMA. After the necessary testing has been accomplished, the calculation of the volumetric parameters can begin. The averaged results of the various volumetric calculations need to be plotted relative to the corresponding binder content. The design binder content is selected as that which satisfies the specified volumetric criteria at 4 percent air voids (refer to AASHTO R35 for more details).

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1.5.6

Work Instruction of Step 3- Selection of DAC

1

To select the deign asphalt content, do the following: After selecting the most conforming blend (DAS) from step 2, prepare enough hot mix to make two 150 mm (or 100 mm) gyratory specimen and two specimens to measure the Maximum Specific Gravity (Gmm) for four trial mixes using DAS of the selected blend and four asphalt binder levels as specified in item (5.5.4) herein.

(b)

Compact two 150.0 mm (or 100 mm) specimens for each mix using the Superpave Gyratory compactor to Ndes according to AASHTO T312 (total number of specimens are eight)

(c)

For the specimens that were compacted to Ndes, measure the bulk specific gravity (Gmb), and obtain the specimen height at Nini and Ndes from the gyratory compactor that is automatically recording the specimen height for each gyration.

(d)

Input the measured values into ePAVE3. The program will perform all calculations, produce the results and compare the results with required mix design properties for the project.

(e)

ePAVE3 will generate the design curves, these are: % air voids vs. asphalt content.

(ii)

% VMA vs. asphalt content.

(iii)

% VFA vs. asphalt content.

(iv)

% Gmm at Nini vs. asphalt content.

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(i)

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(a)

From the percentage, air voids vs. asphalt content curve determine the design asphalt content (DAC) which corresponds to 4.0 % air voids.

(g)

Use the %VMA vs. asphalt content, %VFA vs. asphalt content % and %Gmm vs. asphalt content graphs to obtain the VMA, FVA and the % Gmm @ Nini values at the design asphalt content.

(h)

Input the DAC, %VMA, %VFA % and Gmm @ Nini into the appropriate cells in ePAVE3. ePAVE3 will perform the computations, display results, and check them against the criteria of the project.

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(f)

(i)

If the mix properties at the design asphalt content conform to the Superpave criteria then go to the Nmax verification; if not then analyze, evaluate and modify the design as needed until the mix properties at the design asphalt content (DAC) conform to the criteria.

1.5.7

Nmax and Ndes Verification

1

After conforming to Superpave criteria, then do the Nmax verification as follows: (a)

Prepare enough hot mix at the selected gradation from (DAS) step 2 and the selected design asphalt content (DAC) from step 3, to compact two 150 mm (or 100 mm) specimens and two Gmm specimens.

(b)

Compact the specimens to Nmax using the gyratory compactor according to AASHTO T312.

(c)

Measure the Gmb at Nmax for the two specimens that were prepared using SGC and measure the Gmm.

QCS 2014

Page 53

(d)

Input the values into ePAVE3, which will perform the computations, provide the results, and compare them with the Superpave criteria.

(e)

Check the results of ePAVE3, if acceptable then the design is concluded if not then redesign the mix.

After conforming that the mix properties at Nmax meet Superpave criteria, then do the Ndes verification as follows: Prepare enough hot mix at the selected gradation from (DAS) step 2 and the selected design asphalt content (DAC) from step 3, to compact two 150 mm (or 100 mm) specimens and two Gmm specimens.

(b)

Compact the specimens to Ndes using the gyratory compactor according to AASHTO T312.

(c)

Measure the Gmb at Ndes for the two specimens that were prepared using SGC and use the Gmm from the previous step. Obtain the specimen height at Ndes and Nini from the gyratory compactor that is automatically recording the specimen height for each gyration.

(d)

Input the values into ePAVE3, which will perform the computations, provide the results, and compare them with the Superpave criteria.

(e)

Check the results of ePAVE3, if acceptable then the design is concluded if not then redesign the mix.

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Section 06: Roadworks Part 05: Asphalt Works

Step 4: Evaluation of the Strength and the Moisture Sensitivity of the Mixture

1

The identification of the combination of a design aggregate structure and design binder content is now complete. The mixture now needs to demonstrate that it is capable of resisting the moisture induced damage. This evaluation is performed in accordance with AASHTO T283.

2

Moisture sensitivity evaluation requires that a total of six specimens consisting of the proposed aggregate blend and binder at the design binder content, be prepared and compacted to approximately 7 ± 0.5% air voids. This group of specimens is divided into two subsets with three of the specimens being identified as the control specimens and the other three being identified as conditioned specimens.

3

At the end of the conditioning period all of the specimens are loaded to failure in indirect tension. Report the average Indirect Tensile Strength (IDT) of the dry subset in the mix design report (see Table 5); and if the ratio of the average strength of the conditioned subset to the control subset (retained strength) is more than or equal to 80% , then the mixture passes the test. If the retained strength is less than 80%, then the mixture fails. The retained strength can be increased by substituting part of the material finer than 0.075 mm by mineral admixtures or by using chemical anti-stripping agents. Prepare another six (6) specimens and test them as previously described. If this procedure does not improve the retained strength to more than 80%, then the design process should be repeated using different source.

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1.5.8

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Section 06: Roadworks Part 05: Asphalt Works

Page 54

1.5.9

Work Instructions of Step 4 Evaluation of Strength and the Moisture Sensitivity

1

To check the Strength and the moisture sensitivity of the designed mix, do the following: Prepare enough hot mix to make six 150 mm (or 100 mm) gyratory compactor specimens using the selected gradation (DAS) and the design asphalt content (DAC).

(b)

Use the Nmax verification densification data to identify the number of gyrations required to achieve 7.0 ± 0.5% % air voids (i.e. %Gmm = 92.5 to 93.5 %).

(c)

Compact six 150.0 mm (or 100 mm) specimens using the Superpave Gyratory Compactor according to AASHTO T312 compactor (total number of specimens are six) to a number of gyrations that will provide approximately 7.0 ± 0.5 % air voids.

(d)

Use ASSHTO T283 to test the six specimens.

(e)

Input the measured values into ePAVE3. ePAVE3 will perform the computations and provide the results and compare them with the Superpave criteria

(f)

Check the results given by ePAVE3. Report the average IDT of the Dry group in the mix design report (see Table 5). If the ratio of the average IDT of the conditioned subset to the control subset is 80% or more, then the mixture passes the test if not consider redesigning the mix and use some additives.

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(a)

JOB MIX DESIGN PROPOSAL

1

A proposed Job Mix Formula (JMF) shall be formulated by the Contractor and submitted to the Engineer and LSA for approval. The JMF shall be prepared by the Contractor in precise compliance with Superpave system. The Contractor shall select his sources of aggregate and bituminous material and, after sufficient quantities have been stockpiled or are available for use, obtain representative specimens of the materials and test to determine if they conform to the requirements of the specifications.

2

Before producing bituminous concrete mixtures, the Contractor shall submit in writing to the Engineer, detailed information for each mix which he proposes to furnish. The information shall include, but not be limited to the following:

The source(s) of the aggregate for each mix.

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(b)

Copy of mix certificate approval obtained from LSA.

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(a)

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(c)

Pertinent test data and a written certification that the aggregates conform to all of the quality requirements specified herein and in section 5.2.

(d)

Type of Asphalt modifier intended to be used in the project. The Asphalt binder modifier shall be an approved modifier; along with the Certificate of Conformity of the modified asphalt binder to the required grade according to the Superpave Performance Based Grading System.

(e)

Pertinent test data on the type and properties of the asphalt binder, modified asphalt binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.

(f)

Superpave mix design report in ePAVE3 format.

(g)

The type and location of plant to be used for mixing each mix.

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Page 55

Type of Asphalt modifier intended to be used in the project. The Asphalt binder modifier shall be an approved modifier; along with the Certificate of Conformity of the modified asphalt binder to the required grade according to the Superpave Performance Based Grading System.

(i)

Pertinent test data on the type and properties of the asphalt binder, modified asphalt binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.

(j)

Superpave mix design report in ePAVE3 format.

(k)

The type and location of plant to be used for mixing each mix.

(l)

The proposed beginning date for producing bituminous concrete mixtures.

(m)

Any other support data and information special to the project (e.g. technical data sheets of a polymer in case it was used).

.

(h)

The Engineer shall be provided access to the materials sampling and testing operations at all times.

4

At the same time that the above information is provided, the Engineer shall obtain one hundred (100) kilogram specimens of each individual aggregate size, eight (8) liters of bituminous material and, when used, sufficient quantities of the mineral filler and the chemical admixture/asphalt modifier to complete two (2) proposed mix design checks, all representing the materials which the Contractor proposes to furnish. The final job mix formula shall be made by using hot-bins aggregate.

1.6.2

Acceptance of Job Mix Formula

1

The Engineer shall review the JMF to determine that it contains all required information. If it does not contain all required information, it shall be returned within seven (7) days to the Contractor for further action and resubmission by the Contractor.

2

If the proposed JMF contains all required information but fails to meet all of the requirements specified, it shall not be accepted by the Engineer and will be returned to the Contractor within fourteen (14) days. The Contractor shall prepare and submit to the Engineer a new JMF conforming to the requirements specified and propose a new date for beginning production of the bituminous mixtures.

3

When the Engineer is satisfied that the JMF proposed by the Contractor conforms to all the requirements of the specifications, he shall order the Contractor to construct a minimum of two hundred (200) meter long field test strip; but, not exceeding one day's production. The test strip is used for three purposes:

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(a)

To check the contractor ability to produce the approved mix within tolerances.

(b)

To check the contractor ability to construct and compact the mix to satisfy job specifications.

(c)

To check the riding quality according to project specifications.

4

The Engineer shall evaluate the test strip as to its constructability and compactability and the mix for conformance to the laboratory tested JMF within the tolerances listed in Table 9. Five (5) specimens shall be obtained from the test strip and tested.

5

If the Engineer is not satisfied with the results of the test strip, he shall state his objections in writing and request a revised JMF and a new test strip.

QCS 2014

Section 06: Roadworks Part 05: Asphalt Works

Page 56

When the Engineer is satisfied that the JMF proposed by the Contractor conforms to all requirements of the specifications and the test strip results are acceptable, he will issue written acceptance to the Contractor to begin producing the proposed mixes. Production of bituminous concrete mixtures shall not begin until the Engineer has given written acceptance of the Job Mix Formula.

7

Acceptance of the JMF by the Engineer does not relieve the Contractor of his obligation to produce bituminous concrete mixtures conforming to all specified requirements.

1.6.3

Construction Quality Control:

1

Testing to control the quality of bituminous concrete mixtures produced shall be the responsibility of the Contractor.

2

For each class of bituminous concrete produced and each day's production, the Contractor shall perform one (1) complete Superpave analysis at Ndes including gradation and asphalt binder content, air voids, %VMA, %VFA, DP ratio, Indirect tensile strength on a specimen obtained from the discharge gate or hauling vehicle. In addition, the Contractor shall evaluate on a weekly basis the strength and moisture sensitivity of the mix from a specimen obtained from the discharge gate or hauling vehicle.

3

No mixture conditioning is required when assurance testing on plant-produced mixture.

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quality

control

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conducting

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Table 9 Superpave Job Mix Formula Tolerances for HMA Plant Mix

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Mix Composition Property

o

Asphalt Binder Content (Pb)

et it

Gradation Passing 4.75 mm and Larger Sieves Gradation Passing 2.36mm to 150μm Sieve

Tolerance Limit ±0.40 ±5 ±4 ±1.2

Air Voids (Va)

±1.3

Voids in Mineral Aggregate (VMA)

±1.5

m

Gradation Passing 75μm Sieve

Field Density

92 to 94 (%Gmm)

or

quality

QCS 2014

Page 57

REFERENCES Hot Asphalt Mix Design System Using Superpave System Detailed in Asphalt Institute SP-2 and the AASHTO 2005 Standards – MOT – Saudi Arabia, 2006.

2)

AASHTO M323: Standard Specification for Superpave Volumetric Mix Design.

3)

(NCHRP) Report 567: Volumetric Requirements for Superpave Mix Design.

4)

(NCHRP) Report 409: Quality Control and Acceptance of Superpave-Designed Hot Mix Asphalt.

5)

(NCHRP) Report 539: Aggregate Properties and the Performance of SuperpaveDesigned Hot-Mix Asphalt.

6)

(NCHRP) Report 513: Simple Performance Tester for Superpave Mix Design.

7)

(NCHRP) Report 648: Mixing and Compaction Temperatures of Asphalt Binders in Hot-Mix Asphalt.

8)

AASHTO T320: Standard Method of Test for Determining the Permanent Shear Strain and Stiffness of Asphalt Mixtures Using the Superpave Shear Tester (SST).

9)

AASHTO T321: Standard Method of Test for Determining the Fatigue Life of Compacted Hot-Mix Asphalt (HMA) Subjected to Repeated Flexural Bending.

10)

AASHTO T322: Standard Method of Test for Determining the Creep Compliance and Strength of Hot-Mix Asphalt (HMA) Using the Indirect Tensile Test Device.

11)

AASHTO T340: Standard Method of Test for Determining the Rutting Susceptibility of Hot Mix Asphalt (APA) Using the Asphalt Pavement Analyzer (APA).

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1.7

Section 06: Roadworks Part 05: Asphalt Works

END OF PART

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 1

CONCRETE ROAD PAVEMENTS .......................................................................... 3

6.1 6.1.1 6.1.2 6.1.3

GENERAL REQUIREMENTS .................................................................................. 3 Scope 3 References 3 Quality Control of Concrete Strength 4

6.2 6.2.1 6.2.2 6.2.3

TRIAL LENGTH ....................................................................................................... 5 General Requirements for Trial Length 5 Assessment of Trial Length 6 Approval and Acceptance of Trial Length 7

6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8 6.3.9 6.3.10 6.3.11 6.3.12 6.3.13 6.3.14 6.3.15 6.3.16 6.3.17 6.3.18 6.3.19 6.3.20 6.3.21 6.3.22 6.3.23 6.3.24 6.3.25 6.3.26 6.3.27 6.3.28 6.3.29 6.3.30 6.3.31 6.3.32 6.3.33 6.3.34 6.3.35 6.3.36

REQUIREMENTS FOR PAVEMENT QUALITY CONCRETE .................................. 7 Materials and Mix Designs for Pavement Quality Concrete 7 Workability of Pavement Quality Concrete 7 Trial Mixes 8 Separation Membrane 8 General Requirements for Steel Reinforcement 8 Jointed Reinforced Concrete Slabs 9 Continuously Reinforced Concrete Slabs (CRCP or CRCR) 10 General Requirements for Transverse Joints 10 Transverse Contraction Joints 11 Transverse Expansion Joints 11 Transverse Warping Joints 11 Transverse Construction Joints 11 General Requirements for Longitudinal Joints 12 Longitudinal Construction Joints 13 Dowel Bars 13 Joint Grooves 16 Groove Formers and Bottom Crack Inducers 17 Joint Filler Board 18 Preparation and Sealing of Joint Grooves 18 Sealing with Applied Sealants 19 Sealing with Compression Seals 20 Joint Seals 21 Joints at Manhole and Gully Slabs 21 Inspection of Dowel Bars 22 Side Forms, Rails and Guide Wires 22 Delivery, Storage and Batching of Concreting Materials 23 Mixing Concrete 24 Transport and Delivery 24 General Requirements for Construction by Machine 24 Construction by Fixed Form Paving Machines 25 Construction by Slip-Form Paving Machine 26 Construction by Small Paving Machines or Hand Guided Methods 26 Surface Textures 28 Strength 29 Trial Mixes 29 Trial Length 29

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Section 06: Road Works Part 06: Concrete Road Pavements

Page 2

Surface Finish

30

6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8 6.4.9 6.4.10 6.4.11 6.4.12 6.4.13

REQUIREMENTS FOR CEMENT BOUND MATERIALS ....................................... 30 General Requirements for Cement Bound Materials 30 Batching and Mixing 31 Transporting 31 Laying 31 Compacting 32 Curing 32 Preliminary Trial 33 Cement Bound Material Category 1 (CBM1) 33 Cement Bound Material Category 2 (CBM2) 34 Cement Bound Material Category 3 (CBM3) 34 Cement Bound Material Category 4 (CBM4) 34 Testing of Cement Bound Materials 35 Special Requirements for Cement Bound Materials 35

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6.3.37

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Page 3

6

CONCRETE ROAD PAVEMENTS

6.1

GENERAL REQUIREMENTS

6.1.1

Scope

1

This part of the specification covers the; materials, mix designs, production and laying of pavement quality concrete, lean mix concrete and cement bound materials.

2

Related Sections and Parts are:

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This Section Part 3 ............... Earthworks Part 4 ............... Unbound Pavement Materials Part 5 ............... Asphalt Works

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Section 5 - Concrete

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Part 16 ............ Miscellaneous - Pavement Quality Concrete References

1

The following standards are referred to in this part of the specification

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6.1.2

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BS 1377: Part 9 ..........Methods of testing soils – in-situ tests BS 1881...................... Methods of testing concrete Hot applied joint sealants for road pavements

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BS 2499 & BS EN 14188

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BS 1924: Part 1 & 2.... Stabilised materials for civil engineering purposes BS 2752...................... Chloroprene rubber compounds

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BS 3900: Part F12 ...... Determination of resistance to neutral salt spray BS 3963...................... Method for testing the performance of concrete mixers

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BS EN ISO 11600 ...... Two part polysulphide sealants

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BS 4449...................... Reinforcing bars BS 4482...................... Cold drawn steel wire for reinforcing concrete

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BS 4483...................... Reinforcing mesh BS 5212: Part 1 & 2.... Cold applied joint sealants for concrete pavements BS EN 206 & BS 8500

Supply of concrete

BS 7542...................... Methods for test of curing compounds for concrete BS 812........................ Testing methods for aggregates

ASTM D3406 .............. Specification for joint sealant - hot applied elastomeric types ASTM 7116 ................ Specification for joint sealant - hot applied elastomeric types (jet fuel resistant) ASTM D2628-91......... Specification for preformed joint seals DTP ............................ Manual of contract documents for highway works -Volume 1 specification for highway works

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Page 4

6.1.3

Quality Control of Concrete Strength

1

Sampling and testing for, and compliance with the specified characteristics strength of designed mixes shall be in accordance with BS EN 206 & BS 8500, except that it shall be at the following rates of sampling and testing and meet the following requirements: (a)

Concrete cubes of the appropriate size shall be made, cured and tested in accordance with BS 1881 respectively from concrete delivered to the paving plant, each group being from a different delivery of concrete. At least 3 cubes shall be made per group 2 for each 600 m of concrete slab and not less than 6 groups shall be made each day, 2

for each type of mix. For areas less than 600 m , at least 4 cubes shall be made for 2

each 100 m or less. This rate of sampling and testing may be reduced at the Engineer's discretion.

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2

For areas of 600 m or more, one cube shall be tested in compression at 7 days and

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the other two at 28 days after mixing. Groups of four consecutive results at 28 days shall be used for assessing the strength for compliance with BS EN 206 & BS 8500. 2 For areas less than 600 m , two cubes shall be tested at 7 days and two tested at 28

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days and assessed in accordance with BS EN 206 & BS 8500. The ratio R between 7 and 28 day strengths shall be established for the mix to be used in the slab by testing pairs of cubes at each age on at least six batches of the proposed mix or it shall be quoted by the supplier of the concrete. The average strength of the 7 day pair of cubes shall be divided by the average strength of the 28day pair of cubes for each batch and the ratio R shall be the average of these six values. The ratio R shall be expressed to three decimal places.

(d)

If during the construction of the trial length or during normal working, the average value of any 4 consecutive 7 day test results falls below the strengths required then the cement content of the concrete shall be increased by 5 % by mass or by an amount

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(c)

The values in columns 3 and 4 of Table 6.1 may only be used with the permission of the Engineer when sufficient test results on trial mixes for calculating the ratio are not available. Once sufficient results are available from normal working the ratio R shall be calculated from the results available on Site.

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agreed by the Engineer. The increased cement content shall be maintained at least until the four corresponding 28-day tests have been assessed. If the cement content is increased, the concrete mix shall be adjusted to maintain the required workability.

(f)

To assess the time for use of a concrete slab by traffic, the strength development rate may be predetermined by trial mixes. Alternatively pairs of cubes shall be made for 2 each 600 m or less and stored alongside the pavement in containers or in such a way that their sides are well insulated. If thermal insulation is used for accelerated curing the cubes shall be similarly insulated. Pairs of cubes shall be tested at intervals decided by the Engineer. Tests for compliance with the specified strength shall be made in the normal way.

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Section 06: Road Works Part 06: Concrete Road Pavements

Page 5

Table 6.1 7 Day Cube Strength

All Mixes, R available

PC Mixes, R not available

PFA or ggbs mixes, R 2 not available N/mm

C40

43R

35

29

C30

33R

27

22

C20

22R

18

14

C15

17R

13

11

C10

10R

8

7

C7.5

7R

5.5

4.5

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Grade of Concrete

TRIAL LENGTH

6.2.1

General Requirements for Trial Length

1

Except in rapid construction projects, at least one month prior to the construction of the trial length of surface slabs or CRCR (Continuously Reinforced Concrete Road Base) the Contractor shall submit for the Engineer's approval a detailed description of the proposed materials, mix proportions, plant, equipment and construction methods.

2

No trials of new materials, plants, equipment or construction methods; nor any development of them shall be permitted either during the construction of the trial length or in any subsequent paving work, unless they form part of further approved trials.

3

The Contractor shall demonstrate the materials, mix proportions, plant, equipment and method of construction that are proposed for concrete paving, by first constructing a trial length of slab, at least 150m but not more than 300 m, long for mechanised construction, and

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6.2

at least 30m long for hand guided methods, or otherwise as directed by the Engineer. The mix proportions decided by trial mixes may be adjusted during the trial but shall not be changed once the trial length has been approved except with the agreement of the Engineer.

5

The trial length shall be constructed in two parts over a period comprising at least part of two separate working days, with a minimum of half the proposed trial lengths constructed each day. The trial length shall be constructed at a similar rate to that which is proposed for the main construction in the permanent works.

6

At least two transverse joints and one longitudinal joint of each type that are proposed for unreinforced concrete slabs and jointed reinforced concrete slabs in the main construction in the permanent works shall be constructed and assessed in the trial length.

7

If in the trial length expansion joints are not demonstrated, the first 2 expansion joints and at least the first 150 m of longitudinal construction joint for mechanised paving, or 30 m for hand

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guided method of construction laid in the main construction in the permanent works, shall be considered the trial length for these joints.

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Page 6

8

One construction joint shall be demonstrated in each trial length of CRCP or CRCR.

6.2.2

Assessment of Trial Length

1

The trial length shall comply with the Specification in all respects, with the following additions and exceptions provided in (a) through (d) below. (a)

Surface Levels and irregularity (i)

in checking for compliance the levels shall be taken at intervals of not more than 2.5 m along any line or lines parallel to the longitudinal centre line of the trial length. The maximum number of permitted irregularities of pavement surfaces shall comply with the requirements for asphalt pavements as per Part 5 for 300 m lengths. Shorter trial lengths shall be assessed pro-rata based on values for a 300 m length.

(b)

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(ii)

Joints

At least 3 cores of minimum diameter 100 mm shall be taken from the slab at

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(i)

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joints to check the lateral and vertical location of joint grooves and bottom crack inducers. After a minimum of 24 hours following construction the removable part of the joint groove former shall be taken out and at least three joints and the sides of the groove shall be inspected for compaction. If there are voids the size and number should be compared with a similar size section of the photograph for 3% excess voidage in BS 1881. If there is excess voidage, additional compaction shall be provided and further joints inspected. The joints so exposed shall be temporarily or permanently sealed

(iii)

Alignment of dowel bars shall be inspected in any two consecutive transverse joints. If the position or alignment of the dowel bars at one of these joints does not comply after the next 3 consecutive joints of the same type have been inspected then the method of placing dowels shall be deemed to be satisfactory.

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(ii)

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(iv)

(c)

Density (i)

(d)

If there are deficiencies in the first expansion joint constructed as a trial, the next expansion joint shall be a trial joint. Should this also be deficient further trial expansion joints shall be made as part of a trial length which shall not form part of the Permanent Works, unless agreed by the Engineer.

Density shall be assessed from at least 3 cores drilled from each part of the trial length.

Position of Reinforcement and Tie Bars (i)

Compliance for the position of steel reinforcement and for the position and alignment of tie bars shall be checked by drilling additional cores from the slab unless they can be determined from cores taken for density assessment.

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Section 06: Road Works Part 06: Concrete Road Pavements

Page 7

Approval and Acceptance of Trial Length

1

Approval of the materials, mix proportions, plant, equipment and construction methods will be given when a trial length complies with the specifications. The Contractor shall not proceed with normal working until the trial length has been approved and any earlier defective trial lengths have been removed, unless they can be remedied to the satisfaction of the Engineer.

2

When approval has been given, the materials, mix proportions, plant, equipment and construction methods shall not thereafter be changed, without the approval of the Engineer except for maintenance of plant. Any changes in materials, mix proportions, plant, equipment, and construction methods shall entitle the Engineer to require the Contractor to lay a further trial length as described in this Clause to demonstrate that these changes will not adversely affect the permanent works.

3

Trial lengths which do not comply with the Specification, with the exception of areas within the pavement surface which can be remedied shall be removed immediately upon notification of deficiencies by the Engineer and the Contractor shall construct a further trial length.

6.3

REQUIREMENTS FOR PAVEMENT QUALITY CONCRETE

6.3.1

Materials and Mix Designs for Pavement Quality Concrete

1

The constituent materials and mix designs for pavement quality control shall be as per Section 5: Part 16.

6.3.2

Workability of Pavement Quality Concrete

1

The workability of the concrete at the point of placing shall enable the concrete to be fully compacted and finished without undue flow. The optimum workability for the mix to suit the paving plant being used shall be determined by the Contractor and approved by the Engineer.

2

The workability shall be determined by the compacting factor test, or the Vebe test or alternatively for concrete grade C20 or below, by the slump test, all in accordance with BS 1881, at the minimum rate of one determination per 300 m2 of slab laid or 6 times per day,

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6.2.3

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whichever is greater. For areas less than 300 m2 the rate shall be at least one determination to each 20 m length of slab or at least 3 times per day. 3

Alternatively the volumetric method of determining the Compacting Factor in BS 1881 may be used. Tests for workability shall be carried out at the point of placing, in conjunction with tests for strength and any tests for air content. The workability shall be maintained at the optimum within the following tolerances. Compacting Factor (CF) Slump Vebe

4

+0.03 +20mm +3 seconds or as agreed by the Engineer as a results of trial mixes.

Any alteration to the optimum workability necessitated by a change in conditions shall be agreed beforehand by the Engineer.

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Section 06: Road Works Part 06: Concrete Road Pavements

Page 8

If any determination of workability gives result outside the tolerance, a further test shall be made immediately on the next available load of concrete. The average of the two consecutive results and the difference between them shall be calculated. If the average is not within the tolerance or the difference is greater than 0.06 for CF or 20 mm for slump, or 6 seconds for Vebe or other value agreed with the Engineer, subsequent samples shall be taken from the delivery vehicles, which shall not be allowed to discharge into the Works until compliance with the Specification has been established. Trial Mixes

1

For concrete grades C15 and above the Contractor shall carry out laboratory trials of designed mixes with the materials from all sources to be used in the Works, in accordance with BS EN 206 & BS 8500 unless recent data relating entirely to the proposed mix is approved by the Engineer.

2

The trial mixes shall be repeated if necessary until the proportions of ingredients are determined which will produce a concrete which complies in all respects with the Specification.

3

Apart from minor adjustments to the mix as permitted by BS EN 206 & BS 8500 any changes in sources of materials or mix proportions that are proposed by the Contractor during the course of the Works shall be assessed by making laboratory trial mixes and the construction of a further trial length unless otherwise approval is given by the Engineer.

6.3.4

Separation Membrane

1

A separation membrane shall be used between jointed reinforced concrete surface slabs or unreinforced concrete surface slabs and the sub base.

2

Separation membranes shall be impermeable plastic sheeting 125 microns thick laid flat without creases. Where an overlap of plastic sheets is necessary, this shall be at least 300 mm. There shall be no standing water on or under the membrane when the concrete is

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placed upon it.

Under CRCP and CRCR a waterproof membrane shall be provided, which shall be a bituminous spray before concreting. Where a bituminous spray has been used to cure cement bound material or wet lean concrete then only those areas which have been damaged shall be resprayed after making good. The waterproof membrane shall be bituminous cutback in accordance with clause 5.12 of this Section.

6.3.5

General Requirements for Steel Reinforcement

1

Reinforcement shall comply with any of the following standards and be in prefabricated sheets or cages, or bars assembled on site and shall be free from oil, dirt, loose rust and scale:

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(a)

(Carbon steel bars for the reinforcement of concrete) BS 4449

(b)

(Cold-reduced steel wire for the reinforcement of concrete) BS 4482

(c)

(Steel fabric for the reinforcement of concrete) BS 4483

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(d)

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Section 06: Road Works Part 06: Concrete Road Pavements

Page 9

When deformed bars are used they shall conform to Type 2 bond classification of BS 4449.

Spacing of bars shall not be less than twice the maximum size of aggregate used. Laps in longitudinal bars shall be not less than 35 times bar diameters or 450 mm which ever is greater. In continuously reinforced concrete slabs (CRCP or CRCR) only one third of the laps may be in any one transverse section, except in single bay width construction where half the laps may be in any one transverse section. There shall be a minimum of 1.2 m longitudinally between groups of transverse laps or laps in prefabricated reinforcement sheets. Alternatively the reinforcement may be butt welded by a process approved by the Engineer.

3

Laps in a transverse reinforcement shall be a minimum of 300 mm. Where prefabricated

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reinforcement sheets are used and longitudinal and transverse laps would coincide, no lap is required in the transverse bars within the lap of the longitudinal reinforcement. These transverse bars may be cropped or fabricated shorter so that the requirements for cover are met. If the reinforcement is positioned prior to concreting, it shall be fixed on approved metal supports and retained in position at the required depth below the finished surface and distance from the edge of the slab so as to ensure that the required cover is achieved. Reinforcement assembled on site shall be tied, or firmly fixed, by a procedure agreed with the Engineer, at sufficient intersections to provide sufficient rigidity to ensure that the reinforcement remains in the correct position during construction of the slab.

5

Alternatively, when a reinforced concrete slab (JRC, CRCP or CRCR) is constructed in two layers, the reinforcement in the form of prefabricated sheets may be placed on or into the bottom layer which shall be spread and compacted to such a level that it will support the reinforcement without distortion at the required position in the slab. The sheets shall be tied together at overlaps and after the second layer has been spread and compacted, the reinforcement shall have the required cover.

6

When a reinforced concrete slab is constructed at maximum width the transverse reinforcement in the centre of each slab width shall be a minimum of 12 mm nominal

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diameter bars at 600 mm centres. This reinforcement shall be at least 600 mm longer than one third of the width of the slab and be lapped to other transverse reinforcement bars or sheets, or be continuous across the whole width of each slab. 6.3.6

Jointed Reinforced Concrete Slabs

1

The reinforcement shall be so placed that after compaction of the concrete, the cover below the finished surface of the slab is 50 + 10 mm for slabs less than 200 mm thick, 60 + 10 mm for slabs 200 mm or more but less than 270 mm thick and 70+20 mm for slabs 270 mm thick or more.

2

The negative vertical tolerance shall not be permitted beneath road stud recesses.

3

Where traffic signal detector loops are to be installed, the minimum cover to the reinforcement from the surface shall be 100 mm.

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Section 06: Road Works Part 06: Concrete Road Pavements

Page 10

4

The vertical cover between any longitudinal joint groove forming strip and any reinforcement or tie bars shall be at a minimum of 30 mm.

5

Any transverse bars shall be at right angles to the longitudinal axis of the carriageway. Any transverse reinforcement shall terminate at 125+25 mm from the edges of the slab and longitudinal joints, where tie bars are used.

6

No longitudinal bars shall lie within 100 mm of a longitudinal joint. The reinforcement shall terminate 300 mm + 50 mm from any transverse joint, excluding emergency construction joints. Continuously Reinforced Concrete Slabs (CRCP or CRCR)

1

The reinforcement shall be Grade 460 deformed steel bars as detailed on the Contract Drawings.

2

The reinforcement shall consists of bars assembled on site, or of prefabricated sheets.

3

Except where otherwise shown on the Drawings the longitudinal bars shall be parallel to the centre line of the road.

4

The reinforcement shall be positioned so that, after compaction of the concrete, it shall be at the mid depth of the specified thickness of the slab + 25 mm. No longitudinal bar shall lie

In reinforcement assembled on site, longitudinal bars shall be placed immediately above any transverse bars, which shall be at right angles to the longitudinal axis of the carriageway. Any transverse reinforcement shall terminate 125+25 mm from the edges of the slab and

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within 100mm of a longitudinal joint.

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6.3.7

longitudinal joints where tie bars are used. General Requirements for Transverse Joints

1

Transverse joints shall be provided in unreinforced and jointed reinforced concrete slabs and shall be contraction, expansion or warping joints at the spacing shown on the Drawings such that for unreinforced concrete slabs the length/width ratio shall be not greater than 2.0.

2

Joints in the surface slab and sub-base shall be staggered so that they are not coincident vertically and are at least 1m apart.

3

Transverse joints shall be straight within the following tolerances along the intended line of the joint, which is the straight line transverse to the longitudinal axis of the carriageway at the position proposed by the Contractor and agreed by the Engineer, except at road junctions or roundabouts where the positions shall be as shown on the Drawings:

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6.3.8

(a)

Deviations of the filler board or bottom crack inducer from the intended line of the joint shall be not greater than ± 10 mm.

(b)

The best fit straight line through the joint groove as constructed shall be not more than 25 mm from the intended line of the joint.

(c)

Deviations of the joint groove from the best fit straight line of the joint shall be not greater than 10 mm.

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(d)

Section 06: Road Works Part 06: Concrete Road Pavements

Page 11

When top groove formers and bottom crack inducers are used, the joint groove as constructed shall be located vertically above the bottom crack inducer within a horizontal tolerance of ± 25 mm.

Transverse joints on each side of a longitudinal joint shall be in line with each other and of the same type and width. The position of the joints relative to manholes and gullies shall be in accordance with the Drawings.

5

Transverse joints shall have a sealing groove which shall be sealed in compliance with Clause 6.3.20 of the specification.

6.3.9

Transverse Contraction Joints

1

Contraction joints shall consist of: Either a sawn joint groove, or

(b)

a wet formed joint groove and a bottom crack inducer

(c)

dowel bars

(d)

a sealing groove.

1

Expansion joints shall consist of:

(b)

dowel bars

(c)

a sealing groove.

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a joint filler board

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(a)

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Transverse Expansion Joints

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(a)

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4

The filler board shall be positioned vertically within the prefabricated joint assemblies along the line of the joint and at such depth below the surface as will not impede the passage of the finishing beams on the paving machines.

3

The joint filler board together with the sealing groove shall provide a complete separation of adjacent slabs and any spaces around dowel bars and between the sub-base and the filler board shall be packed with a suitable compressible material after fixing the joint assembly.

6.3.11

Transverse Warping Joints

1

Warping joints shall consist of:

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(a)

Either a sawn joint groove, or

(b)

a wet formed joint groove and a bottom crack inducer

(c)

tie bars

(d)

a sealing groove.

6.3.12

Transverse Construction Joints

1

Construction joints made at the end of a working day in unreinforced concrete slabs and jointed reinforced concrete slabs shall be expansion joints or contraction joints. In the event of mechanical breakdown of the concreting machinery, or at the onset of adverse weather, emergency joints may be formed.

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Section 06: Road Works Part 06: Concrete Road Pavements

Page 12

2

Emergency joints in unreinforced concrete slabs shall be either contraction or expansion joints not less than 2.5 m from the preceding or succeeding joint position.

3

Emergency joints in jointed reinforced concrete slabs shall be not less than 2.5 m from the preceding or succeeding joint position. The stop end formwork shall be sufficiently rigid to ensure that dowel bars, tie bars or reinforcement will be held in position in compliance with the specification, and placed in such a position that it permits the longitudinal reinforcement to project through the joint for a distance of at least 750 mm.

4

Construction joints in continuously reinforced concrete slabs (CRCP and CRCR) in an emergency shall not be constructed within 1.5 m of any lap in the longitudinal reinforcement

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without the approval of the Engineer. The stop end formwork shall be sufficiently rigid to ensure that the longitudinal reinforcement and the tie bars projecting through the joint are held in the correct position. General Requirements for Longitudinal Joints

1

Longitudinal joints shall be provided in surface slabs between or at the centre of traffic lanes within the allowable positions as shown on the Drawings, so that bay widths are not greater than 4.2 m (or 5.0 m with limestone aggregate) for unreinforced slabs, or 6 m (or 7.6 m with

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6.3.13

limestone aggregate) for reinforced concrete surface slabs with transverse reinforcement.

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Longitudinal joints shall be provided in CRCR between lanes or at the centre of lanes, within a tolerance of +150 mm so that bay widths are not greater than 6 m (or 7.6 m with limestone

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aggregate).

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Joints in the surface slab, road base or sub-base shall be staggered so that they are not coincident vertically and are least 300 mm apart. The positions of all longitudinal joints in any

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slab shall be agreed by the Engineer prior to construction of the slab. Wet-formed longitudinal joints shall consists of wet-formed joint grooves, bottom crack inducer and tie bars except where transverse reinforcement is permitted in lieu.

5

Longitudinal joints shall be constructed in the positions agreed by the Engineer within the following tolerances:

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(a)

Deviations of the bottom crack inducer from the intended line of the joint parallel to the axis of the road shall not be greater than +13 m.

(b)

The joint groove shall be located vertically above the bottom crack inducers within a horizontal tolerances of +25 mm.

(c)

The best fit line along the constructed joint groove, shall be not more than 25 mm from the intended line of the joint.

(d)

Deviations of the joint groove from the best fit line of the joint shall be not greater than 10 mm.

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Section 06: Road Works Part 06: Concrete Road Pavements

Page 13

Tie bars may be replaced by continuous transverse reinforcement across the joints in continuously reinforced concrete slabs, which are constructed in more than one lane width in one operation, provided that the transverse reinforcement is a minimum of 12 mm diameter bars at 600 mm centres.

6.3.14

Longitudinal Construction Joints

1

Longitudinal construction joints between separate slabs shall have tie bars with a joint groove. Alternatively, if split forms are used, the transverse reinforcement, if 12 mm diameter or more, may be continued across the joint for a minimum of 500 mm or 30 times the diameter of the transverse reinforcement bars, whichever is greater. A joint sealing groove is not required in construction joints in continuously reinforced concrete road bases. Where the edge of the concrete slab is damaged it shall be made good to the approval of the Engineer before the adjacent slab is constructed.

6.3.15

Dowel Bars

1

Dowel bars shall be Grade 250 steel complying with BS 4449 and shall be free from oil, dirt, loose rust and scale. They shall be straight, free of burrs and other irregularities and the sliding ends sawn or, if approved by the Engineer, cropped cleanly with no protrusions outside the normal diameter of the bar. For expansion joints, dowel bars shall be 25mm diameter at 300 mm spacing, 600 mm long for slabs up to 239 mm thick and 32 mm diameter

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for slabs 240 mm thick or more. For contraction joints, dowels shall be 20 mm diameter at

240 mm thick or more.

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300 mm spacing 400 mm long for slabs up to 239 mm thick and 25 mm diameter for slabs

Dowel bars shall be supported on cradles in prefabricated joint assemblies positioned prior to construction of the slab. For contraction joints, as an alternative to prefabricated assemblies, dowel bars may be mechanically inserted with vibration into the concrete by a method which shall ensure full recompaction of the concrete around the dowel bars and the surface finished by a diagonal finishing beam. Or a longitudinal oscillating float travelling across the slab.

3

Dowel bars shall be positioned at mid-depth from the surface level of the slab ± 20 mm.

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They shall be aligned parallel to the finished surface of the slab, to the centre line of the carriageway and to each other within the following tolerances: (a)

for bars supported on cradles prior to construction of the slab and for inserted bars in two layers construction prior to placing the top layer: (i)

All bars in a joint shall be within ± 3 mm per 300 mm length of bars.

(ii)

Two thirds of the bars shall be within ± 2 mm per 300 mm length of bar.

(iii)

No bar shall differ in alignment from an adjoining bar by more than 3 mm per 300 mm length of bar in either the horizontal or vertical plane.

(b)

for all bars, after construction of the slab: (i)

Twice the tolerances for alignment as in (i) above.

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Page 14

Equally positioned about the intended line of the joint within a tolerance of ± 25 mm.

4

Cradles supporting dowel bars shall not extend across the line of the joint.

5

Dowel bars, supported on cradles in assemblies, when subjected to a load of 110N applied at either end and in either the vertical or horizontal direction (upwards and downwards and both directions horizontally) shall not deflect more than the following limits:

6

Two thirds of the number of bars of any assembly tested shall not deflect more than 2 mm per 300 mm length of bar.

7

The remainder of the bars in that assembly shall not deflect more than 3 mm per 300 mm

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length of bar.

The assembly of dowel bars and supporting cradles, including the joint filler board in the case of expansion joints shall have the following degree of rigidity when fixed in position:

9

For expansion joints the deflection of the top edge of the filler board shall be not greater than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical

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8

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face of the joint filler board and distributed over a length of 600 mm by means of

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a bar or timber packing at mid depth and midway between individual fixings, or 300 mm from either end of any length of filler board, if a continuous fixing is used.

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The residual deflection after removal of the load shall be not more than 3 mm. The joint assembly fixings to the sub-base shall not fail under the 1.3kN load applied for testing the rigidity of the assembly but shall fail before the load reaches 2.6 kN.

11

The fixings for contraction joints shall not fail under a 1.3 kN load and shall fail before the load reaches 2.6 kN when applied over a length of 600 mm by means

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12

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of a bar or timber packing placed as near to the level of the line of fixings as practicable. Failure of the fixings shall be deemed to be when there is displacement of the assemblies by more than 3 mm with any form of fixing, under the test load. The displacement shall be measured at the nearest part of the assembly to the centre of the bar or timber packing. 13

Dowel bars shall be covered by a thin plastic sheath over the whole length of the bar. The sheath shall be tough, durable and of an average thickness not greater than 1.25 mm. The sheathed bar shall comply with the following pull out test:

QCS 2014

14

Section 06: Road Works Part 06: Concrete Road Pavements

Page 15

Four bars shall be taken at random from stock and without any special preparation shall be covered by sheaths. The dowel bars which have been sheathed shall be cast centrally into concrete specimens 150x150x450 mm, made of the same mix proportions to be used in the pavement, but with a maximum nominal aggregate size of 20 mm and cured in accordance with BS 1881.

At 7 days a tensile load shall be applied to achieve a movement

of the bar at least 0.25 mm.

The average bond stress to achieve this movement

shall be not greater than 0.14 N/mm2. 15

For expansion joints a closely fitting cap 100 mm long consisting of waterproofed cardboard

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or an approved synthetic material shall be placed over one end of each dowel bar. An expansion space 10 mm greater than the thickness of the joint filler board shall be formed between the end of the cap and the end of the dowel bar. Tie Bars

17

Tie bars in transverse or longitudinal joints shall be Grade 250 steel or Grade 460 deformed steel bars complying with BS 4449, in accordance with the requirements given below and Table 6.2. Deformed bars shall have Type 2 bond classification. Tie bars shall be free from oil, dirt, loose rust and scale. Tie bars which are to be cranked and later straightened shall be Grade 250.

18

Tie bars projecting across a longitudinal joint shall be protected from corrosion by a flexible polymeric corrosion resistant coating, bonded onto the previously cleaned centre section, leaving between 250 mm and 300 mm of each of the bars uncoated.

19

Where tie bars are cranked for construction joints and later straightened the coating shall be shown to be capable of being straightened through 90 degrees without cracking. The coating shall also be able to withstand 250 hours immersion in a salt fog cabinet complying with BS 3900 : Part F12, without showing any visible cracking, or corrosion of the protected part of the bar. Any damage observed on the coating after straightening shall be made good before the concrete is placed.

20

Tie bars in warping joints and wet-formed longitudinal joints shall be made up into rigid assemblies with adequate supports and fixings to remain firmly in position during the construction of the slab.

21

Alternatively, tie bars at longitudinal joints may be mechanically inserted by vibration from above using a method which ensures recompaction of the concrete around the tie bars.

22

At longitudinal construction joints, tie bars may be adequately fixed to side forms or inserted into the side of the slab by a method which ensures recompaction of the concrete around the tie bars and adequate bond and which shall be approved by the Engineer.

23

Tie bars shall be positioned and remain within the middle third of the slab depth, approximately parallel to the surface and approximately perpendicular to the line of the joint, with the centre of each bar on the intended line of the joints within a tolerance of ± 50 mm,

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and with a minimum cover of 30 mm below any top crack inducer or joint groove for slabs 200 mm thick or more, or 20 mm for slabs up to 200 mm thick.

QCS 2014

24

Section 06: Road Works Part 06: Concrete Road Pavements

Page 16

At transverse construction joints in continuously reinforced concrete, tie bars shall be 1.5 m long and of the same grade and size as the longitudinal reinforcement, and shall be fixed at twice the normal spacing midway between the longitudinal reinforcement bars so that 750 mm ± 50 mm extends each side of the joint at the same level as the longitudinal reinforcement and be tied to the transverse reinforcement. Where paving from a construction joint is not resumed within 5 days, and extra longitudinal reinforcement bar at 8 m long shall be lapped and tied to each tie bar. These extra bars may be combined with the tie bars. Where the spacing between longitudinal reinforcement and the extra 8 m long bars is less than 90 mm, the nominal size of aggregate shall be 20 mm for a sufficient number of concrete batches to complete that section of pavement. Where tie bars are used in longitudinal joints in continuously reinforced concrete they shall be placed at the same level as the transverse reinforcement and tied to the longitudinal reinforcement.

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25

Length (mm)

Spacing (mm)

460

1500

Twice the spacing of main reinforcement

12

250 or 460 deformed

1000 750

600 600

12

250 or 460 deformed

1000 750

300 600

12

250 or 460 deformed

1000 750

600 600

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As for main reinforcement

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Transverse construction joints in continuously reinforced concrete Emergency construction joints in jointed reinforced concrete slabs other than at contraction or expansion joints

Grade of Steel

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Diameter (mm)

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Joints

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Table 6.2 Tie Bar Details

m

Warping joints

Longitudinal. All joints, except where transverse reinforcement is permitted in lieu

Note: The transverse reinforcement may be continued across the joint in reinforced concrete with the approval of the Engineer if the bars are of a minimum nominal diameter of 12 mm and the bars are protected from corrosion and the cover is as required in this Clause. 6.3.16

Joint Grooves

1

Transverse contraction or warping joint grooves shall be sawn in the hardened concrete.

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 17

Transverse joint grooves which are initially constructed less than the full width of the slab shall be completed by sawing through to the edge of the slab and across longitudinal joints as soon as any forms have been removed and before an induced crack develops at the joint.

3

Sawn transverse joint grooves shall be undertaken as soon as possible after the concrete has hardened sufficiently to enable a sharp edged groove to be produced without disrupting the concrete and before random cracks develop in the slab. The grooves shall be between 1/4 and 1/3 of the specified depth of the slab and of any convenient width not less than 3mm. The sealing groove may be constructed at the same time to be sawn to the required width later. Unless otherwise approved by the Engineer, expansion joint sealing grooves shall be sawn immediately before sealing.

4

Construction Joint Grooves in Surface Slabs shall be formed by fixing a groove-former, strip or cork seal along the top edge of the slab already constructed, before concreting the adjacent slab. Where the edge of the concrete is damaged it shall be ground or made good to the approval of the Engineer before fixing the groove forming strip.

5

Alternatively the subsequent slab may be placed adjacent to the first and a sealing groove sawn later in the hardened concrete to the minimum depth required in Table 6.3 or to the manufacturer's instructions if greater, and to sufficient width to eliminate minor spalling of the joint arris, up to a maximum of 25mm for longitudinal joints and 40mm for transverse joints. The joints shall be sealed.

6.3.17

Groove Formers and Bottom Crack Inducers

1

Except where joint grooves are sawn, a bottom crack inducer shall be provided at each contraction, warping or longitudinal joint position.

2

The bottom crack inducer shall be an approved triangular or inverted Y-shaped fillet, with a base width not less than the height, made of timber or rigid synthetic material. It shall be firmly fixed to the sub-base so as to remain in position during the whole process of constructing the slab.

3

The combined depth of groove formers and bottom crack inducers shall be between 1/4 and 1/3 of the depth of the slab and the difference between the depth of the groove former and the height of the bottom crack inducer shall not be greater than 20mm.

4

The groove former for wet formed transverse joint grooves shall be made of an approved rigid material of a width not greater than the required width of sealing groove as in Table 6.3. The groove former shall be smooth sides with rounded protrusions no greater than 3mm. Any removable part of the groove former may be tapered with a maximum difference in width of 2mm in 20mm depth.

5

Groove forming sealing strips for wet formed longitudinal joints shall be of firm compressible strips of ethylene vinyl acetate foam of a minimum density of 90kg/m3, or synthetic rubber, or equivalent material subject to approval by the Engineer. They shall have a minimum thickness of 5mm and shall be sufficiently rigid to remain vertical and straight in the concrete without curving or stretching. They shall be inserted continuously along the joint.

6

For CRCP Universal Beam Anchorage Transverse Joints one side of the beam shall be separated from the CRCP slab by an expansion joint filler board against the vertical face and ethylene vinyl acetate foam or similar compressible material, between 5 mm and 10mm thick, stuck under the top flange.

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QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 18

Joint Filler Board

1

Joint filler board for expansion joints and manhole and gully slab joint shall be 25mm thickness unless otherwise shown in the Drawings, within a tolerance of ± 1.5mm.

2

It shall be self expanding cork seal or a firm compressible material or a bonded combination of compressible and rigid materials of sufficient rigidity to resist deformation during the passage of the concrete paving plant.

3

The depth of the joint filler board for manhole and gully slabs shall be the full depth of the slab minus the depth of the sealing groove. In expansion joints, the filler board shall have a ridged top as shown on the Drawings, except where a sealing groove former is permitted by the Engineer.

4

Holes for dowel bars shall be accurately bored or punched out to form a sliding fit for the sheathed dowel bar.

6.3.19

Preparation and Sealing of Joint Grooves

1

All transverse joints in surface slabs, except for construction joints in CRCP shall be sealed using one of the joint seals described. Additionally longitudinal joints which are sawn or widened shall be sealed.

2

Joint grooves shall be prepared in accordance with BS 5212: Part 2 and in compliance with (a) through (g) below:

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that part of the groove former used to form the sealing groove or any temporary seal shall be removed cleanly without damaging the joint arises to a minimum depth of 25 mm where compression seals are used or otherwise to such depth as will provide

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(a)

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6.3.18

if joint grooves are not initially constructed to provide the minimum dimensions for the joint seals as given in Table 6.3, they shall be widened by sawing. Joint grooves formed by tapered formers need not to be widened. The sealing grooves shall be cleaned out immediately after sawing using high pressure water jets, to remove all slurry from the joint, before the slurry hardens. if rough arrises develop when grooves are made they shall be ground to provide a chamfer approximately 5mm wide. If the groove is at an angle up to 10 degrees from the perpendicular to the surface, the overhanging edge of the sealing groove shall be sawn or ground perpendicular. If spalling occurs or the angle of the former is greater than 10 degrees the joint sealing groove shall be sawn wider and perpendicular to the surface to encompass the defects up to a maximum width, including any chamfer, of 40 mm for transverse joints and 25mm for longitudinal joints. If the spalling cannot be

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an applied seal to the dimensions as will provide in Table 6.3.

so eliminated then the arris shall be repaired by an approved thin bonded arris repair using cementitious materials. (d)

for applied sealants the sides of the joint sealing groove shall be scoured by dry abrasive blasting. This shall not be carried out before the characteristics compressive 2 strength of the concrete is expected to reach 15 N/mm . When compression seals are used, the sides of the groove may be ground or wire brushed.

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 19

(e)

for hot and cold applied sealants, compressible caulking material, debonding strip or tape or cord compatible with the sealant, of a suitable size to fill the width of the sealing groove shall be firmly packed or stuck in the bottom of the sealing groove to such a depth so as to provide the correct depth of seal as described in Table 6.3 with the top of the seal at the correct depth below the surface of the concrete.

(f)

all grooves shall be cleaned of any dirt or loose material by air blasting with filtered, oil free compressed air. The groove shall be clean and dry at the time of priming and sealing.

(g)

for applied sealants the joint grooves shall be primed with the relevant primer for the hot or cold applied sealant in accordance with the manufacturer's recommendations and with BS 5212: Part 2, except that when necessary the joint grooves may be

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primed and sealed earlier than 14 days after construction, as soon as the grooves have been grit-blasted and cleaned. Sealing with Applied Sealants

1

Sealing shall be carried out continuously along the full length of joint in any one rip, except for remedial areas. When hot or cold applied sealants are used the sealant shall be applied within the minimum and maximum drying times of the primer recommended by the manufacturer. Priming and sealing with applied sealants shall not be carried out when the naturally occurring temperature in the joint groove to be sealed is below 10 C except between 8 C and 10 C it may be carried out when the temperature is rising.

2

Hot applied sealants shall be heated in and applied from a thermostatically controlled, indirectly heated dispenser with the recirculating pump. The sealant shall not be heated to a temperature higher than the safe heating temperature nor for a period longer than the safe heating period, both as specified by the manufacturer. The dispenser shall be cleaned out at the end of each day and reheated materials shall not be used.

3

The components of cold-applied sealants shall be thoroughly mixed in the correct proportions in accordance with the manufacturer's instructions using an automatic metering and mixing dispenser approved by the Engineer or, for hand application, using a power operated paddle mixer for sufficient time to produce homogenous mix without entrapped air. As soon as possible after mixing and within the worklife of the sealant, the material shall be dispensed into the joint, or applied using a caulking gun, to the correct level below the concrete surface. The tack-free time shall be achieved within 3 hours, for machine dispensed material, or within 12 hours for hand applied material.

4

Test certificates shall be supplied from an approved testing laboratory stating that the sealant complies with the relevant standard. Site testing of cold applied sealants shall be in accordance with BS 5212: Part 2. Hot-applied sealants shall be sampled at the same rate and checked for dimensions as in BS 5212: Part 2 and by the penetration test of the relevant standard for the material.

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6.3.20

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 20

Table 6.3 Dimensions of Applied Joint Seals Hot Applied (mm)

Impregnated Foam Compression Strips (mm)

Depth of Seal Below the Concrete Surface(mm)

13 (Note 2) 20 30 30 10

13 15 20 20 10

15 20 25 25 13

30 30 40 40 30

5+2 5+2 5+2 7+2 5+2

10

10

13

30

20

15

20

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Cold Applied (mm)

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Contraction: 15 and under Over 15 to 20 Over 20 to 25 Expansion All Transverse Warping Longitudinal Joints (if sealed) Gully and Manhole Slabs

Minimum Width (mm)

30

0 to 5

0 to 3

ta

Type and Spacing of Joints (m)

The depth of seal is that part in contact with the vertical face of the joint groove. The depth of seal below the surface shall be taken at the centre of an applied seal relative to a short straight edge, 150mm long, placed centrally across the joint within 7 days of sealing.

Note: (2)

For cork seals other than in construction joints, grooves shall be 20 mm wide and 50 mm deep.

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Note: (1)

Sealing with Compression Seals

1

When compression seals are used, the widths of the seal shall be selected in relation to the width of the sealing groove, the bay lengths and manufacturer's recommendations so that the estimated maximum width of the joint opening shall be not more than 70% of the original width of the seal, the estimated maximum width being calculated on the basis of a movement of 4mm per 10m run of slab.

2

The maximum calculated width of sealing groove shall be 30mm.

3

The depth of groove shall be such that the contact face of the seal with the side of the groove shall be not less than 20mm and that the top of the seal shall be a minimum of 3mm below the surface of the concrete.

4

Compression seals shall be inserted into the grooves without prior extension or rotation and, where recommended by the manufacturer, with a lubricant adhesive which is compatible with the seal and the concrete. The adhesive shall be applied to both sides of the sealing groove or the seal, or to both. The seal shall be positioned with its axis perpendicular to the concrete surface. Excess adhesive on top of the seal shall be removed to prevent adhesion of the top faces of the seal under compression.

5

Except when compression seals are used in longitudinal joints the transverse joint seal shall be continuous across the slab and the longitudinal joint groove forming strips shall be cut to the required depth after the concrete has hardened for the transverse seal to be inserted.

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6.3.21

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 21

If compression seals are used in longitudinal joints where the grooves have been sawn after construction of the slab they shall be continuous across transverse joints, with the transverse seals butted and fixed to the longitudinal seals with adhesive.

6.3.22

Joint Seals

1

Joint seals shall consist of hot or cold applied sealants or compression seals or self expanding cork seals.

2

Hot-applied sealants shall comply with ASTM Standard D3406, or D7116 (for fuel-resistant sealant).

3

For joints between concrete surface slabs and bituminous surfacing, polymer modified bitumen sealing strips shall be used and applied in accordance with the manufacturer's instructions. Hot-applied sealants complying with BS 2499 & BS EN 14188 may be used for such joints and in joints in asphalt kerbs laid on concrete pavements.

4

Cold applied sealants shall be Type N complying with BS 5212: Part 1 except that Type F shall be used for lay-bys and hardstandings.

5

For joints in kerbs and joints other than in pavements, seals may be any of the pavement sealants if they have the suitable characteristics for the application. Also, gunning grade cold applied plasticised bituminous rubber sealant or gunning grades of two part polysulphidbased sealants complying with BS EN ISO 11600 may be used.

6

Alternatively, polyurethane-based sealing compounds may be used provided their performance is not inferior to BS EN ISO 11600 material.

7

Compression seals shall be pre-compressed neoprene impregnated expanding foam sealing strip, or rubber seals made of polychloroprene elastomers complying with BS 2752 and conforming to the requirements of ASTM Standard D2628-91.

8

Compression seals shall be shaped so that they will remain compressed at all times and shall have a minimum of 20mm contact face with the sides of the sealing groove. If lubricant adhesive is used, it shall be compatible with the seal and the concrete and shall be resistant to abrasion, oxidisation, fuels and salt.

9

Self Expanding Cork seals may be used in longitudinal joints, joints for manhole and gully slabs and for transverse joints in short lengths of individual slabs or for replaced slabs.

6.3.23

Joints at Manhole and Gully Slabs

1

Manhole covers, gullies and their frames shall be isolated from the pavement slabs and be contained in separate small slabs, which shall be larger than the exterior of the manhole and gully shafts, including any concrete surround less than 150mm below the underside of the sub-base layer. The joint around the manhole or gully slab shall be vertical and incorporate joint filler board but without dowel bars and tie bars.

2

Gully slabs in unreinforced concrete slabs shall be adjacent to or straddle a transverse joint, extending the gully slab as necessary to a maximum of 2m. Where this is impractical, an extra tied warping joint shall be provided adjacent to or within the gully slab and at least 2m from the next transverse joint. If the edge of an isolator slab is within 1m of any longitudinal joint the isolator slab shall be extended to that joint.

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6

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 22

Manhole slabs in unreinforced concrete slabs shall be adjacent to or straddle transverse or longitudinal joints. If the manhole is within the middle third of the bay length a warping joint shall be constructed on one side of the manhole slab across the whole width of the bay to the nearest longitudinal joint.

4

Reinforcement as shown on the Drawings shall be placed in the main concrete slabs in the corners between the manhole and gully slab and the transverse or longitudinal joints. Extra reinforcement as described in the Contract shall be placed in reinforced concrete slabs around the manhole or gully slabs.

5

Manhole and gully slabs shall have oblique corners, minimum 200mm long, at approximately 45 degrees to the axis of the pavement at all corners which are not adjacent to a transverse or longitudinal joint in the main slab.

6

Reinforcement as shown on the Drawings shall be placed in the gully or manhole slab and concrete grade C40 shall be placed by hand in the space between the main slab and the manhole frame. The concrete shall be fully compacted and finished.

7

A sealing groove shall be made directly above the joint filler board and sealed.

6.3.24

Inspection of Dowel Bars

1

The position and alignment of dowel bars at contraction and expansion joints shall be checked by measurement relative to the side form or guide wires.

2

When the slab has been constructed, the position and alignment of dowel bars and any filler board shall be measured after carefully exposing them across the whole width of the slab. When the joint is an expansion joint the top of the filler board shall first be exposed sufficiently in the plastic concrete to permit measurement of any lateral or vertical displacement of the board. During the course of normal working these measurements shall be carried out at a rate of one joint per 1500m length of slab or one per 5 working days whichever occurs the sooner. For small areas the rate shall be decided by the Engineer.

3

If the position or alignment of the bars in a single joint in the slab is unsatisfactory then the next two joints shall be inspected. If only one joint of the three is defective, the rate of checking shall be increased to one joint per day until the Engineer is satisfied that compliance is being achieved. In the event of non-compliance in two or more successive joints, the Contractor shall revert to the construction of trial lengths and make any necessary alterations to the concrete mix, paving plant or methods until the dowel bar position and alignment is satisfactory.

4

After the dowel bars have been examined, the remainder of the concrete shall be removed 500mm on each side of the line of the joint, and reinstated to the satisfaction of the Engineer. Alternatively if the dowels are examined in the penultimate joint of a day's work that joint shall be made a construction joint for the next day's work and the remainder of the concrete in the last slab may be discarded.

6.3.25

Side Forms, Rails and Guide Wires

1

All side forms and rails shall be made of steel and be sufficiently robust and rigid to support the weight and pressure caused by the paving equipment. Side forms for use with wheeled paving machines shall incorporate metal rails firmly fixed at a constant height below the top of the forms.

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QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 23

The forms shall be secured by using not less than three pins for each 3m length having one pin fixed at each side of every joint. Forms shall be tightly joined together by a locked joint, free from play or movement in any direction. Forms shall be cleaned and oiled immediately before each use. The rails or running surface shall be kept clean in front of the wheels of any paving machine. The forms shall be straight within a tolerance of 3mm in 3m.

3

The forms shall be bedded on low moisture content cement mortar or concrete grade C7.5 and set to the pavement surface level as shown on the Drawings within a tolerance of +3mm. The bedding shall not extend under the slab. There shall be no vertical step between the end of adjacent forms greater than 3mm. The horizontal alignment for forms shall be to the required alignment of the pavement edge as shown on the Drawings within a tolerance of + 10mm. The mortar or concrete bedding shall be broken out after use.

4

Side forms shall not be removed earlier than 6 hours after the completion of the construction of the slab. Care shall be taken to prevent damage to the concrete and any projecting tie bars during the removal of the forms. If the removal of forms results in any damage to the concrete the period of 6 hours shall be increased to that which is necessary to avoid further damage and the Contractor shall make good the damaged areas.

5

Unless otherwise agreed by the Engineer, a guide wire shall be provided along each side of the slab to be constructed by slip form paving plant. Each guide wire shall be at a constant height above and parallel to the required edges of the slab as shown on the Drawings, within a vertical tolerance of + 3mm. Additionally one of the wires shall be at a constant horizontal distance from the required edge of the pavement as shown in the drawings within a lateral tolerance of + 10mm.

6.3.26

Delivery, Storage and Batching of Concreting Materials

1

Aggregate for roadworks shall be delivered to and stored on the Site in one of the following ways: in separate nominal single sizes of coarse aggregate and fine aggregate.

(b)

as graded coarse aggregate of appropriate size and fine aggregate.

(c)

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as all-in aggregate for grades C20 to below.

If the Contractor proposes to blend aggregate off the site from two separate sources, he shall obtain the Engineer's approval for the blending process, and for the arrangements for inspection during the course of the work.

3

Aggregate brought on to the Site shall be kept free from contact with deleterious matter. Fine aggregate nominally below 5 mm sieve size shall have been deposited at the site for at least 8 hours before use.

4

Batching plant and storage for aggregate shall comply with the following requirements as appropriate to the method of delivery:

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2

(a)

if separate gradings of aggregate are stockpiled, separate accommodation shall be provided for each nominal size of coarse aggregate or blend of fine aggregate. The base for stockpiles shall be suitably surfaced to prevent contamination of the aggregate. Drainage of the stockpile bases shall be provided.

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 24

(b)

aggregate shall be measured by mass and provision shall be made for batching each nominal size or blend of aggregate separately, to the tolerances specified in BS EN 206 & BS 8500.

(c)

all-in aggregate shall be delivered and stockpiled in such a manner and to a height that avoids segregation.

Mixing Concrete

1

Mixing concrete shall conform to the requirements of Section 5 Part 7 except as amended herein.

2

Concrete shall be mixed on site in a stationary batch type mixer in compliance with BS EN 206 & BS 8500 unless with the approval of the Engineer, ready mixed concrete is supplied from an approved source.

3

The drums or blades of all mixers shall be operated at the speed using for testing, in accordance with BS 3963 for the mix proportions required, within a tolerance of ± 1 revolution per minute. The mixing blades of a pan mixer shall be maintained within the tolerances specified by the manufacturers of the mixer and the blades shall be replaced when it is no longer possible to maintain the tolerances by adjustment. All drums or pans which have been out of use for more than 30 minutes shall be thoroughly cleaned before any fresh concrete is mixed in them.

4

The rated output of the batching and mixing plant shall exceed by at least a third the amount of concrete that is required at a constant rate to enable the paving train to move forward continuously, at the planned rate of progress.

6.3.28

Transport and Delivery

1

Transportation, delivery of concrete shall conform to the requirements of Section 5 Part 8.

6.3.29

General Requirements for Construction by Machine

1

The concrete slab shall be constructed in a continuous process by either slip-form or by fixed form paving plant or by small paving machines or hand guided methods.

2

The slab may be constructed in either one or two layers. In two layer construction the thickness of the top layer shall be not less than 50mm or twice the maximum size of the coarse aggregate whichever is greater, and shall be at least 15 mm thick than the depth of the groove former, if used.

3

While the concrete is still plastic its surface shall be brush-textured and the surface and edges shall be cured.

4

The spreading, compacting and finishing of the concrete shall be carried out as rapidly as possible and the paving operation shall be so arranged as to ensure that the time between the mixing of the first batch of concrete in any transverse section of the slab and the application of the sprayed curing membrane to the surface of that section shall not exceed those given in Table 6.4.

5

Each bay in jointed concrete surface slabs shall be consecutively numbered near the verge next to a transverse joint while the concrete is plastic. In continuously reinforced concrete pavement the slab shall be marked with the chainage at intervals not greater than 50m apart.

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6.3.27

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 25

Construction by Fixed Form Paving Machines

1

A fixed form paving train shall consist of separate, powered machines which spread compact and finish the concrete in a continuous operation.

2

Concrete shall be discharged without segregation into a hopper spreader which is equipped with the means of controlling its rate of deposition onto the sub-base or onto the lower layer. The concrete shall be spread in each layer without segregation and to a uniform uncompacted density over the whole area of the slab.

3

The deposited concrete shall be struck off to the necessary level by the underside of the hopper as it is traversed across the spreading machine.

4

The machine shall be capable of being rapidly adjusted for changes in average and differential surcharge necessitated by changes in slab thickness or crossfall. When the slab is constructed in two layers, the spreading of the concrete in the top layer shall follow the completion of the bottom layer within the times given in Table 6.4.

5

Prior to being compacted, the surface level of each loose spread layer shall be adjusted to the correct surcharge by means of rotating strike-off blades or a screw device.

6

The concrete shall be compacted by vibration or by a combination of vibration and mechanical tamping throughout the full depth of the slab. Poker vibrators shall be used in each layer adjacent to the side forms and the edge of a previously constructed slab.

7

The initial regulation and finish to the surface of the slab shall be effected by means of a beam oscillating transversely or obliquely to the longitudinal axis of the pavement. This beam shall be readily adjustable for both height and tilt.

8

When grooves are wet-formed the concrete shall be recompacted around the former by a hand held vibrating plate compactor drawn along or on each side of the joint, prior to regulation of the surface by the diagonal finishing beam. Or recompacted and finished if the former is inserted after the finishing beam.

9

The regulation and finishing of the surface of the slab shall be carried out by a machine which incorporates twin oblique oscillating finishing beams which shall be readily adjustable for both height and tilt. The beams shall weigh not less than 170 kg/m, be of rectangular section and span the full width of the slab. The leading beam shall be vibrated. The beams shall be supported on a carriage, the level of which shall be controlled by the average level of not less than four points evenly spaced over at least 3.5m of the supporting rail, beam or slab, on each side of the slab that is being constructed. After the final regulation and before texture is applied any excess concrete on top of the groove former shall be removed.

10

When a concrete slab is constructed in more than one width, flanged wheels on the paving machines shall not be run directly on the surface of any completed part of the slab. The second or subsequent slabs shall be constructed either by supporting machines with flanged wheels on flat bottom section rails weighing not less than 15 kg/m laid on the surface of the completed slab, or by replacing the flanged wheels on that side of the machines by smooth flangeless wheel.. Flangeless wheels or rails shall be positioned sufficiently far from the edge of the slab to avoid damage to that edge.

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6.3.30

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 26

Construction by Slip-Form Paving Machine

1

A slip-form paving train shall consist of powered machines which spread, compact and finish the concrete in a continuous operation.

2

The slip-form paving machine shall compact the concrete by internal vibration and shape it between sliding side forms or over fixed side forms by means of either a conforming plate or by vibrating and oscillating finishing beams.

3

The concrete shall be deposited without segregation in front of the slip-form paver across its whole width and to a height which at all times is in excess of the required surcharge. The deposited concrete shall be struck off to the necessary average and differential surcharge by means of a strike-off plate or a screw auger device extending across the whole width of the slab. The equipment for striking off the concrete shall be capable of being rapidly adjusted for changes of the average and differential surcharge necessitated by changes in slab thickness or crossfall.

4

The level of the conforming plate and finishing beams shall be controlled automatically from the guide wires by sensors attached at the four corners of the slip form paving machine. The alignment of the paver shall be controlled automatically from the guide wire by at least one sensor attached to the paver. The alignment and level of ancillary machines for finishing, texturing and curing of the concrete shall be automatically controlled relative to the guide wire or to the surface and edge of the slab.

5

Slip-form paving machines shall have a vibration of variable output, with a maximum energy output of not less than 2.5 kW per metre width of slab per 300mm depth of slab for a laying speed of up to 1.5m per minute or pro rata for higher speeds. The machines shall be of sufficient mass to provide adequate reaction on the traction units to maintain forward movements during the placing of concrete in all situations.

6

Where grooves are wet-formed the concrete shall be compacted around the former by a separate vibrating plate compactor with twin plates. The groove former shall be compacted to the correct level by a vibrating pan which may be included with the transverse joint finishing beam. In addition a hand held vibrating float, at least 1m wide, shall be drawn over the surface along the joint. Alternatively the surface shall be regulated with a longitudinal oscillating float travelling across the slab. Any excess concrete on top of the groove former shall be removed before the surface is textured.

7

Where a concrete surface slab is constructed in more than one width or where the edge needs to be matched for level to another section of surface slab, and the surface levels at the edges are not achieved, paving shall be carried out over separate fixed side forms to support the edge to the required levels.

6.3.32

Construction by Small Paving Machines or Hand Guided Methods

1

As an alternative to fixed form or slip-form paving trains, the concrete slab may be constructed using parts of trains, small paving machines, truss type finishing beams or hand guided methods. Hand tamping beams may only be used for short lengths or infill bays or tapers. Reinforcement, dowel bars and tie bars shall be supported in position, except where two layer construction is used and reinforcement is placed on the bottom layer in a method of construction approved by the Engineer.

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6.3.31

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 27

The concrete shall be spread uniformly without segregation or varying degrees of precompaction, by conveyor, chute, blade or auger. The concrete shall be struck off by a screed or auger so that the average and differential surcharge is sufficient for the surface of the slab to be at the correct levels after compaction of the concrete.

3

The concrete shall be compacted by vibrating finishing beams across the slab and with vibrating pokers adjacent to the side forms or the edge of a previously constructed slab. In addition, internal poker vibration shall be used for slabs thicker than 200mm and may be used for lesser thicknesses. When used, the pokers shall be at points not more than 500mm apart over the whole area of the slab, or drawn continuously across the slab in front of the finishing beams.

4

The finishing beams shall be metal with a contact face at least 50mm wide. They shall be rigid or supported by a frame or truss without sag across the width of slab being paved. The beams shall be supported on rails or forms or an adjacent slab and shall be moved forward at a steady speed of 0.5m to 2m per minute whilst vibrating, to compact the concrete and to produce a smooth surface finished to the correct crossfalls, crowns and levels relative to the top of the forms or adjacent slab.

5

Any irregularities at wet-formed joint grooves shall be rectified by means of a vibrating float at least 1.0 m wide drawn along the line of the joint. The whole area of the slab shall be regulated by two passes of a scraping straight edge not less than 1.8m wide or by a further application of a twin vibrating finishing beam. All slabs shall be checked for level using a straight edge at least 4m long. Any excess concrete on top of the groove former shall be removed before the surface is textured.

6

The surface shall be brush textured.

7

The surface shall be cured within the time to completion given in Table 6.4

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Table 6.4 Maximum Working Times

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Temperature of concrete at discharge from the delivery vehicle

Reinforced Concrete Slabs Consumed in Two layers Mixing first layer to finishing concrete

Not more than 25 °C

All other Concrete Slabs

between layers

Mixing first layer to finishing concrete

between layers in 2 layer work

3 hours

1/2 hour

3 hours

1 1/2 hours

Exceeding 25 °C

2 hours

1/2 hour

2 hours

1 hour

Exceeding 30 °C

unacceptable for paving

unacceptable for paving

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 28

Surface Textures

1

After the final regulation of the surface of the slab and before the application of the curing membrane, the surface of concrete slabs to be used as running surfaces shall be brush textured in a direction at right angles to the longitudinal axis of the carriageway.

2

The texture shall be applied evenly across the slab in one direction by a brush not less than 450 mm wide. The texture shall be uniform both along and across the slab.

3

Curing

4

Immediately after the surface treatment, the surface and exposed edges of surface slabs shall be cured for a minimum period of 7 days (unless the Engineer agrees to a shorter period). This will be by the application of an approved resin based aluminised curing compound, or polythene sheeting or an approved sprayed plastic film which hardens into a peelable plastic sheet. It shall be removed before road marking and opening to traffic.

5

Resin based aluminised curing compound shall contain sufficient flake aluminium in finely divided dispersion to produce a complete coverage of the sprayed surface with a metallic finish. The compound shall become stable and impervious to evaporation of water from the concrete surface within 560 minutes of application and shall have an efficiency index of 90% when tested as described in BS 7542.

6

The curing compound shall not react chemically with the concrete to be cured and shall not crack, peel or disintegrate within three weeks after application.

7

Prior to application, the contents of any containers shall be thoroughly agitated. The curing compound shall be mechanically applied using a fine spray onto the surface at a rate of at least 0.221L/m2. For the sides of slip-formed slabs or when the side forms are removed within 24 hours and for small areas where mechanical application cannot be used, the compound shall be sprayed by hand lance at a rate of at least 0.271/m2. The rate of spread shall be checked during construction of each trial length and subsequently whenever required by the Engineer.

8

The mechanical sprayer shall incorporate an efficient mechanical device for continuous agitation and mixing of the compound in its container during spraying.

9

Continuously reinforced concrete road bases shall also be cured. Wet lean concrete road bases and sub-bases shall also be cured.

10

REQUIREMENTS FOR WET LEAN CONCRETE

11

Materials and Mix Designs

12

The constituent materials and the grades of concrete for wet lean mix shall comply with the requirements of Section 5: Part 16.

13

Placing

14

Wet lean concrete shall be spread uniformly without segregation and without varying degrees of pre-compaction.

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6.3.33

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 29

The concrete shall be struck off to a level so that the surcharge is sufficient to ensure that after compaction the surface is at the required level.

16

Compaction

17

The spread wet lean concrete shall be compacted using internal or external vibration, or combination of both to meet the required density.

18

Compaction and finishing to level shall be completed within the times given in Table 6.4.

19

Joints

20

At transverse and longitudinal construction joints between two separately constructed slabs, the previously laid slab end or edge shall present a vertical face before construction of subsequent slabs.

21

Longitudinal joints in wet lean concrete shall be staggered by at least 300mm from the position of longitudinal joints in any superimposed concrete slab, and by 1m for transverse joints.

6.3.34

Strength

1

From each sample, three cubes of the appropriate size shall be made, cured and tested in compliance with BS 1881.

2

One of each group shall be tested at 7 days and the other two at 28 days. The cubes shall be assessed for compliance on groups of four 28-day test results in accordance with BS EN 206 & BS 8500 for compliance with the grade required.

3

If the average value of any four consecutive results of tests at 7 days falls below the required values the cement content of the mix shall be increased by an amount agreed with the Engineer which shall be maintained until the corresponding 28-day test results have been assessed.

6.3.35

Trial Mixes

1

Trial mixes complying with the requirements for pavement quality concrete shall be required for designed mixes for Grade C15 and above, unless recent data relating to the proposed mix is approved by the Engineer.

6.3.36

Trial Length

1

At least 10 days before the start of the main wet lean concrete works a trial length of at least 400 m2 for mechanised construction and 30m for hand guided methods shall be constructed.

2

The trial length shall be laid to assess the suitability of the proposed material, plant, equipment and construction methods to meet the requirements of the Specification.

3

The main construction in the permanent works shall not start until the trial length has been approved by the Engineer.

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15

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 30

If any trial length does not conform to the Specification another trial length shall be constructed. Trial lengths not complying with the Specification shall be removed unless they can be rectified to comply with the Specification to the satisfaction of the Engineer.

5

After approval has been given, the material plant, equipment and construction methods shall not be changed without the approval of the Engineer.

6

Any proposed changes shall entitle the Engineer to require the Contractor to lay a further trial length to assess the suitability of the proposed changes.

6.3.37

Surface Finish

1

The surface of the wet lean concrete after compaction and finishing and before overlaying shall be free from ridges, loose material, pot holes, ruts or other defects.

2

The surface texture shall comply with the sub-Clause for pavement quality concrete, Section 5: Part 16.

6.4

REQUIREMENTS FOR CEMENT BOUND MATERIALS

6.4.1

General Requirements for Cement Bound Materials

1

Cement bound materials shall be made and constructed as described in the following clauses.

2

Cement bound materials shall be tested in accordance with this specification for the requirements of Table 6.5

3

Cement water and aggregates shall comply with the requirements of the Section 5: Part 16.

4

Cement for use in all cement bound materials and aggregates for use in CBM3 and CBM4 shall be delivered and stored in compliance with the requirements of Section 5: Part 16.

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Table 6.5 Cement Bound Materials Field Requirements

Category

Mixing Plant

Method of Batching

Moisture Content

Minimum Compaction

CBM 1

mix in place or mix in the plant

volume or mass

NOTE 1

NOTE 2

CBM 2

mix in place or mix in the plant

volume or mass

NOTE 1

NOTE 2

CBM 3

mix in the plant

mass

NOTE 1

NOTE 2

CBM 4

mix in place or mix in the plant

volume or mass

NOTE 1

NOTE 2

NOTE 1 NOTE 2

to suit the requirements for strength surface, level regularity and finish 95% of cube strength

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 31

Table 6.6 Cement Bound Materials Specimen Requirements

Category

Curing

Compressive Strength Testing

CBM 1

BS 1924 Part 2 1990

CBM 2

CBM 3

Individual (Note2) (MPa)

BS 1924 Part 2 1990 or BS 1881Part 116

4.5

2.5

BS 1924 Part 2 1990

BS 1924 Part 2 1990 or BS 1881 Part 116

7.0

4.5

BS 1881 Part 111

BS 1881 Part 116

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Average (Note1) (MPa)

BS 1881 Part 116

10.0

6.5

15.0

10.0

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CBM 4

The average strength of 5 cubes shall not be less than the stated figure The strength of any individual cube shall not be less than the stated figure

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NOTE 1 NOTE 2

Minimum 7 days Cube Strength

Batching and Mixing

1

Batching and mixing shall be carried out in the appropriate manner described in Table 6.5.

2

Where the mix-in plant method is used and materials are batched by mass, the materials shall be batched and mixed in compliance with BS EN 206 & BS 8500. Where continuous mixers are used and materials are batched by mass, the continuous mixers shall comply and tested in accordance with BS 3963.

6.4.3

Transporting

1

Plant-mixed cement bound material shall when mixed be removed at once from the mixer, transported directly to the point where it is to be laid and protected from the weather both during transit from the mixer to the laying site and whilst awaiting tipping.

6.4.4

Laying

1

All cement bound material shall be placed and spread evenly in such manner as to prevent segregation and drying.

2

Spreading shall be undertaken either concurrently with placing or without delay.

3

Road base cement bound material shall be spread using a paving machine or a spreader box approved by the Engineer and operated with a mechanism which levels off the cement bound material to an even depth.

4

Cement bound material shall be spread in one layer so that after compaction the total thickness is as specified.

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6.4.2

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 32

At longitudinal or transverse construction joints, unless vertical forms are used, the edge of compacted cement bound material shall be cut back to a vertical face where the correct thickness of properly compacted cement bound material has been obtained.

6

In the case of cement bound sub bases under a concrete surface slab or continuously reinforced concrete road base, longitudinal construction joints in the sub-base shall be staggered by at least 300mm from the position of the longitudinal joints in the concrete surface slab or continuously reinforced concrete road base, and by 1m for transverse joints.

6.4.5

Compacting

1

Compaction shall be carried out immediately after the cement bound material has been spread and in such a manner as to prevent segregation.

2

Special care shall be taken to obtain full compaction in the vicinity of both longitudinal and transverse construction joints.

3

Compaction shall be carried out in compliance with Table 6.5 and be completed within 2 hours of the addition of the cement. The 2 hours may be varied at the discretion of the

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Engineer if the preliminary trial indicates that this is necessary or appropriate. After compaction has been completed, compacting equipment shall not bear on cement bound material for the duration of the curing period. The surface of any layer of cement bound material shall on completion of compaction and immediately before overlaying, be well closed, free from movement under compaction plant and from ridges, cracks, loose material, pot holes, ruts or other defects. All loose, segregated or otherwise defective areas shall be removed to the full thickness of the layer and new cement bound material laid and compacted.

6.4.6

Curing

1

Immediately on completion of compaction, the surface of concrete or wet lean concrete or cement bound road bases and sub-bases shall be cured for a minimum period of 7 days (unless the Engineer agrees to a shorter period) by one of the following methods:

2

Covering with an impermeable sheeting with joints overlapping at least 300 mm and set to

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prohibit egress of moisture. The sheeting shall be removed at the end of the curing period. 3

Bituminous spraying which shall only be applied when there is no visible water. When the cement bound material is likely to be exposed to high temperatures and solar radiation, the bituminous spray shall be blinded with light coloured material.

4

Spraying with a curing compound.

5

Spraying with an approved plastic film which when hardened shall be removed before applying any other pavement layer.

6

Whichever method is used, immediately prior to overlaying with any bituminous layer in cationic bituminous tack coat shall be applied at a rate between 0.351/m2 to 0.551/m2.

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 33

6.4.7

Preliminary Trial

1

At least 10 days before the start of the main cement bound material works a trial area of at least 400 m2 shall be laid to asses the suitability of the proposed materials, mix proportions, mixing, laying, compaction plant and construction procedures. When applicable the area shall include one longitudinal and one transverse construction joint. The location and area of the trial shall be subject to the approval of the Engineer.

3

The rate of testing for the trial area shall not be less than that required in this section of the specification.

4

The trial area will only be accepted for main construction in the Permanent Works if it complies with the Specification.

5

The main construction in the Permanent Works shall not start until the trial has been approved by the Engineer.

6

After approval has been given, the materials, mix proportions, mixing, laying compaction plant and construction procedures shall not be changed without the approval of the Engineer who may require the Contractor to lay a further trial area to assess the suitability of the proposed changes.

6.4.8

Cement Bound Material Category 1 (CBM1)

1

CBM1 shall be made from material which has a grading finer than the limits of Table 6.7

2

In addition to the requirements of Table 6.6 the average compressive strength determined after immersion in water of five test specimens of CBM1 shall not be less than 80% of the average compressive strength of five control specimens when subjected to the test procedure described in BS 1924: Part 2: 1990, clause 4.3.

3

After the 7 days immersion period the specimens shall not show any signs of cracking or swelling.

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Table 6.7 Material for CBM1 - Limit of Grading

BS Sieve Size (mm)

Percentage by Mass Passing

50

100

37.5

95

20

45

10

35

5

25

0.600

8

0.300

5

0.075

0

The particle size distribution shall be determined by the washing and sieving method of BS812:

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 34

Cement Bound Material Category 2 (CBM2)

1

CMB2 shall be made from gravel sand, a washed or processed granular material, crushed rock, all in aggregate, blastfurnace slag or any combination of these. The material shall fall within the grading limits of Table 6.8.

2

The material shall have 10 % fines value of 50 kN or more when tested in accordance with BS 812 with samples in a soaked condition.

3

In addition to the requirements of Table 6.6 the average compressive strength determined after immersion in water of five test specimens of CBM2 shall not be less than 80% of the average compressive strength of five control specimens when subjected to the test procedure described in BS 1924: Part 2: 1990, clause 4.3. After the 7 days immersion period the specimen shall not show any signs of cracking or swelling.

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Table 6.8 Material For CBM2 - Range Of Grading

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6.4.9

20

100 95-100 45-100 35-100 25-100

2.36

15-90

0.600

8-65

0.300

5-40

0.075

0-10

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Percentage by Mass Passing

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BS Sieve Size

The particle size distribution shall be determined by the washing and sieving method of BS 812.

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NOTE: 6.4.10

Cement Bound Material Category 3 (CBM3)

1

CBM3 shall be made from aggregates as in the sub-Clause 6.5.9.

2

The grading of the aggregate shall be within the limits of Table 6.9.

6.4.11

Cement Bound Material Category 4 (CBM4)

1

CBM4 shall be made from aggregates as in sub-Clause 6.5.9

2

The grading of the aggregate shall be within the limits of Table 6.9.

QCS 2014

Section 06: Road Works Part 06: Concrete Road Pavements

Page 35

Table 6.9 Material for CBM3 and CBM4 - Range of Grading Percentage by Mass Passing. Nominal Maximum Size

BS Sieve Size (mm)

50

100

-

37.5

95-100

100

20

45-80

95-100

5

25-5-

35-55

0.600

8-30

10-35

0.150

0.8*

0-8*

0.075

0.5

0-5

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20 mm

The particle size distribution shall be determined by the washing and sieving method of BS 812. *0-10 for crushed rock fines

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NOTE:

40 mm

Testing of Cement Bound Materials

1

Samples shall be provided in accordance with BS 1924: Part 1: 1990 Clause 5 from the laid cement bound material before compaction. One group of five samples shall be provided from five locations equally spaced along a diagonal that bisects each 800 mm2 or part thereof laid each day. The number of groups may be increased if required by the Engineer.

2

One 150 mm cube shall be made from each sample taken in accordance with sub-clause 1 of this clause. The cubes shall be made in accordance with BS 1924: Part 2: 1990, clause 4.2.5 without further mixing of the material and within 2 hours of the addition of the cement. Cubes shall be cured and tested in accordance with Table 6.6.

3

To determine the wet density of cubes the mould shall be weighed prior to making the cube and the mass recorded. Immediately after completion of compaction, the cube and mould shall be weighed and the mass recorded. These masses together with the nominal volume of the mould shall be used to derive the wet density of the cube.

4

The in-situ wet density of a layer of cement bound material shall be taken as the average of the wet densities at five locations equally spaced along a diagonal that bisects each 800 m2 or part thereof laid each day. The wet density at each location shall be the average of two readings obtained using a nuclear density gauge complying with BS 1377: Part 9. The two readings shall be taken at 180 degrees to each other using the same source rod hole. The source rod shall be lowered to within 25mm of the bottom surface of the layer. Readings shall be taken within two hours of completing final compaction.

6.4.13

Special Requirements for Cement Bound Materials

1

Where specified in the contract documents or on the project drawings cement bound road base in flexible composite construction shall be laid in individual widths with longitudinal construction joints in locations as detailed below:

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6.4.12

(a)

Single All purpose. One longitudinal construction joint at the centre lane line marking.

QCS 2014

2

Section 06: Road Works Part 06: Concrete Road Pavements

Page 36

(b)

Dual 2 lane All-purpose. One longitudinal construction joint at the lane line marking.

(c)

Dual 3 lane All-purpose. Two longitudinal construction joints, one at each of the lane line markings.

(d)

Dual 2 lane Motorway. Two longitudinal construction joints, one at the lane line marking and one at the edge line marking between hard shoulder and left hand lane.

(e)

Dual 3 lane Motorway. Three longitudinal construction joints, one at each lane line marking and one at the edge line markings between hard shoulder and left hand lane.

(f)

Dual 4 lane Motorway. Four longitudinal construction joints, one at each lane line marking and one at the edge line marking between hard shoulder and left hand lane.

Longitudinal constructions joints shall not be more than 150 mm from the centre of the centre

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Longitudinal construction joints shall not be located within the left hand lane or dual carriageways. At tapers and other changes in section the construction joint layout shall be agreed with the Engineer, and where necessary joints shall also be permitted within 150 mm

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END OF PART

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line, lane line, or edge line marking, with individual widths not exceeding 4.75 m.

QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 1

ASPHALT PLANTS ................................................................................................. 3

7.1

ASPHALT BINDERS DELIVERY, HANDLING AND STORAGE .............................. 3

7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6

ASPHALT PLANTS PRODUCTION CONTROL ...................................................... 4 Factory Production Control (FPC) 4 Factory Production Control Quality Plan 4 Organizational Structure 5 Internal Audits 5 Management Review 5 Document Control 5

7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6

PRODUCT REALISATION ...................................................................................... 6 Constituent Materials 6 Customer Supplied Product 6 Process Control 6 Handling, Storage and Delivery 7 Plant Calibration and Maintenance 7 Plant Quality Control Laboratory 8

7.4 7.4.1 7.4.2 7.4.3

INSPECTION AND TESTING .................................................................................. 9 General 9 Incoming constituent materials 9 Finished Asphalt Mixture 9

7.5 7.5.1 7.5.2

NON-CONFORMITY ............................................................................................. 10 General 10 Non-conformity of Material or Asphalt Mixtures 10

7.6

INSPECTION, MEASURING AND TEST EQUIPMENT ......................................... 11

7.7

PLANT GENERALLY ............................................................................................. 11

7.8 7.8.1 7.8.2 7.8.3 7.8.4 7.8.5 7.8.6 7.8.7 7.8.8 7.8.9 7.8.10 7.8.11 7.8.12 7.8.13 7.8.14 7.8.15 7.8.16

ASPHALT PLANT .................................................................................................. 12 General 12 Automatic Operation 12 Cold Bins System 12 Drier 13 Dust Collector 13 Screens 13 Hot Bins 13 Asphalt Binder Storage 14 Thermometric Equipment 14 Control of Mixing Time 14 Pugmill 14 Temporary Storage of Mix 15 Safety Requirements 15 Weigh-Box 15 Scales or Meters 16 Plant Control System 16

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7

QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 2

APPENDICES APPENDIX “A” .................................................................................................................... 17 APPENDIX “B” .................................................................................................................... 22

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APPENDIX “C” .................................................................................................................... 25

QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 3

7

ASPHALT PLANTS

7.1

ASPHALT BINDERS DELIVERY, HANDLING AND STORAGE

1

Before loading, the bitumen manufacturer shall examine the shipping container and remove all remnants of previous cargos that may contaminate the material to be loaded.

2

The manufacturer shall furnish with each shipment two (2) copies of the delivery ticket containing the following: Consignees’ details.

(b)

Net liters.

(c)

Net weight.

(d)

Type and amount of anti-stripping agent (if any).

(e)

Identification number (truck, car tank, etc.)

(f)

Destination.

(g)

Date.

(h)

Loading temperature, and the recommended delivery temperature range.

(i)

Specific gravity.

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(a)

The bitumen manufacturer shall deliver a signed Certificate of Compliance to cover the quality and quantity of material and the condition of container for each shipment. Test results shall be provided with the shipment.

4

Bituminous materials furnished without a Certificate of Compliance should not be introduced into the work until the Contractor has had sufficient time to sample and test the delivered materials.

5

The delivery tanker shall be insulated with a rock wool or similar material. Burner tubes shall be designed so that the bituminous material is evenly heated with no hot spots within the tanker. Temperature gauges shall be calibrated and positioned such that the maximum temperature in the tanker shall be indicated. The temperature of unmodified and modified bitumen during delivery shall be maintained in accordance with the manufacturer recommendations. Tankers shall be designed to enable the safe sampling of the bitumen from the top of the tanker or from a sampling valve. Sampling shall not take place whilst the tank is under pressure.

6

The Contractor shall obtain acceptance samples of bituminous material according to ASTM D140 at the applicable point of acceptance.

7

For bituminous material used in direct application on the road, samples shall be taken from each shipping container at the time of discharge into distributors or other conveyances on the project.

8

For bituminous material initially discharged into storage tanks on the project, samples shall be taken from the line between the storage tank and the distributor or the asphalt plant after each delivery. Samples shall be taken after a sufficient period of circulation has taken place to ensure samples are representative of the material in the storage tank.

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The manufacturer of bituminous materials shall test all materials produced and the test results retained for reference. Each shipment of bituminous material delivered to the asphalt plant shall be sampled. The samples shall be numbered consecutively and identified by project, type and grade of bituminous material, date of delivery and use. Samples testing frequency shall be based on LSA and the Engineer approval.

10

Each bitumen delivery and storage tank and its associated delivery pipe and control valve must be independently and uniquely identified with the tank number.

11

Storage tanks must also display the grade of bitumen held in the tank.

12

Adequate and reliable means of gauging the bitumen tank contents and ullage must be available at the discharge point.

13

Vent pipes must be fitted in bitumen tanks and located where they do not pose a risk to any personnel or delivery vehicles and must be kept clear at all times.

14

It is recommended that bitumen tanks should be fitted with a correctly designed drain valve to enable the safe emptying of the tank for cleaning and maintenance. In the absence of a drain valve, a specific risk assessment must be carried out prior to any uplift of product.

15

Samples must not be taken from the bitumen delivery vehicle or hoses at the delivery site unless equipment is fitted to do so safely.

16

If there is a requirement to take bitumen samples a purpose designed valve should be permanently fitted to the tank (or corresponding pipework).

7.2

ASPHALT PLANTS PRODUCTION CONTROL

7.2.1

Factory Production Control (FPC)

1

The Organization shall establish and operate a permanent factory production control system to ensure delivery of the quality requirements of the project specification whilst maintaining a regime of continuous improvement and ensure the competence and training of staff and operators. The Organization shall document and maintain the FPC system in which procedures, regular inspections and tests and/or assessments and the use of the results to control raw and other incoming materials or components, equipment, the production process and the product.

2

A sample plant inspection checklist, which includes the minimum items to be covered as part of LSA inspection, Engineer inspection and producer internal audit system, is provided in Appendix “C”.

7.2.2

Factory Production Control Quality Plan

1

The Organization shall establish and maintain FPC documentation for each asphalt production site used to supply the works.

2

The FPC documentation shall include a means for identifying and detailing the specific processes that directly affect the quality of the asphalt. This shall particularly address:

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(a)

Producer’s organizational structure relating to conformity and quality.

(b)

Document control.

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(c)

Control procedures for constituent materials and purchaser supplied product.

(d)

Process control

(e)

Requirements for the handling and storage of the product.

(f)

Plant calibration and maintenance.

(g)

Quality control laboratory calibration and maintenance.

(h)

Requirements for inspection and testing of processes and products.

(i)

Procedures for handling non-conformity.

Organizational Structure

1

The responsibility, authority and inter-relation of all personnel who manage, perform and verify work affecting conformity and quality shall be defined in the quality plan, particularly for personnel who have authority to:

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Initiate action to prevent the occurrence of product non-conformity.

(b)

Identify and record any product quality problems.

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The producer shall identify a person with appropriate authority, knowledge and experience to supervise Factory Production Control and to ensure that the requirements of the quality plan are implemented and maintained. The person identified may exercise such supervision over a group of plants.

3

The management structure shall be documented. Names, affiliations, and positions of principal staff shall be listed. The organization chart shall clearly define relationships with other partner organizations where applicable.

7.2.4

Internal Audits

1

The Organization shall carry out internal audits to verify which activities comply with the planned arrangements and to determine the effectiveness of the Factory Production Control system. Audits shall be scheduled on the basis of the status and importance of the activity. The audits and follow up action shall be carried out in accordance with documented procedures. The results of the audits shall be documented and brought to the attention of the personnel having responsibility in the area audited. The management personnel responsible for the area shall take timely corrective action on the non- conformities found by the audit and shall keep a record of the action taken.

2

The frequency of such audits shall be that each area of process is audited at least annually.

7.2.5

Management Review

1

The system shall be reviewed at least annually by management to ensure its continuing suitability and effectiveness.

7.2.6

Document Control

1

The producer shall establish and maintain documented procedures to control all documents and data that relate to the requirements of these specifications.

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The producer shall maintain all documents related to daily production quality records, test methods, practices, procedures, and specifications.

3

Records relating to Factory Production Control shall be maintained and accessible by the Organization and shall be produced if requested by the Engineer or any authorized audit body.

4

Management review, internal audits, 3rd party assessment, and inspection and testing of finished asphalt shall be kept for a minimum of ten years. All other quality records shall be kept until at least five years after the completion of the project, or longer as the Organization requires.

7.3

PRODUCT REALISATION

7.3.1

Constituent Materials

1

Adequate supplies of constituent materials shall be available to ensure that the planned rates of production and delivery can be maintained.

2

The specification and tolerances for incoming constituent materials shall be established and communicated to suppliers by appropriate traceable and confirmable means.

3

The control procedures shall verify that suppliers of incoming materials are capable of providing the required quality of materials.

4

Different material types or grades shall be transported and stored in such a manner as to avoid intermingling, contamination or deterioration which may adversely affect the quality of the product.

5

The general requirements of this clause shall be translated into more detailed plant specific requirements within the FPC and include the following:

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Procedures for the control of aggregates delivered to a depot or plant site.

(b)

Requirements for labelling of storage bays and silos.

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Requirements for heating, temperature control and insulation of binder tanks, pipes and pumps.

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(d)

Requirements for controlling delivery of binders into the correct tanks, including stirrers/agitators and labelling of tanks, and the selection of the correct tanks for use.

(e)

Requirements for the control of additives.

(f)

Requirements for the manufacture of polymer modified binders at site by the Organization or its supplier, where applicable.

7.3.2

Customer Supplied Product

1

Any constituent material supplied by the customer for inclusion in the asphalt shall be handled, stored and maintained free of contamination by the Organization.

7.3.3

Process Control

1

The FPC quality plan shall include the following items of process control:

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A description of the flow of materials and the processes carried out on them from receipt at the plant to delivery to the job site. This shall incorporate a flow diagram.

3

A statement of the production control processes necessary to maintain and regulate the quality of material in conformity with the specification. This will include the procedure for the control of batching instructions.

4

A schedule for monitoring the performance of the process, which is shown in Table A-1 in Appendix “A”, resulting in a record of plant performance against stated tolerances.

5

A detailed method statement for the production of polymer modified binder including storage and quality control, and the procedure for the handling of nonconforming product.

7.3.4

Handling, Storage and Delivery

1

The FPC quality plan shall contain procedures to ensure that the asphalt mixture is handled, stored, discharged and delivered at the specified temperature range, minimizing segregation and degradation.

2

The asphalt mixture shall be identifiable and traceable with regard to its production data and can be referenced from information on the delivery ticket from its manufacture to its point of installation. The quality plan shall however make clear the point to which the Organization’s responsibility for handling storage and delivery extends.

3

The quality plan shall describe the characteristics of any hot storage system and define its mode of operation. The Organization shall ensure thorough checks, inspections and records that such systems are used correctly and that bituminous mixtures maintain their suitability for use.

4

Bituminous materials shall not be heated during the process of its manufacture or during construction so as to cause damage to the materials as evidenced by the formation of carbonized particles.

7.3.5

Plant Calibration and Maintenance

1

The FPC quality plan documentation shall identify those items of measuring equipment which require calibration and the frequency of such calibration which shall comply with the requirements of QCS 2014, or its revisions, and the contract specification.

2

Calibration procedures shall be provided, including the permitted tolerances for the equipment to remain in service. The quality plan shall state the required accuracy of all plant calibrations and shall identify any that require traceability to national reference standards (e.g. mass or weight).

3

The plant shall be maintained to ensure that it continues to be capable of producing asphalt to the required specifications and tolerances. Table A-2 gives guidance with regard to schedules for calibration and checks.

4

The FPC quality plan documentation shall identify those items and areas of the plant where constant use and wear will affect the quality of production including, but not limited to, the dryer drum, hot elevator, screen deck and meshes, hot bins, weighing and mixing apparatus, and state the inspection and maintenance schedules for these items in order to maintain them to the condition necessary to ensure the quality of production.

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A maintenance schedule shall be available and maintenance records shall be kept.

7.3.6

Plant Quality Control Laboratory

1

The asphalt plant shall have a quality control testing laboratory capable of conducting the following tests: Sieve analysis (ASTM C117, C136, and D5444).

(b)

Specific gravity for coarse and fine aggregates (ASTM C127, C128).

(c)

Theoretical maximum specific gravity and density of asphalt mixtures (ASTM D2041).

(d)

Quantitative extraction of asphalt binder from asphalt mixtures (ASTM D2172).

(e)

Bulk specific gravity and density of compacted asphalt mixtures (ASTM D1188, D2726).

(b)

Qualified laboratory manager.

(c)

Qualified technicians.

(d)

Calibrated equipment.

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The asphalt plant laboratory shall have a database includes but not limited to the following: (a)

Production data.

(b)

Testing data.

(c)

Materials type and materials traceability to source data.

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The asphalt plant laboratory shall have the following:

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(a)

The plant laboratory shall keep records of materials and asphalt mixtures properties on a daily basis.

5

The laboratory shall maintain a position description for each technical operational position shown on the laboratory’s organization chart. Position descriptions shall identify the position and include a description of the duties, required skills, and education and experience associated with the position.

6

The laboratory shall maintain technical staff training records, qualifications, work experience, licensure, certifications, and current position for each supervisory technical staff member.

7

The laboratory shall maintain a procedure which describes the methods used for laboratory personnel training to perform tests in accordance with standard procedures. Records of laboratory personnel training shall be maintained.

8

The laboratory shall maintain a procedure describing the method used to evaluate staff competency to ensure that each test covered by the scope of this standard is performed in accordance with standard procedures. This description shall include the frequency of competency evaluations for each technician and indicate what position or employee is responsible for evaluating staff competency and maintaining records. The procedure shall ensure that each technician receives a performance evaluation for each test that technician performs.

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The laboratory shall calibrate, standardize, and check all significant equipment associated with tests which the laboratory performs.

10

The laboratory shall have a procedure for the storage, retention, and disposal of test samples.

7.4

INSPECTION AND TESTING

7.4.1

General

1

All necessary facilities, equipment and personnel shall be available to carry out the required inspections and tests.

2

Inspection and testing shall be carried out at least as frequently as indicated in Tables A-3 to A-7. Sampling shall be randomised so as not to introduce undue bias in the assessment of compliance. Due care shall be taken to adequately cover both large and small volumes of material.

3

At least 10% of quality control tests related to constituent materials and finished mixtures shall be carried out by an approved thirty party laboratory. Third party testing schedule shall be liaised with the Engineer.

4

The results of all tests carried out on materials shall be recorded. Tests taken specifically for the resolution of problems arising from process control shall be kept separately and need not be used for the purpose of calculating compliance with the technical specifications.

5

All sampling and testing shall be carried out in accordance with the relevant standard procedures required by the specification.

7.4.2

Incoming constituent materials

1

Incoming constituent materials shall be inspected and tested using procedures detailed in the quality plan and to a schedule complying with this clause and the requirements of QCS 2014, or its revisions, and the contract specification.

2

The required inspections of materials in storage shall be maintained to establish that no deterioration has occurred.

3

Detailed requirements shall be as follows:

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(a)

Aggregates: see Table A-3.

(b)

Filler: see Table A-4.

(c)

Additive: see Table A-5.

(d)

Binders: see Table A-6.

(e)

Finished Asphalt Mixture: see Appendix “B”.

7.4.3

Finished Asphalt Mixture

1

The finished asphalt mixture shall be inspected and tested using procedures detailed in the quality management system documentation and to a schedule complying with the requirements of QCS 2014 and the contract specification.

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Appropriate statistical records shall be maintained in order to monitor and verify process capability and product characteristics.

3

Individual batch readings shall be recorded as part of the quality records. The plant pyrometer shall be calibrated in accordance with ASTM E2847 and checked daily against a calibrated laboratory thermometer, the record of which shall be maintained in the plant control cabin/office. The temperature of the finished asphalt shall be the average load temperature however no batch or part of the load shall exceed the maximum JSM temperature for the mix. Measurement shall be in accordance with QCS 2014.

4

As a regular audit check on the efficacy of the plant quality control laboratory, 10% of samples analysed for mix composition by the plant control laboratory shall have a duplicate sample analysed in an independent laboratory, which is ISO17025 accredited in related tests. The duplicate sampling may be done simultaneously as part of the Organization’s other testing obligations conducted by an approved independent laboratory. The duplicate results shall be regularly reviewed and any differences falling outside the reproducibility limits published in the test standard applicable to the ASTM test methods employed shall be investigated.

5

The results of all tests carried out on materials shall be recorded. Tests taken specifically for the resolution of problems arising from process control shall be kept separately and need not be used for the purpose of calculating compliance with the technical specifications.

6

All sampling and testing shall be carried out in accordance with the relevant standard procedures required by the specification.

7

Sampling frequencies, operating compliance level (OCL) and test frequencies are provided in Appendix “B”.

7.5

NON-CONFORMITY

7.5.1

General

1

The producer shall establish and maintain documented procedures to ensure that constituent materials or asphalt mixture which when identified by in-process inspection does not conform to specified requirements is prevented from use or installation. This control shall provide for identification, evaluation, separation from conforming product (when practical) and disposal of the nonconforming material or asphalt mixture.

2

The non-conformance process shall include:

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(a)

Constituent materials upon arrival at the plant or storage site.

(b)

Constituent materials in storage.

(c)

The manufacturing process.

(d)

Handling, storage and delivery of the finished product.

7.5.2

Non-conformity of Material or Asphalt Mixtures

1

Where non-conforming constituent materials or finished asphalt mixtures are identified, the cause of the non-conformance shall be investigated and identified to effect appropriate corrective actions to prevent a reoccurrence. Such corrective actions shall be incorporated into the FPC quality plan.

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Corrective actions may involve reworking the material, adjusting the process, redirection to another use where it may be acceptable, recycling for further use or rejection and disposal.

3

The FPC quality plan shall identify the action to be taken in process control when nonconforming product is identified from analysis.

4

The FPC quality plan shall state the process under which the installation contractor and the supervising agency will be notified of non-conforming analysis results.

7.6

INSPECTION, MEASURING AND TEST EQUIPMENT

1

The Organization shall control, calibrate and maintain suitable measuring and test equipment as required by this guidance document and QCS 2014.

2

To ensure the testing of incoming constituent materials and finished asphalt conforms to the relevant test method specification, the Organization, or where an independent laboratory is employed by the Organization to conduct its quality control testing, shall ensure within the FPC quality plan that the measuring and test equipment used is maintained in a known state of calibration and maintenance.

3

The equipment control procedures shall demonstrate the following:

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Accuracy and frequency of calibration, which should be in accordance with the relevant test standard.

(b)

Equipment is used in accordance with a documented procedure.

(c)

Equipment is uniquely identified.

(d)

Calibration records to be maintained.

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(a)

PLANT GENERALLY

1

The machinery and tools used in constructing the various items involved in asphalt works shall be in good working condition and free of oil and fuel leaks. The Contractor shall maintain and preserve them for the whole duration of the work. The Engineer shall approve the machinery and tools before works begin and the Contractor shall supply adequate quantities of such machinery in order to execute the work with due speed and precision. Equipment approved for use shall not be removed from the Site without the approval of the Engineer.

2

If required the Contractor shall furnish the Engineer with the manufacturer's catalogues, specifications and other published data for the equipment and machinery he proposes to use.

3

On first erecting an asphalt plant and at least once each three months thereafter, the plant shall be calibrated by a calibration service organisation approved by the LSA. Production shall not be permitted if the weigh batch calibration does not comply with the requirements of ASTM D995-95.

4

The Engineer shall have the right to stop the use of any equipment or plant which he deems to be inferior to the quality required or detrimental to the permanent works and to instruct the removal of such equipment and to have it replaced by suitable equipment.

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The Contractor shall immediately comply with such instructions without being entitled to any indemnities or extensions as a result of such instructions. The Contractor shall not be allowed to use any equipment or plant before obtaining the approval of the Engineer, and the Contractor shall undertake to follow sound technical methods in operation and to engage skilled and trained operators, mechanics and labour to carry out the works. The Engineer shall have the right to expel any operators, mechanics or labour and to instruct suitable replacement thereof at any time he deems such action is necessary.

6

The Contractor shall comply with any special plant requirements published by the concerned authority.

7.8

ASPHALT PLANT

7.8.1

General

1

All plant used by the Contractor for the preparation of asphalt hot mixes shall be batch type plants conforming to the requirements as detailed below.

2

The Engineer may permit the use of continuous drier drum type asphalt plants after a fully detailed technical submission by the Contractor itemising the differences from the specification. In such cases after approval of the technical submission the Contractor shall carry out a full scale laying trial with testing of the hot and laid mix and monitoring of the plant operation by the Engineers staff to assess the suitability of the proposed plant.

3

No laboratory verification or plant trial shall be carried out by the LSA unless an automatic compaction apparatus is available at the producer’s laboratory.

7.8.2

Automatic Operation

1

The plant shall be designed, co-ordinated and operated so as to continually produce an asphalt mix within the job mix tolerances specified.

2

The plant shall be equipped and operated so that the proportioning of the hot aggregate, filler and bitumen, together with the dry and wet mixing cycles are all controlled automatically. Positive interlock shall be provided so that proportioning, mixing and discharge are accomplished by one operation without manual control of the separate phase.

3

The use of manual and semi-automatic plants for the production of asphalt is not permitted unless specific approval is given in writing by the Engineer.

7.8.3

Cold Bins System

1

The plant shall include a sufficient number of cold storage bins so that there is at least one bin for each different stockpile of material being used.

2

Intermixing of material from different stockpiles in one bin or on the ground before putting into the bin is prohibited.

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The cold bins and loading equipment used shall be compatible to prevent overflow between the bins. Baffle plates shall also be used between bins to prevent overflow of one bin into another. Each cold bin shall include an accurate means for continuously feeding the required amount of mineral aggregate so that uniform production is achieved. The settings on the cold bins shall be approved by the Engineer and shall be checked and calibrated as often as he may deem necessary to ensure their continued accuracy. Change of settings shall be made only with the approval of the Engineer.

7.8.4

Drier

1

A drier of satisfactory design shall be provided. The drier shall be capable of uniformly drying and heating the aggregate to the moisture and temperature required without leaving any visible burned oil or carbon residue on the aggregate when discharged from the drier.

7.8.5

Dust Collector

1

The plant shall be provided with a dust collector designed to waste, or to return all or part of the material collected to the asphalt plant.

2

The asphalt plant shall have an efficient fugitive emission collection and control system to control dust or fume emissions from the drying, screening, weighing and mixing operations. The collection system shall be so designed to prevent the emission of dust and fumes into the atmosphere in accordance with the environmental standards of Qatar.

3

The collected dust from the drying process shall pass through a coarse collector which will pass the coarse particles, substantially greater than 0.075mm, back to the hot elevator or to a silo for the controlled return to the asphalt mix. The reclaimed dust substantially less than 0.075mm shall be collected and passed into a storage silo for the controlled return as mineral filler to the asphalt mix through the filler weighbox or sent to waste.

4

The plant shall be equipped with a filler silo for recovered filler. An additional dry storage silo shall be provided for imported mineral filler with a provision of a separate weighing hopper to proportion this filler into the mix.

7.8.6

Screens

1

Plant screens shall be capable of screening all aggregates to the specified sizes and proportions. They shall have capacities equal to or greater than the maximum rated capacity of the plant. They shall have an operating efficiency such that the aggregate deposited in any bins shall not contain more than 10 % oversize or undersize material. This screen tolerance shall not invalidate the job mix tolerances specified.

7.8.7

Hot Bins

1

The plant shall include at least three storage bins for hot aggregate of sufficient size to supply the pugmill when it is operating at full capacity. They shall be arranged to ensure separate and adequate storage of appropriate fractions of the aggregate. Each compartment shall be provided with an overflow pipe that shall be of such size and at such location as to prevent any backing up of material into other bins or against the screens. Bins shall be so constructed that samples can be readily obtained therefrom. The hot bins shall be equipped with continuous level indicators to provide information about the level of each ingredient of the JMF and to avoid shortage or overflow of aggregate from one bin to another.

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Asphalt Binder Storage

1

Tanks for storage of asphalt binders shall be equipped for heating the material using positive and automatic control at all times, to a temperature within the specified range. The heating shall be accomplished by hot thermal oil, electricity or other approved means such that no direct flame shall come in contact with the bitumen or heating tank.

2

The circulating system for the asphalt binder shall be of adequate size to ensure proper and continuous circulation during the entire operating period. Suitable means shall be provided either by double jacketed steam or hot oil or other insulation for maintaining the specified temperature of the bituminous material in the pipeline, meters, weigh buckets, spray bars, and other containers and flow lines.

3

The storage tank capacity shall be sufficient for at least one day's operation. Circulation return lines to the asphalt storage tanks should be submerged to the same elevation in the storage tanks as the feeder line. Two or three vertical slots may be cut in the return line above the high level mark to break vacuum when reversing the pump.

4

The Contractor shall provide a sampling outlet in the asphalt binder feed line connecting the plant storage tanks to the asphalt binder weighing or metering box. The outlets shall consist of valves installed in such a manner that samples may be withdrawn slowly at any time during plant operation. The locations of the sampling outlets shall be readily accessible and free from obstructions. Drainage receptacles shall be provided for flushing the outlets before sampling.

7.8.9

Thermometric Equipment

1

An armoured thermometer reading from 38 C to 204 C shall be fixed in the bituminous feed

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line at a suitable location near the discharge valve. Similar devices shall be fixed in the heating and storage tanks. The plant shall be further equipped with either an approved dial-scale, mercury-actuated thermometer, an electric pyrometer, or other approved thermometric instruments placed at the discharge chute of the drier and in the hot fines bin so as to register automatically or indicate the temperature of the heated aggregates. For better regulation of the temperature of the aggregates, replacement of any thermometer by an approved temperature recording apparatus may be required by the Engineer and he may further require that daily temperature charts be submitted to him by the Contractor.

7.8.10

Control of Mixing Time

1

The Plant shall be equipped with positive means to govern the time of mixing and to maintain it constant unless changed at the direction of the Engineer.

7.8.11

Pugmill

1

The batch mixer shall be an approved twin pugmill type, capable of producing a uniform mixture within the job-mix tolerances. It shall be so designed as to permit a visual inspection of the mix. The mixer capacity shall be not less than 600 kg per batch and shall be so constructed as to prevent leakage of contents.

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The bitumen system shall deliver an even flow of binder into the mixer to ensure an even distribution of bitumen binder throughout the mix during the wet mixing cycle.

3

The mixer shall be fully enclosed with sufficient air extraction to prevent emissions of dust and fumes. The mixing cycle shall be controlled such that from charging of the mixer until the closing of the mixer door at the completion of the cycle there shall be no leakage of aggregate, filler or bitumen from the weighing hoppers. The system shall permit a dry mixing period, defined as the interval of time between opening of the weigh box gate and the start of application of bitumen, if required by the mixing process.

4

The wet mixing period is defined as the interval between the discharge of the bitumen binder into the mixer and the mixer gate is opened to discharge the mix, and shall be not less than 30 seconds. The wet mix time shall be capable of being incrementally set at intervals of not more than five seconds up to a wet mix time of three minutes. A mechanical batch counter shall register the completely mixed batches.

5

The mixer shall be equipped with a full set of mixer paddles in a suitable arrangement, in accordance with the manufacturer’s specification, to produce a proper and uniformly mixed batch. All paddle arms and tips, and mixer liners shall be in good condition. Mixing shall cease if any mixer arms or tips are missing, and shall not resume until replaced and inspected.

7.8.12

Temporary Storage of Mix

1

Plants may be equipped with skips or elevators for delivering batched mix to hoppers or silos before discharging to hauling units. The skips or elevators shall not be sprayed with diesel or other solvents; where necessary they may be sprayed with a minimum amount of lime water, soap or detergent solution. Hoppers or silos shall be of such design that no segregation or loss in temperature of the mix occurs.

7.8.13

Safety Requirements

1

Adequate and safe stairways to the mixer platform and guarded ladders to other plant units shall be placed at all points required for accessibility to all plant operations. Accessibility to the top of truck bodies shall be provided by means of a platform or other suitable device to enable the Engineer to obtain mixture temperature data. To facilitate handling scale calibration equipment and sampling equipment, a hoist or pulley system shall be provided to raise or lower the equipment from the ground to platform or vice-versa. All gears, pulleys, chains, sprockets and other dangerous moving parts shall be thoroughly guarded and protected. Ample and unobstructed passage shall be maintained at all times in and around the truck loading space. This space shall be kept free from drippings from the mixing platform.

2

Accessibility to the top of loaded truck body shall be provided by means of a platform to enable obtaining asphalt mixture samples and temperature readings and to check truck body condition. All necessary safety measures shall be provided for accessing the top of loaded truck body.

7.8.14

Weigh-Box

1

The plant shall include means for accurately weighing each size of aggregate in a weigh-box or hopper, suspended on scales, ample in size to hold a full batch without hand raking or running over.

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The weigh-box or hopper shall be so constructed that they will not be thrown out of alignment or adjustment. All edges, ends and sides of weighing hoppers shall be free from contact with any supporting rods and columns or other equipment that will in any way affect the proper functioning of the hopper.

3

There shall also be sufficient clearance between hoppers and supporting devices to prevent accumulations of foreign materials. The discharge gate of the weigh-box shall be so hung that the aggregate will not be segregated when dumped into the mixer and shall close tightly when the hopper is empty so that no material is allowed to leak into the batch in the mixer during the process of weighing the next batch.

4

Weighing boxes and hoppers shall be free hanging and placed on high precision load cells or strain gauges.

7.8.15

Scales or Meters

1

Scales or meters used for proportioning aggregates, mineral filler and bitumen shall be accurate to 1 % of the indicated quantity. Scales and meters shall be substantially constructed. Scales and meters that require frequent adjustment shall be replaced. Scales shall be constructed and located so as to prevent vibration in the dial pointer.

2

Weighing sequence of hot aggregates shall progress from coarse to fine.

3

Bituminous material shall be automatically proportioned by either weighing or metering. The minimum gradation shall be not more than 1 litre or 1 kg. Bituminous scales and weigh buckets shall be such that the required amount of bitumen is provided in a single weighing and delivered to the pugmill without loss due to overflow, splashing or spillage.

4

Bituminous weigh buckets shall be satisfactorily insulated to prevent loss of heat in the bitumen or accumulation of bitumen in the bucket. Bituminous metering devices shall be rotating positive displacement pumps and shall be capable of providing the designated quantity of material for each batch.

5

All scales and meters shall be approved by the Engineer and shall be checked and calibrated as detailed in Clause 5.3. Production shall not be permitted if the weight batch calibration does not comply with the requirements of ASTM D955-95.

7.8.16

Plant Control System

1

The asphalt plant operations shall be fully automated and connected to a centralized control system. Preferably, the plant operating software shall be capable to store the detailed production history.

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APPENDIX “A”

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QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 18

Table A-1: Process control minimum inspection schedule Inspection/Test

Purpose Identify contamination, intermingling, level ground for tipping, stock availability

Aggregate stockpiles

As FPC quality plan

Cold feed bins

As FPC quality plan

Aggregate dryer

As FPC quality plan

Dried heated aggregate

Aggregate temperature

Control for conformance

Aggregate screens

As FPC quality plan

Identify mechanical and physical defects

As FPC quality plan

Identify mechanical and physical defects

Hot bin gradations

Check screening efficacy

Daily

Weekly

Monthly or as FPC quality plan

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Continuously in production Weekly or as FPC quality plan

Weekly

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Hot aggregate bins

Ensure correct feeding to plant and maintenance of bins Maintenance inspection to ensure effective heating and drying

Minimum frequency

.

Control Area

As FPC quality plan

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Weighing apparatus

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Identify mechanical and physical defect

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Tank temperature

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Bitumen

Binder properties

Check weighing efficacy against truck scale Check storage conformance

Daily

In accordance with storage recommendations

As FPC quality plan or in case of doubt

Temperature monitoring equipment for drying/heating and asphalt mix process

Test of accuracy comparison with calibrated reference thermometer

To ascertain the equipment is functioning correctly

Asphalt mix

Mix temperature

Ensure temperature conformance

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Weekly

Weekly

Each batch or continuously in production

QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 19

Table A-2: Minimum plant calibration and check requirements Inspection/Test

Purpose

Weighing equipment Testing of weighing accuracy - calibration

Organoleptic* inspection Admixture/additive dispensers

Test for accuracy as described in procedures.

To ensure that weighing equipment is Daily functioning correctly 1

To ensure accuracy within quality plan requirements

a) on installation b) every 3 months c) in case of doubt.

To ensure that dispenser is functioning correctly

First batch of the day containing admixture

To ensure accuracy within quality plan requirements

a) on installation b) every 3 months c) in case of doubt.

Batching system (on batch plants)

Comparison of actual mass of constituents in the batch with the intended mass using the method prescribed in the quality plan

1

a) on installation b) every 3 months c) in case of doubt.

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Flow meters

Comparison of the actual To ensure accuracy amount with the metered within quality plan amount by reconciliation requirements

1

.

Visual inspection as described in procedures

Minimum frequency

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To ensure the batching 1 a) on installation accuracy in b) every 3 months accordance with the c) in case of doubt. quality plan

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Comparison of actual mass in a measured Proportioning period of time with the system (cold feed) intended mass using the method prescribed in the quality plan

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Temperature monitoring equipment (infrared pyrometer)

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Visual as described in procedures Test of accuracy comparison with calibrated reference thermometer Test of accuracy calibration

Temperature monitoring equipment (contact probe or thermocouple for drying heating process)

Visual as described in procedures

Test of accuracy calibration

To ensure the accuracy in accordance with the quality plan To ensure the equipment is functioning correctly To ensure the equipment is functioning correctly

1

a) on installation b) every 12 months c) in case of doubt.

Daily

Weekly 1

To ensure correct temperatures are recorded

a) on installation b) every 12 months c) in case of doubt.

To ensure the equipment is functioning correctly

Daily

To ensure correct temperatures are recorded

a) on installation b) every 3 months c) in case of doubt.

1

QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 20

Table A-3: FPC Inspection and test guidance for aggregate stockpiles Inspection/Test

Purpose

Minimum frequency

Tests for aggregate properties

To check suitability for intended use

As required by QCS 2014, or its revisions

Tests for aggregate consistency by sieve analysis

Each size: Weekly To check consignment quality Each consignment: in case of doubt

Inspection of delivery ticket

To check consignment is as ordered and from correct source

Each delivery

To check suitability for intended use

Tests for filler consistency

To check consignment or production quality

As required by QCS 2014, or its subsequent revisions

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Minimum frequency

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Inspection/Test

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Table A-4: FPC inspection and test guidance for Filler

Gradation: Weekly Plasticity: Weekly

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Filler: Non plastic

To confirm characteristics of product or check compliance with specification

Each delivery or weekly for reclaimed filler dust

Inspection of delivery ticket

To check consignment is as ordered and from correct source

Each delivery

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Table A-5: FPC inspection and test guidance for additives Inspection/Test

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Appropriate tests to determine intrinsic properties

Inspection of delivery ticket

Organoleptic* check of consignment

Purpose

Minimum frequency

To confirm characteristics of product or check compliance with specification To check that consignment is as ordered and from the correct source

a) Source approval prior to initial use and b) as stated in the quality plan

For comparison with normal appearance

Each delivery, if practicable; otherwise in accordance with quality plan.

Each delivery

QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 21

Table A-6: FPC Inspection and test guidance for bitumen binder Inspection/Test

Purpose

Minimum frequency

Tests for bitumen properties

To check suitability for intended use

As required by QCS 2014 and project particular specification

Inspection of delivery ticket

To check consignment is as ordered and from the correct source To check that binder is within specified temperature limits

Each delivery or production batch

Temperature

(a) Each delivery or production batch (b) Each tank recorded daily

To assess compliance with specification

1 per 450 tons of binder delivered in normal production

Grade Properties (PG76- 10)

To assess compliance with specification

1 per 450 tons of binder delivered in normal production

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Grade Properties (60/70)

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Prior to production if stored for more than 3 days without further deliveries or production batches

For comparison with normal perceptible properties

Each delivery or daily survey of tanks

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Table A-7: FPC minimum inspection/test frequencies for product quality control Minimum frequency Every load

Suitability of delivery vehicles by visual assessment Cleanliness of delivery vehicles by visual assessment

To check adequacy of insulation

a) Prior to first use b) In case of doubt.

To avoid contamination To control use of release agent

Every load prior to loading

Mixed asphalt temperature

To assess conformity

Grading and binder content

To assess conformity

a) As required under Table 1 b) Whenever samples are taken In accordance with QCS 2014

Other characteristics included in technical specifications

To assess conformity

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For comparison with normal appearance with regard to grading, evenness of mixing and adequacy of binder coating

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Organoleptic* check on mixed asphalt

Purpose

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Inspection/Test

In accordance with QCS 2014

* Organoleptic check: a broader evaluation made with the senses: sight, touch, smell, hearing etc. rather than a visual inspection.

Section 06: Roadworks Part 07: Asphalt Plants

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APPENDIX “B”

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QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 23

MINIMUM SAMPLING FREQUENCIES AND TOLERANCES FOR THE FACTORY PRODUCTION QUALITY CONTROL OF FINISHED ASPHALT General This Appendix includes sampling frequencies and tolerances for mixture composition for use in the evaluation of conformity of mixed asphalt during production. It is consistent with QCS 2014 but is specifically intended as guidance for the Organization (Asphalt Producer) to maintain the quality control of the finished asphalt mixture at the point of manufacture and does not impede on the requirements of QCS 2014, or its revisions, or the contract specification. The sampling and frequencies are the minimum that should be considered for control but it is to discretion of the Organization to ensure sufficient samples, tests and assessments are made in order for the asphalt mixture conforms to specification requirements.

2

The properties of asphalt mix characteristics shall conform to the requirements of QCS 2014 and the contract specification. Should these not properties be found not to conform to the Job Mix Formula the design should be assessed.

3

The guidance provides for three levels of minimum frequency. The minimum frequency which shall be carried out for all production circumstances and higher frequencies which are appropriate where it is necessary to give a greater assurance of consistency where the measured level of conformity has decreased.

4

A guide to assessment of production quality control test conformity is given.

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Asphalt mixture composition Job Mix Tolerances shall be in accordance with QCS 2014, as indicated in Table B.1:

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Table B.1: Job Mix Tolerances Base Course

Intermediate Course

Wearing Courses

Aggregate retained on 4.75mm sieve or larger

±5%

±4%

±4%

Aggregate passing 4.75mm sieve and retained on 850m sieve

±4%

±3%

±3%

Aggregate passing 850m sieve and retained on 75m sieve

 3%

 2%

 2%

Aggregate passing 75μm sieve

± 1.5 %

± 1.0 %

± 1.0 %

Binder Content

± 0.3 %

± 0.2 %

± 0.2 %

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Operating Compliance Level 1

The Operating Compliance Level (OCL) shall be applicable to each single plant and shall be determined on an ongoing basis from the number of non-conforming compositional test results within the last 32 analyses of all asphalt mixtures tested. In addition, the OCL shall take into account the consistency of production with assessment of the mean deviation from target as detailed in Table B.2.

QCS 2014

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Section 06: Roadworks Part 07: Asphalt Plants

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In the event of 5 or more of the previous 32 results being non-conforming, and/or variance of the mean deviation from target from the prescribed tolerances, the plant shall be subject to an immediate and comprehensive review of equipment and procedures.

Mean Deviation from Target For each analysis the deviation from target shall be determined for each of the sieves sizes and binder content indicated in Table B.1. A running mean of the deviations for the last 32 analyses of each asphalt mixture shall be maintained.

2

Should the running mean of the deviations exceed the values stated in Table B.2, this shall be deemed to be non-conforming asphalt mixture in accordance with Clause 25.4.2 and the appropriate corrective quality control action taken. The Operating Compliance Level shall be lowered by one level for as long as the mean deviation stays outside tolerance.

Intermediate Course

±4

±3

-

Aggregate passing 12.5 mm

-

Aggregate passing 9.5 mm

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±3

±2

±2

±3

±2

±2

± 1.5

± 1.0

± 1.0

± 0.3

± 0.2

± 0.2

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±3

±3

Aggregate passing 75 μm sieve Soluble Binder Content

±3

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Aggregate passing 4.75 mm (Superpave) Aggregate passing 2.36 mm (Marshall)

Wearing Course

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Aggregate passing 19 mm

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Base Course

Description

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Table B.3: Determination of Operating Compliance Level and Sampling Frequency

2

Number of nonconforming analyses in last 32

Operating Compliance Level

0-2

A

1 per 250t per mix or part thereof

3-6

B

1 per 200t per mix or part thereof

≥6

C

1 per 100t per mix or part thereof

Minimum Sample Frequency

New plants commencing production, plants restarting after relocating, a major repair or overhaul, or those recommencing commercial production after a period exceeding 3 months cessation shall operate under OCL until 32 results have accumulated after which the frequency shall revert to the OCL achieved.

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APPENDIX “C”

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Section 06: Roadworks Part 07: Asphalt Plants

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Page 26

Table C-1: Sample of plant inspection checklist Aggregate Stockpiles

Yes

1

Are aggregate stockpiles separated by walls or clear space with signed labelling?

2

Are the stockpiles free of significant contamination and segregation? (Plant drain-out aggregate is acceptable if the aggregate size is similar and uncoated.)

6

Aggregate Cold Feed

6 7 8

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Is the aggregate collecting conveyor in good condition, with no holes or splits, or evidence of tracking (side movement) and the belt scrapers are in good order?

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2

Has each aggregate size its own designated and labelled bin/hopper? Are bins/hoppers in good condition with no holes, with bin wall divider plates between each? Is aggregate overflow between hoppers being prevented by divider plates? If meshes (grizzlies) are fitted over the bins/hoppers, are they in reasonable condition and fit for purpose? Are the feeder gates, feeder belts and vibrators in good condition? Are there no-flow paddles/sensors on each feeder and are they working? Date of the last feeder calibrations:

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Is the truck tipping area at the stockpile level? (Non-level surfaces can cause trucks to tip over.) Do the aggregate delivery and test records conform to the approved mix designs? Have the aggregates been sampled and tested in accordance with requirements?

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Is the aggregate in good condition with no signs of degradation on the stockpile due to vehicle/plant movements?

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No

1

2

Is there any significant aggregate spillage under the dryer conveyor, the dryer drum or around the base of the hot elevator? Are the dryer lifters and flights are in good condition without undue bending or deformation and none missing. (when dryer is cold and stopped)

4

Is the drum exit chute temperature pyrometer, thermocouple or probe clean, working and in calibration? Date of last pyrometer, thermocouple or probe calibration:

5

Has the drum exit chute temperature equipment been checked recently with a referenced laboratory probe?

3

Date: Drum chute:

°C

Laboratory probe: °C

QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 27

Dust Collection 1

Does the pre-skimmer or knockout box return the collected fine sand to the plant hot elevator? a: returned to a silo for re-use?

2

Is the bag house extracted dust:-

b: directly fed back into the asphalt plant?

5

Date of last certified plant stack emission test?

6

Is the plant stack emission is visually clean with no obvious dust or smoke??

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Does the laboratory monitor the gradation of the coarse preskimmer or knockout box fines and bag house filler? Is there a dust emission monitoring system on the plant?

3

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Aggregate Screening Is there any spillage around the screen deck area?

2

Did the last screen inspection indicate any defects?

3

Date of last screen deck inspection:

7

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Are there any loose screen meshes that need tightening or support bars that are loose and need welding? Is there evidence of side seal seepage which could contaminate screened aggregate or wear other parts?

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Are there any signs of damage or wear, especially adjacent to screen bearings or shafts? Is there any significant dust emission from the screen housing lids, covers or doors? Is there any evidence of holes, splits or tears in the screen meshes and is there any apparent and significant pegging or blockages?

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3

Is there any indication of hot bin oversize or undersize in hot bin drain-outs? Bin 1 Aggregate size 0 / X mm

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Bin 2 Aggregate size X / X

mm

4

Bin 3 Aggregate size X / X

mm

5

Bin 4 Aggregate size X / X

mm

6

Bin 5 Aggregate size X / X

mm

7

Bin 6 Aggregate size X / X

mm

8

9

10

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c: wasted?

Are the individual hot stone bin overflow chutes/pipes blocked or damaged? Are there holes or damaged seams or welds in the hot bin walls, especially in the corners and in the lower half of the bins? Do the hot stone bin doors stick or seize? Is there evidence of holes in or leakage from the doors?

QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 28

Weighing and Measuring Apparatus

3

Are the calibrations of the aggregate, filler and bitumen weighing apparatus current and in date? Aggregate weighing apparatus calibration date: Bitumen weighing apparatus calibration date:

4

Filler weighing apparatus calibration date:

5

Mixed asphalt pyrometer calibration date:

6

Has the mixed asphalt pyrometer been checked recently with a referenced laboratory probe?

1 2

Date: Pyrometer:

°C

Laboratory probe:

°C

Do the printed batch weights equal the weight indicators and are total load batch weights similar to the truck scale net weight?

2

Does the bitumen bucket/kettle pass the static load test? (Hold a fully weighed batch of bitumen for at least 30 seconds and note any change in weight. Repeat when empty and note any major change in tare)

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Is the bitumen bucket/kettle adequately insulated and heated? Seepage or leakage from the charge and the discharge pipes? Check the butterfly valve underneath for direct gravity discharge systems.

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4

Does the aggregate and filler weighing apparatus pass the static load test? Is there any bitumen seepage or leakage from the charge and the discharge pipes, and the butterfly valve underneath on direct gravity discharge bitumen bucket/kettle systems?

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Bitumen Storage and Pumping

Where fitted, are breather vents clear on the bitumen weigh bucket/kettle and delivery pipe to the mixer? Are the bitumen tanks and are all tanks clearly labelled according to the grade of binder stored? Are stored binder tank temperatures compliant with specification or supplier recommendations? Where PMB is stored, are the stirrers operational and in good condition? Is there a supplier defined procedure for the storage and use of polymer modified binders? Are all tanks, pipes, pumps and flow meters properly insulated and the surrounds clean and in good order? Is there any evidence of excessive bitumen or oil seepage/leaks from pump(s), valves or manifolds? Are bitumen tank temperatures monitored and recorded daily by the plant staff? Are the bitumen binders tested for foaming when heated to 175°C? Is there a control or procedure for tank/binder grade selection according to asphalt mix recipe to avoid using the incorrect grade?

3 4 5 6 7 8 9 10

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QCS 2014

Section 06: Roadworks Part 07: Asphalt Plants

Page 29

Asphalt Mixing

4 5 6 7 8

Is there excessive overflow from the aggregate overflow chutes? Check the required batch weights on the mix card. Are batch deviations within acceptable guide tolerance?

.

3

Are inspection hatches secure and sealed to prevent dust emission? Are electric cables, hydraulic and air lines well maintained and in good order? Are all mixer arms, paddles and tips, liners and door seals present and in good condition? Is the aggregate weighing sequence, coarse size to fine size?

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Are the weighing apparatus and mixer external surrounds in clean and good order with no apparent seepage or leakage of aggregate, filler or bitumen?

Batch aggregate component ±1.5% of total batch weight

10

Bitumen deviation ±0.1% of total batch weight

11

Mineral filler deviations ±0.1% of total batch weight

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sec.

14

What is the delay time after aggregate discharge for filler:

sec.

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On completion of the mixing cycle, does the mixer fully empty?

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16

What is the total wet mixing time in seconds? (From the complete discharge of the bitumen and filler to the emptying of the finished batch)

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13

Are the in-flight adjustments being made automatically by the plant control system? What is the delay time after aggregate discharge for bitumen:

12

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On visually inspecting single batches of asphalt, is the appearance consistent from side to side and front to back, and not segregated? Does each batch conform to the mix temperature specification requirement?

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Does the plant indicated mixed asphalt temperature correspond with a laboratory check? Where used, is the skip hopper acceptably clean? Are the empty hot storage silos acceptably clean without cold asphalt sticking to the sides and corners?

Loading 1 2 3

Are all trucks acceptably clean prior to loading without any evidence of diesel being used as a release agent? Are all trucks equipped with load cover sheets or canvasses? Are the loaded trucks free of significant segregation?

sec.

QCS 2014

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Section 06: Roadworks Part 07: Asphalt Plants

Page 30

Is the asphalt temperature acceptably consistent and within range tolerance throughout the load front to back? Has the correct delivery ticket been issued to the driver with accurate asphalt description, truck reference or number, site address, driver name, and ticket number? Is the plant sampling technician equipped with all necessary PPE including safety helmet, steel-capped boots, overalls, gloves, hi-visibility jacket, and protective eye glasses? Are the plants sampling procedures being following by the technician to ensure a representative sample? (Ask for and retain a copy of the sampling procedures.) Are plant sample details, including truck delivery details, are recorded on each plant sample?

9

Request plant compliance rate for each product supplied to the project or contract for record purposes.

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END OF PART

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 1

RECYCLED AND STABILISED ROAD MATERIALS ............................................................ 2

8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5

GENERAL SCOPE REFERENCES DEFINITIONS SUBMITTALS QUALITY ASSURANCE

2 2 2 3 4 4

8.2

COLD STABILISED MATERIAL - GENERAL

4

8.3

MATERIALS

5

8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6 8.4.7 8.4.8

CEMENT TREATED BASE (CTB) PREPARATION AND MIX DESIGN FOR CEMENT TREATED BASE SITE TRIALS FOR CEMENT TREATED BASE AND BITUMEN STABILISED MATERIAL INSITU STABILISATION AND COMPACTION OF CEMENT TREATED BASE EXSITU PRODUCTION OF CEMENT TREATED BASE LAYING AND COMPACTION OF CEMENT TREATED BASE JOINTS IN CEMENT TREATED BASE SAMPLING AND TESTING - CEMENT TREATED BASE EVENNESS AND LEVEL

8.5 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5 8.5.6 8.5.7 8.5.8

BITUMEN STABILISED MATERIAL (BSM) PREPARATION AND MIX DESIGN FOR BITUMEN STABILISED MATERIAL SITE TRIALS FOR BITUMEN STABILISED MATERIAL INSITU STABILISATION AND COMPACTION OF BITUMEN STABILISED MATERIAL EXSITU PRODUCTION OF BITUMEN STABILISED MATERIAL LAYING AND COMPACTION OF BITUMEN STABILISED MATERIAL JOINTS IN BITUMEN STABILISED MATERIAL SAMPLING AND TESTING - BITUMEN STABILISED MATERIAL EVENNESS AND LEVEL

12 12 13 13 14 15 16 16 17

8.6

DETERMINATION OF THE FOAMING CHARACTERISTICS OF BITUMEN (EXPANSION RATIO AND HALF LIFE) SCOPE DEFINITIONS APPARATUS METHOD REPORTING SITE QUALITY CONTROL

18 18 18 18 19 19 20

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APPENDIX ............................................................................................................................................ 21 GUIDANCE FOR THE DESIGN OF RECYCLED AND STABILISED MATERIALS (MIX DESIGNS)

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 2

RECYCLED AND STABILISED ROAD MATERIALS

8.1

GENERAL

8.1.1

Scope

1

This Part includes materials, equipment, mix design guidelines and other requirements for the construction of insitu and exsitu recycled pavement layers.

2

Incorporation of stabilized or cement bound materials in pavement layers shall be based on pavement structural design criteria such as layer(s) strength characteristics, load distribution, layer(s) thickness equivalency, layers strength balance and the target level of pavement performance.

3

Use of recycled and stabilized materials and their associated construction and quality assurance and quality control processes shall be approved by the Engineer.

4

Related Parts are: General Earthworks Asphalt Works

Part 4

Water

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References

AASHTO T180: ..........Standard Method of Test for Moisture-Density Relations of Soils

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ASTM C150: ..............Standard Specification for Portland Cement

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ASTM C977: ..............Standard Specification for Quicklime and Hydrated Lime for Soil Stabilization

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ASTM C1097: ............Standard Specification for Hydrated Lime for Use in Asphalt Cement or Bituminous Pavements

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ASTM D422: ..............Standard Test Method for Particle-Size Analysis of Soils ASTM D946: ..............Standard Specification for Penetration-Graded Asphalt Cement for Use in Pavement Construction

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Section 6

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ASTM D1556: ............Standard Test Method for Density and Unit Weight of Soil in Place by Sand-Cone Method ASTM D1632: ............Standard Practice for Making and Curing Soil-Cement Compression and Flexure Test Specimens in the Laboratory ASTM D1633: ............Standard Test Methods for Compressive Strength of Molded SoilCement Cylinders ASTM D2216: ............Standard Test Methods for Laboratory Determination of Water (Moisture) Content of Soil and Rock by Mass ASTM D2922: ............Standard Test Methods for Density of Soil and Soil Aggregate in Place by Nuclear Methods (Shallow Depth) ASTM D4215: ............Standard Specification for Cold-Mixed, Cold-Laid Bituminous Paving Mixtures ASTM D4318: ............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 3

ASTM D4944: .............Standard Test Method for Field Determination of Water (Moisture) Content of Soil by the Calcium Carbide Gas Pressure Tester ASTM D4944: ............Standard Test Method for Field Determination of Water (Moisture) Content of Soil by the Calcium Carbide Gas Pressure Tester ASTM D6926: ............Standard Practice for Preparation of Bituminous Specimens Using Marshall Apparatus ASTM D6931: ............Standard Test Method for Indirect Tensile (IDT) Strength of Bituminous Mixtures ASTM D6938: ............Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth)

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ASTM D7382: ............Standard Test Methods for Determination of Maximum Dry Unit Weight and Water Content Range for Effective Compaction of Granular Soils Using a Vibrating Hammer ASTM E2583: ............Standard Test Method for Measuring Deflections with a Light Weight Deflectometer (LWD) MCHW Specification for Highways Works Series 900, UK

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TG2 Technical Guideline: Bitumen Stabilised Materials: Asphalt Academy, South Africa

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TRL 611: A Guide to the Use and Specification of Cold Recycled Materials Definitions

1

Stabilisation is the permanent modification of soils and aggregates, including recycling existing pavements, to enhance the engineering properties thereby improving the load bearing capacity and performance of a new pavement structure.

2

Aggregate: Granular material used in construction. Aggregate may be natural, manufactured or recycled.

3

Primary Aggregate: aggregate extracted directly from the ground in quarries or pits, or dredged from rivers or the sea. They can be either hard rock such as gabbro and limestone, or sand and gravel.

4

Secondary Aggregate: materials produced as a by-product of other mining or quarrying activities or as a by-product of other industrial processes, e.g. blast furnace slag, incinerator ash, or the ash from power stations.

5

Recycled Aggregate: materials produced by the recycling of construction and demolition waste. These can be crushed concrete, bricks or glass, asphalt planings (i.e. the asphalt layers of roads removed during roadworks, also known as RAP – Recycled Asphalt Pavement).

6

Cold Stabilised Material (CSM): materials produced for pavement construction structural layers using recycled or secondary aggregates.

7

Bitumen Stabilised Material (BSM): bitumen or bitumen emulsions.

8

Cement Treated Base (CTB): granular aggregate materials bound with cement or hydrated lime hydraulic binder.

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granular aggregate materials bound with foamed

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 4

Exsitu Stabilisation: mixing processes that are carried out away from the construction location in a remote mixing plant.

10

Insitu Stabilisation: mixing processes that are carried out at the construction location by specialised stabilisation equipment.

11

Optimum Moisture Content: the moisture content of soil at which a specific degree of compaction will produce the maximum dry density when determined in accordance with the AASHTO T180.

12

Maximum Dry Density: the dry density of soil obtained using a specific degree of compaction at the optimum moisture content when determined in accordance with AASHTO T180.

8.1.4

Submittals

1

The Contractor shall submit recent test results for the proposed sources of materials for all quality requirements of the Contract. The contractor shall submit a test certificate that proves that the raw materials that are purchased/used comply with specifications. The testing may be performed by an approved private laboratory or by the laboratory associated with the plant itself.

2

The contractor shall submit to the Engineer for approval method statements, which includes but not limited to the following:

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Quality assurance and quality control plans of all construction activities

(b)

Material, handling, storage, identification and marking, traceability to source of production and testing.

(c)

Equipment suitability to fulfil all construction activities to the required quality

(d)

Personnel capability

(e)

Safety and environment preservation plans

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The Contractor will be required to produce detailed method statements for the chosen method of recycling rehabilitation and shall include all stages of the process for approval by the Engineer. This shall include the credentials and details of experience of the stabilising contractor, the site investigation report, the stabilised material mix design and the equipment to be used for the entire process. A separate method statement shall be submitted for each of the production and construction activities of each layer.

8.1.5

Quality Assurance

1

If requested the Contractor shall arrange for the Engineer to visit the source of the materials and jointly take samples for testing. The Contractor shall carry out testing as directed by the Engineer.

8.2

COLD STABILISED MATERIAL - GENERAL

1

Cold Stabilised Material (CSM) comprises base and binder courses produced by the process of in-place recycling (insitu) or in a fixed or mobile mixing plant (exsitu) where the aggregate source shall be obtained by cold pulverisation of all, or part, of the existing road structure, blended if necessary with other aggregate and bound with cementitious / hydraulic (CTB) or bituminous binders (BSM), separately or in combination, or by the use of primary aggregates.

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Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 5

Cold Stabilised Material (CSM) shall be designed and produced to form the foundation or main structural layer of the road pavement.

3

For Bitumen Stabilised Material (BSM) the primary active binder (stabilising agent) shall be foamed bitumen, with cement as an adhesion agent as required by the design. For Cement Treated Base (CTB) the primary active binder shall be cement, hydrated lime or a blend of both in accordance with the mix design. The aggregate grading may be adjusted by the addition of inactive mineral filler.

4

Insitu and exsitu methods of stabilisation rehabilitation are permissible with the approval of the Engineer on a site by site basis.

5

Stabilisation design and installation processes shall be in accordance with internationally recognised standards and specifications, and shall meet the necessary pavement structural design according to the appropriate traffic classification.

6

The Cold Stabilised Material shall be designed to achieve the specified level of the appropriate end performance property to the requirements of the total pavement design. The minimum layer thickness shall be as required by the design method used, as approved by the Engineer.

7

The asphalt type and thickness above the CSM shall be as required by the pavement design method and shall also be sufficient to prevent reflective cracking and early life trafficking, to the satisfaction of the Engineer.

8.3

MATERIALS

1

The method statement submitted by Contractor shall contain details of all aggregates to be used in the CSM.

2

Aggregates may include:

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Material planed or excavated from a road or other paved area.

(b)

Primary, secondary or recycled aggregate from other sources.

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Mineral filler from primary or secondary sources.

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The aggregate including added inactive filler shall not contain deleterious material that adversely affects the performance of the mixture. This includes clay materials, friable materials, organic and metallic materials, or other extraneous or detrimental material.

4

The aggregate gradation for CSM shall follow the requirements stated in the mix design method, as approved by the Engineer, and shall generally follow the recommended gradations in Table 8.1 Recommended Gradations for Cold Stabilised Materials.

5

For BSM, material passing the 0.425mm sieve shall have a maximum liquid limit of 25% and the plasticity index shall not exceed 6.

6

Bitumen specified for use in BSM shall be 60/70 penetration grade in accordance with ASTM D946 and shall only be obtained from approved sources. The temperature of the bitumen prior to foaming shall be greater than 175°C but less than 195°C. Bitumen shall not contain any additives which may suppress foaming.

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Table 8.1 Recommended Gradations for Cold Stabilised Materials Bitumen Stabilised Job Mix Control Cement Treat Base (CTB) Material (BSM) Sieve Tolerances 100

100

100

100

-2

37.5

85

100

87

100

±5

25

72

100

77

100

-

19

60

100

67

99

±8

12.5

50

100

67

90

-

9.5

42

90

48

80

±8

6.3

35

80

40

62

-

4.75

30

72

35

56

± 10

2.36

21

56

25

42

1.18

14

44

18

0.6

9

35

14

0.425

7

31

12

0.3

5

27

10

0.15

2

21

0.075

2.0

18.0

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Sieve Size (mm)

Page 6

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28

±5

26

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7

17

-

4.0

10.0

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Cement specified for use in BSM and CTB shall be Portland cement in accordance with ASTM C150 and shall only be obtained from approved sources. Sulfate resisting cement shall be used if instructed by the Engineer.

8

Hydrated lime for use in BSM shall be in accordance with ASTM C1097 and for CTB shall be in accordance with ASTM C977, and shall only be obtained from approved sources.

9

Water for use in CSM shall in accordance with Section 5 Part 4.

8.4

CEMENT TREATED BASE (CTB)

8.4.1

Preparation And Mix Design For Cement Treated Base

1

The Contractor shall produce a detailed existing pavement investigation report and the proposed stabilised material mix design which shall be submitted for approval by the Engineer, in liaison with Qatar Quality Standards, at least 30 days prior to the commencement of the stabilisation works. The pavement investigation report shall consist of cores and trial pits excavated to the existing subgrade and include tests for, but not limited to, California Bearing Ratio, Dynamic Cone Penetrometer, gradation, plasticity index and liquid limit, and other tests required by the selected design method.

2

All equipment and method statements shall be submitted for approval by the Engineer at least 30 days prior to commencement of works.

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The mix design method for the CTB mix shall be as approved by the Engineer. Methods may include that stated in this part, MCHW Specification for Highways Works Series 900: UK, or other similar and equivalent recognised international design methods for cement or hydraulic bound materials.

4

The CTB mix shall have a minimum individual 7 day compressive strength > 2.1 MPa with a maximum average 7 day compressive strength of 4.2 MPa when tested in accordance with ASTM D1633.

5

The mix design shall derive the gradation tolerance parameters of the pulverised material, moisture content at the point of compaction and target flow rates for the active filler, binder and added water at the point of mixing, appropriate to the production or stabilisation method used for the approval of the Engineer.

8.4.2

Site Trials For Cement Treated Base And Bitumen Stabilised Material

1

The CTB mix design shall be subjected to full preliminary trials and testing at least 10 days prior to commencement of the full works and shall determine:

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The effectiveness of the production and laying plant for exsitu processes;

(b)

The number of passes of the stabilisation machine necessary to achieve uniform pulverisation and mixing for insitu processes;

(c)

The field moisture content control required to achieve specified compaction requirements;

(d)

The compaction routine and rolling patterns necessary to meet the specified compaction requirements;

(e)

The reference density;

(f)

The effectiveness of the contractor’s inspection and test plan.

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(a)

The length of the trial section shall be at least 150 metres and the full width of the carriageway proposed for stabilisation to ensure joints and full width compaction can be achieved without excessive segregation or other significant defects.

3

The trial area shall be sprayed with bituminous prime coat at a rate of 0.45 to 0.75 kg/m2 and allowed to cure for a minimum of 24 hours without trafficking unless otherwise authorised by the Engineer.

4

Tests from the trial areas shall be submitted to the Engineer for approval at least 3 days prior to commencement of the works. No works may proceed until all tests and final method statements have been submitted and approved by the Engineer.

5

Where materials and processes are demonstrably similar, mix designs and trials tests from previous projects may be approved at the discretion of the Engineer, in liaison with Qatar Quality Standards.

8.4.3

Insitu Stabilisation And Compaction Of Cement Treated Base

1

The insitu CTB stabilisation/recycling shall be produced by specialist equipment specifically designed for the purpose of insitu recycling processes.

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Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 8

The material shall be pulverised and stabilised in a single layer if its compacted thickness is 300 mm or less. If the compacted thickness is greater than 300 mm, the material shall be pulverised and stabilised in the minimum number of layers between100 mm and 300 mm thick. Where more than one layer is required, the Contractor shall satisfy the Engineer that the lower layer has achieved adequate stability before proceeding with the overlying layer.

3

Where required by the Engineer the stability of a layer in any area shall be assessed after a curing period of at least 24 hours by channelled trafficking using a rigid three-axle tipper truck loaded to a gross mass of 24 tonnes (assumed equivalent to three standard axles). The vertical deformation shall be measured in all wheel-tracks at monitoring points on each of 5 transverse sections set 1 metre apart after 5, 15, 30 and 40 passes of the truck. The mean vertical deformations at the above trafficking increments shall be plotted against the respective number of truck passes and the mean vertical deformation corresponding to 100 standard axles shall be interpolated. The layer shall be deemed acceptable if the mean vertical deformation corresponding to 100 standard axles is less than 10 mm.

4

The active filler (cement/hydrated lime) shall be supplied to the recycler by a specifically designed and calibrated mobile slurry mixer to ensure the dustless addition of the cement/hydraulic binder. The addition shall be continuously monitored with records taken to confirm the target addition rate, ± 10%, according to the mix design.

5

Mixing uniformity shall be continuously inspected visually by the contractor and work shall stop when the cement or hydrated lime is seen to agglomerate or not fully mix in during the production process.

6

Should either the slurry mixer supply to the mixer fail to operate or deliver the correct proportions to the recycler, all work shall cease until this has been corrected. Prior to resuming work, the process shall be checked fully by trialling in a short sacrificial trial strip exceeding 50 metres to ensure the process is fully operational and under control.

7

The recycler shall proceed in a continuous operation to the full depth of the layer being recycled as required by the pavement design.

8

The CTB moisture content prior to compaction shall be within ± 2 % of the target determined during the mix design procedure to achieve maximum density.

9

Initial rolling shall be carried out using a single-drum vibrating roller with a static mass that is appropriate with the thickness of the layer being compacted. The vibration mode must be set on high amplitude to achieve maximum penetration of compactive effort.

10

The rolling pattern should first concentrate on the middle section between the rear wheel paths of the recycler, then across the full cut width to achieve uniform density. The travel speed of the roller shall not exceed 3 km/h.

11

When initial compaction is complete, the surface shall be struck off to level by a grader and the surface again checked for level and any defects or damage caused during the operation which shall be corrected prior to final compaction.

12

Where the recycler has a screed finisher which achieves the required level, initial compaction shall follow the recommendations of the recycler supplier.

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Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

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Where a second adjacent strip is to be laid immediately an additional insitu stabilisation, the recycler shall overlap the previously stabilised strip by 300mm, ensuring the strip is not excessively over or under bindered, or watered.

14

Upon completion of compaction the surface shall be sprayed with bituminous prime coat at a 2 rate of 0.45 to 0.75 kg/m and allowed to cure for a minimum of 24 hours without trafficking unless otherwise authorised by the Engineer. Where the surface is to be opened to traffic prior to surfacing with asphalt, the prime coat shall be blinded with fine aggregate or sand 2 applied at a rate of 5.5 to 7.0 kg/m .

15

Traffic, including delivery vehicles shall not be permitted on the uncompacted or semicompacted recycled material. The exposed longitudinal joint shall be protected from damage by construction plant and vehicles.

8.4.4

Exsitu Production Of Cement Treated Base

1

The exsitu production of CTB shall be produced by specialist recycling and stabilisation production equipment specifically designed for the purpose of exsitu processes.

2

The active filler (cement/hydrated lime) shall be supplied to the mixer by specifically designed and calibrated weighing apparatus to ensure the correct addition of the cement/hydraulic binder. The addition shall be continuously monitored with records taken to confirm the target addition rate, ± 10%, according to the mix design.

3

Mixing uniformity shall be continuously inspected visually by the contractor and work shall stop when the cement or hydrated lime is seen to agglomerate or not fully mix in during the production process.

4

CTB shall not segregate significantly during production and all measures shall be taken to avoid this occurrence.

5

CTB shall be conveyed from the mixer to its place in the Works as rapidly as possible in covered vehicles which will prevent segregation or drying out and ensure that the material is of the required workability and moisture content at the point of delivery to the paving equipment.

6

Where CTB is produced on an exsitu production plant, the material shall be laid and fully compacted within 2 hours of production, ensuring that the moisture content is within the required limits at the time of laying. CTB that exceeds 2 hours shall be rejected.

8.4.5

Laying And Compaction Of Cement Treated Base

1

Exsitu produced CTB materials shall be laid with paving machines and compaction plant as detailed in Section 6 Part 5, but may include additional specialist equipment deemed appropriate indicated in the detailed method statement.

2

The CTB moisture content prior to compaction shall be within ± 2 % of the target determined during the mix design procedure to achieve maximum density.

3

Material shall be laid to a thickness that would result in layers not more than 150 mm thick after compaction. Where the finished compacted thickness exceeds 150 mm placing shall be executed in composite layers each layer not exceeding 150 mm in compacted thickness as directed by the Engineer.

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QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 10

Final compaction for CTB shall follow the general requirements Section 6 Part 6 using a combination of tandem steel wheeled rollers and pneumatic tyred rollers in accordance with the approved method statement.

5

Where the surface of the recycled layer has been graded to level, it may be dampened with a water spray prior to compaction. Care shall be taken not to use excessive watering.

6

To prevent adhesion of the mix to steel-wheeled rollers, the wheels shall be kept properly moistened but excess water shall not be permitted.

7

Where a second adjacent strip is to be laid immediately by echelon paving of exsitu material, the requirements of Section 6 Part 5 shall be followed.

8

After final rolling, the smoothness, levels, crossfalls, density and thickness shall be checked and any irregularity of the surface exceeding the specified limits and any areas defective in texture, density or composition shall be corrected as directed by the Engineer, including removal and replacement as directed by the Engineer.

9

Upon completion of compaction the surface shall be sprayed with bituminous prime coat at a 2 rate of 0.45 to 0.75 kg/m and allowed to cure for a minimum of 24 hours without trafficking unless otherwise authorised by the Engineer. Where the surface is to be opened to traffic prior to surfacing with asphalt, the prime coat shall be blinded with fine aggregate or sand 2 applied at a rate of 5.5 to 7.0 kg/m .

8.4.6

Joints In Cement Treated Base

1

Transverse joints shall be made by cutting back at least 2 metres to the position of conforming level and compaction, and cleaned to remove any loose material. The joint shall be fully compacted and left level and smooth.

2

Longitudinal joints shall be formed as follows:

3

For paver laid materials, fresh joints may be formed by compacting 500mm at the edge of the initial stabilised strip with a single roller pass and abutting the adjacent new strip prior to cross compaction. Joints are deemed to be fresh when the pavement materials on both sides of the joint have been stabilised and are able to be compacted within 1 hour. The 500mm partially compacted strip together with the exposed edge shall be lightly moistened prior to placement of the second strip.

4

For paver laid materials and where the stabilised layer has been laid previously or is deemed unworkable, the existing strip shall be cut back by 150mm to its full depth and cleaned to remove any loose material prior to paving the new adjacent strip.

5

Longitudinal construction joints in CTB shall always be formed at the lane line marking positions where practically possible.

8.4.7

Sampling And Testing - Cement Treated Base

1

The Contractor shall produce an inspection and test plan for the complete process which shall include daily production control and the finished stabilised pavement for approval by the Engineer.

2

Bulk samples shall be taken from the stabilised material to the full depth of the layer.

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Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 11

Sample increments will be wrapped tightly in plastic bags to prevent moisture loss and protected from the heat and sun in an ambient temperature of no greater than 20°C.

4

Samples shall be provided from the laid CTB before compaction, as approved by the Engineer. One group of five samples shall be provided from five locations equally spaced along a diagonal that bisects each 800m2 or part thereof laid each day. The number of groups may be increased if required by the Engineer. Each group shall be combined to provide samples for reference density, compressive strength and laboratory determined moisture content.

5

For each group, 3 specimens for reference density and compressive strength testing shall be compacted in accordance with AASHTO T180within 2 hours of the addition of the cement and cured in accordance with ASTM D1632, and tested in accordance with ASTM D1633.

6

To determine the reference density of test specimens the mould shall be weighed prior to making the specimen and the mass recorded. Immediately after completion of compaction, the specimen and mould shall be weighed and the mass recorded. These masses together with the nominal volume of the mould shall be used to derive the reference density of the specimen.

7

The in-situ density of a layer of cement bound material shall be taken as the average of the densities at five locations equally spaced along a diagonal that bisects each 800 m2 or part thereof laid each day. The in-situ density at each location shall be the average of two readings obtained using a nuclear density gauge in compliance with ASTM D6938. Readings shall be taken within two hours of completing final compaction.

8

Testing for CTB shall be required as Table 8. 2 Sampling and Testing Requirements for Cement Treated Base

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TEST

SPECIFICATION

FREQUENCY

ASTM D422

Pre-Stabilised Pulverised Materials

Design mix gradation

1/1000m

3

ASTM D4318

Pre-Stabilised Pulverised Materials

Less than design mix determination

1/1000m

3

ASTM D4318

Pre-Stabilised Pulverised Materials

Less than design mix determination

1/1000m

3

ASTM D1556/D6938

Compacted Stabilised Material

100% reference density

5/800m

2

ASTM D4944

Pre-compacted Stabilised Material

± 2% OMC

1/800m

2

ASTM E2583

Compacted Stabilised Material

Report Values

5/800m

2

Compressive Strength

ASTM D1633

Pre-compacted Stabilised Material

Individual >2.1 MPa Average of 3 10 times

1/first 500 2 m /day

Binder Half Life (τ½)

This Part:‎8.6

> 12 seconds

1/first 500 2 m /day

Unconfined Compressive Strength

ASTM D1633 (150mmØ)

1200 to 3500 kPa

1/800m

2

Moisture Content

ASTM D2216

Laid Stabilised Material

± 2% OMC

1/800m

2

Indirect Tensile Strength

ASTM D6931 (100mmØ)

Pre-compacted Stabilised Material

ITSdry >225 kPa ITSwet >100 kPa

1/day if 2 >800m

Pre-compacted Stabilised Material

> 80%

1/day if 2 >800m

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Tensile Strength Retained (TSR)

ITSwet / ITSdry

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Note 1 – The surface modulus determined in accordance with ASTM E2583 shall be reported as directed by the Engineer for data collection. It shall not form part of the acceptance or rejection criteria.

8.5.8

Evenness And Level

1

The transverse regularity of the surface of the BSM shall be tested by means of a 4 metre long straight edge. No irregularity in excess of 10 mm shall be permitted.

2

The longitudinal regularity of the surface of the BSM shall be tested by means of a rolling straight edge. No irregularity in excess of 10 mm shall be permitted.

3

The finished surface shall also be checked by dips or spot levels and shall be constructed to the designated grade levels to within ± 10 mm.

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 18

Where these requirements are not met, the Contractor shall determine the full extent of the area which is out of tolerance and shall make good the surface of the course by scarifying to a minimum depth of 75 mm or 4 times the maximum particle size, whichever is greater, reshaping by adding or removing material as necessary, adding water if necessary and recompacting the layer. The minimum length of rectification shall be 50 metres.

5

Acceptance of the stabilised pavement is subject to completion of all testing and inspection requirements to the satisfaction of the Engineer.

8.6

DETERMINATION OF THE FOAMING CHARACTERISTICS OF BITUMEN (EXPANSION RATIO AND HALF LIFE)

8.6.1

Scope

1

The foaming characteristics of bitumen are defined by the Expansion Ratio and Half Life of the bitumen in its expanded state. The expanded state of the bitumen is achieved when a small percentage of water is introduced into hot bitumen. The objective is to determine the percentage of water required that will produce the best foam characteristics for a particular source of bitumen. The aim is to produce foamed bitumen with the largest expansion ratio with the longest half-life possible.

8.6.2

Definitions

1

The expansion ratio is a measure of the viscosity of the foam and provides an indication of how well the binder will disperse in the mix. It is calculated as the ratio of the maximum volume of foam relative to the original volume of bitumen. The half-life is a measure of the stability of the foam and provides an indication of the rate of collapse of the foam during mixing. It is calculated as the time taken in seconds for the foam to collapse to half of its maximum volume.

8.6.3

Apparatus

1

The following equipment shall be required: For mix design only: Foamed Bitumen Laboratory Unit, capable of producing foamed bitumen at a rate of between 50g and 200g per second. The method of production shall closely simulate that of full scale production of foamed bitumen on the recycling machine. The apparatus shall have a thermostatically controlled kettle capable of holding a mass of 10kg of bitumen at a constant temperature between the range of 160ºC and 200ºC, ± 5ºC. The unit shall have an expansion chamber similar to that on the recycling machine in which cold water is injected into hot bitumen. Water injection shall be variable from 0 to 5% (by mass of the bitumen) with an accuracy of 0.25%. The plant shall capable of accurately discharging a predetermined mass of foamed bitumen directly into the mixing bowl of an electrically driven laboratory mixer with a minimum capacity of 10kg.

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(b)

Cylindrical metal container, 250mm diameter and at least 20 litre capacity.

(c)

Calibrated Dip Stick, calibrated for the cylindrical metal container with 500g of bitumen as 1 unit measure. Prongs are attached to the dip stick at every 5 or 6 times the unit volume.

(d)

A stop-watch with 60 second dial.

(e)

Heat resistant gloves.

(f)

An electronic balance to weigh up to 10kg, accurate to 1g.

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

8.6.4

Method

1

Preparation (a)

The foamed bitumen laboratory unit discharge rates are checked in accordance with the manufactures specifications. If the unit is being used for the first time then the pump rate and water flow rates need to be calibrated as per the manufactures specifications. Check that 500g of bitumen is being discharged at the predetermined settings.

(b)

Ensure that the cylindrical metal container and dip stick are reasonably clean. Discharge foamed bitumen, at least twice, into cylindrical metal container prior to testing in order to pre-heat the container. Decant excess bitumen from the container into a suitable waste receptacle.

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Heat the bitumen in the kettle of the foamed bitumen laboratory unit with the pump circulating the bitumen through the system until the required temperature is achieved (normally starting with 160 °C). Maintain the required temperature for at least 5 minutes prior to commencing with testing.

(b)

Set the water flow-meter to achieve the required water injection rate (normally starting with 2 % by mass of the bitumen).

(c)

Discharge foamed bitumen into the preheated steel drum for the calculated spray time for 500 g of bitumen. Immediately after the foamed bitumen discharge stops, start a stopwatch.

(d)

Using the calibrated dipstick measure the maximum height the foamed bitumen achieves in the drum. This maximum volume is recorded as the expansion. Continue to measure the time in seconds that the foam takes to dissipate to half of its maximum volume. This is recorded as the foamed bitumen’s half-life.

(e)

Repeat the above procedures three times or until similar readings are achieved.

(f)

The expansion and half-life are determined at different percentages of water. Typically, values of 2 %, 3 % and 4 % by mass of bitumen are used.

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Plot a graph of the expansion ratio versus half-life at the different water injection rates on the same set of axes. The optimum water addition is chosen as an average of the two water contents required to meet the minimum criteria. (Figure 7.1 Determination of Optimum Foaming Water)

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(h)

If the required properties are not met at 160°C, further testing should be carried out with the bitumen at higher temperatures (typically 170°C and 180°C).

8.6.5

Reporting

1

The foamed bitumen characteristics and optimum water content are reported as; Optimum water content (%): Expansion (times): Half-life (sec):

Percentage by mass of bitumen; Ratio of maximum expansion to original volume of bitumen; Time taken from maximum expansion to half this volume.

QCS 2014

Page 20

Site Quality Control

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Figure 7.1 Determination of Optimum Foaming Water

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8.6.6

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 21

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APPENDIX

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QCS 2014

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GUIDANCE FOR THE DESIGN OF RECYCLED AND STABILISED MATERIALS (MIX DESIGNS)

QCS 2014

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GENERAL PREPARATION OF SAMPLES FOR MIX DESIGN PROCEDURES MIX DESIGN PROCEDURE FOR CEMENT STABILISED MATERIALS MIX DESIGN PROCEDURE FOR BITUMEN STABILISED MATERIALS (BSMS) DETERMINATION OF THE FLUID / DENSITY RELATIONSHIP PREPARATION FOR STABILISING W ITH BITUMEN EMULSION (BSM-EMULSION) PREPARATION FOR STABILISING W ITH FOAMED BITUMEN (BSM-FOAM) MANUFACTURE OF 100MM DIAMETER SPECIMENS DETERMINATION OF THE STRENGTH OF 100MM DIAMETER SPECIMENS MANUFACTURE OF 150MM DIAMETER SPECIMENS DETERMINATION OF THE STRENGTH OF 150MM DIAMETER SPECIMENS STRENGTH TEST PROCEDURES SELECTION OF THE AMOUNT OF BITUMEN TO BE ADDED FOR BSM DETERMINATION OF THE SHEAR PROPERTIES OF BSM DETERMINATION OF TRIAXIAL SHEAR PARAMETERS USING SIMPLE TRIAXIAL TEST USING LABORATORY TEST RESULTS FOR ESTIMATING STRUCTURAL LAYER COEFFICIENTS PROFORMA REPORT SHEET FOR ITS TESTING LABORATORY EQUIPMENT REQUIREMENTS

m

8.7 8.7.1 8.7.2 8.7.3 8.7.4 8.7.5 8.7.6 8.7.7 8.7.8 8.7.9 8.7.10 8.7.11 8.7.12 8.7.13 8.7.14 8.7.15 8.7.16 8.7.17

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

23 23 25 27 28 29 29 32 34 34 36 37 38 40 40 45 46 47

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8.7

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 23

GENERAL The detailed procedures for carrying out stabilisation mix designs in a laboratory are described below. Procedures for both cement (or lime) and bitumen stabilisation are included as well as guidelines for interpreting the test results for bitumen stabilised materials (BSMs). Comprehensive lists of laboratory equipment are provided. In addition, a chart has been included showing how laboratory test results can be utilised to indicate the relevant structural coefficient for a BSM (for use in the AASHTO 1993 pavement design method). Preparation Of Samples For Mix Design Procedures

1

Field Sampling: Bulk samples are obtained from test pits excavated as part of the field investigations. Each layer in the upper pavement (± 300mm) must be sampled separately and at least 150kg of material recovered from each layer that is likely to be included in any mix design procedure. Representative samples shall be obtained and prepared either from the excavation process at source or by laboratory crushing and screening.

2

Standard soil tests: Carry out the following standard tests on the material sampled from each individual layer:

ta

rw .l. l

.

8.7.1

Sieve analysis to determine the grading (ASTM D 422);

(b)

Atterberg limits to determine the liquid limit and plasticity index (ASTM D 4318); and

(c)

Moisture / density relationship (AASHTO T-180).

as

qa

(a)

Sample blending: Where necessary, blend the materials sampled from the different layers to obtain a combined sample representing the material from the full recycling depth. The in-situ density of the various components must be considered when blending materials, as illustrated in

4

Figure 7.1 Determination of Optimum Foaming Water Repeat the standard soil tests described above to determine the grading and plasticity index of the blended sample.

et it

o

ov

er

se

3

m

Existing upper pavement structure

60mm Asphalt 3 (in situ density 2300 kg/m )

200mm Subbase 3 (in situ density 2000 kg/m )

Recycling depth 200mm =

60mm Asphalt + 140mm Gravel

The materials are blended in proportion to layer thickness and insitu density as follows: Per square metre Proportion by mass Per 10kg sample Material (kg) (%) (g) 0.06 x 2300 = Asphalt (60mm at 2300 kg/m3) 138/418 = 0.33 0.33 x 10000 = 3300 138 0.14 x 2000 = Gravel (140mm at 2000 kg/m3) 280/418 = 0.67 0.67 x 10000 = 6700 280 Total

418

1.00

Figure 7.2 Example of Density Proportioning

10000

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5

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 24

Representative proportioning: Separate the material in the representative sample into the following four fractions: 

Retained on the 19.0mm sieve;



Passing the 19.0mm sieve, but retained the 12.5 mm sieve;



Passing the 12.5 mm sieve, but retained on the 4.75mm sieve; and



Passing the 4.75mm sieve.

.

Reconstitute representative samples in accordance with the grading up to the portion passing the 19.0mm sieve. Substitute the portion retained on 19.0mm sieve with material that passes the 19.0mm sieve, but is retained on the 12.5 mm sieve. The example in Table 8.4 Material Combination explains this procedure:

Sieve analysis

rw .l. l

Table 8.4 Material Combination

Quantity of material to be included in a 10kg sample

Percentage passing (from sieve analysis)

19

90.5

12.5

72.3

4.75

53.6

Passing 4.75mm

Passing 12.5mm Retained 4.75mm

(53.6/100 x 10000) = 5360g

((72.3-53.6)/100 x 10000) = 1870g

Passing 19mm Retained 12.5mm

((100-72.3)/100 x 10000) = 2770g

as

qa

ta

Sieve size (mm)

ov

Sample quantities: The guidelines shown Table 8.5 Test Quantities should be used for the quantity of material required for the respective tests:

7

Table 8.5 Test Quantities Test

Sample quantity required

m

et it

o

6

er

se

If there is insufficient material (i.e. passing the 19mm sieve but retained on the 12.5mm sieve) for substituting that retained on the 19mm sieve, then lightly crush the material retained on the 19.0mm sieve to provide more of this fraction.

Moisture / density relationship (AASHTO T180)

5 x 7kg

Unconfined Compressive Strength (150mm Ø specimens)

20kg per stabiliser content

Bitumen stabilisation mix design (100mm Ø specimens)

Minimum 10kg per stabiliser content

Bitumen stabilisation mix design (150mm Ø specimens )

Minimum 20kg per stabiliser content

Determination of moisture content

Approximately 1kg

Hygroscopic moisture content: Two representative air-dried samples, each approximately 1kg, are used to determine the hygroscopic (air dried) moisture content of the material. (Note: Larger sample size should be used for more coarsely-graded materials.) Weigh the air-dried samples, accurate to the nearest 0.1g, and then place them in an oven at a temperature of between 105ºC and 110ºC until they achieve constant mass. The hygroscopic moisture content (W air-dry) is the loss of mass expressed as a percentage of the dry mass of the sample. Determine the hygroscopic moisture using equation 1:

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

where:

W air-dry

= (Mmoist – Mdry) / Mdry x 100

[Equation 1]

W air-dry

= hygroscopic moisture content

[% by mass]

Mmoist

= mass of moist material

[g]

Mdry

= mass of dry material

[g]

Page 25

8.7.2

Mix Design Procedure For Cement Stabilised Materials

1

Determination of the Moisture / Density Relationship: This test is carried out using standard compaction effort to determine the Optimum Moisture Content (OMC) and Maximum Dry Density (MDD) of the cement stabilised material.

rw .l. l

.

Step 1: Weigh out the required mass of stabilising agent for each of five 7kg samples prepared as described in ‎8.7.1. The amount of stabilising agent required (expressed as a percentage by mass of the dry sample) should be close to the anticipated optimum for the material being treated. In the absence of previous tests, the following can be used as a guideline: Subbase layers:

2% for coarse material (> 50% retained on 4.75mm sieve)

ta

3% for fine material (< 50% retained on 4.75mm sieve) 4% for coarse material (> 50% retained on 4.75mm sieve)

qa

Base layers:

6% for fine material (< 50% retained on 4.75mm sieve)

er

se

as

Step 2: Add the stabilising agent to the raw material and mix immediately prior to the addition of water. In order to simulate conditions on the road, compaction of the stabilised material is delayed for one hour after mixing the untreated material with stabilising agent and water. The mixed material is placed in an air-tight container to prevent loss of moisture and is thoroughly mixed every fifteen minutes.

et it

o

Manufacture of Specimens for Strength Testing: The procedure described below is for the manufacture specimens that are of 150mm in diameter and 127mm in height. These specimens will be used to determine the Unconfined Compressive Strength (UCS) and Indirect Tensile Strength (ITS) of the material.

m

2

ov

Step 3: Determine the OMC and MDD for the stabilised material in accordance with the modified moisture-density relationship test procedure (AASHTO T-180).

Step 1: Place the 20kg sample, prepared as described in ‎8.7.1, into a suitable mixing container. Step 2: Determine the dry mass of the sample using equation 2:

where:

Msample

= (Mair-dry/ (1 + (W air-dry x 100))

[Equation 2]

Msample

= dry mass of sample

[g]

Mair-dry

= air-dried mass of the sample

[g]

W air-dry = moisture content of air-dried sample [% by mass] Step 3: Determine the required amount of stabilising agent using equation 3:

where:

Mcement

= (Cadd / 100) x Msample

[Equation 3]

Mcement

= mass of lime or cement to be added

[g]

Cadd

= percentage of lime or cement required

[% by mass]

Msample

= dry mass of the sample

[g]

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Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 26

Step 4: Determine the percentage water to be added for optimum mixing purposes using equation 4 and then the mass of water to be added to the sample using equation 5:

where:

W add

= W OMC - W air-dry

[Equation 4]

Mwater

= (W add / 100) x (Msample + Mcement)

[Equation 5]

W add

= water to be added to sample

[% by mass]

W OMC

= optimum moisture content

[% by mass]

W air-dry

= moisture content of air-dried sample

[% by mass]

Mwater

= mass of water to be added

[g]

Msample

= dry mass of the sample

[g]

rw .l. l

.

Mcement = mass of lime or cement to be added [g] Step 5: Mix the material, cement and water until uniform. Allow the mixed material to stand for one hour with occasional mixing, as described above, before compacting three 150mm diameter specimens using modified AASHTO (T-180) compaction effort. (Note: Two 150mm diameter specimens are normally manufactured for each test.)

= (Mmoist - Mdry) / Mdry x 100))

W mould

= moulding moisture content

[% by mass]

Mmoist

= mass of moist material

[g]

as

W mould

se

where:

qa

ta

Step 6: Samples are taken during the compaction process and dried to a constant mass (at 105 to 110°C) to determine the moulding moisture content (W mould). Determine the moulding moisture using equation 6: [Equation 6]

er

Mdry = mass of dry material [g] Steps 7 to 9: Repeat the above steps for at least three different stabiliser contents.

o

ov

Step 10: Remove the specimens from the moulds either by dismantling the split moulds or, if ordinary moulds are used, extruding the specimens carefully with an extrusion jack, avoiding distortion to the compacted specimens.

m

et it

Step 11: Record the mass and volume of each specimen and determine the dry density using equation 7:

where:

DD

= (Mbriq / Vol) x (100 / W mould +100) x 1000

[Equation 7]

DD

= dry density

[kg/m³]

Mbriq

= mass of specimen

[g]

Vol

= volume of specimen

[cm ]

W mould

= moulding moisture content

[%]

3

Note: With certain materials lacking cohesion, it may be necessary to leave the specimens in the moulds for 24 hours to develop strength before extracting. When this is necessary, the specimens in the moulds should be kept in a curing room or covered with damp cloth (hessian).

3

Curing the Specimens: Cure the specimens for seven days at 95% to 100% relative humidity and at a temperature of 20ºC to 25ºC in a suitable curing room. An alternative curing method is to place the specimen in sealed plastic bags and cure in an oven at: 70ºC to 75ºC for 24 hours for cement; or

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Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 27

60ºC to 62 ºC for 45 hours for lime. After the curing period, remove the specimens from the curing room (or plastic bags) and allow to cool to ambient temperature, if necessary. Specimens for unconfined compressive strength (UCS) tests should be submerged in water at 22°C to 25°C for four hours prior to testing. Strength Tests: The Unconfined Compressive Strength (UCS) test and the Indirect Tensile Strength (ITS) test procedures are described under ‎8.7.11.

5

Determination of the Optimum Stabiliser Content: The ITS and UCS strengths achieved are plotted against the percentage stabilising agent added using the average UCS or ITS of the three specimens for each stabiliser content, ignoring any obvious incorrect result that may have been caused by damage to the specimen before testing. The required application rate of stabilising agent is that percentage at which the minimum required criteria are met.

8.7.3

Mix Design Procedure For Bitumen Stabilised Materials (Bsms)

1

Active Filler Requirements: Bitumen stabilisation is normally carried out in combination with a small amount (1% by mass) of active filler (cement or hydrated lime) to enhance the dispersion of the bitumen and/or the breaking time (where bitumen emulsion is used as the stabilisation agent). The PI of the material is used as an initial guideline for the use of hydrated lime or cement in the mix:

as

qa

ta

rw .l. l

.

4

Table 8.6 Guide to Addition of Active Filler

se

Plasticity Index: < 10

ov

er

Carry out Preliminary Level 1 tests (explained below) to determine the need to add cement or hydrated lime.

Plasticity Index: > 10 Pre-treat with hydrated lime (ICL value) (The initial consumption of lime (ICL value) must first be determined using the appropriate pH test.)

2

m

et it

o

Pre-treatment of material with a PI > 10 requires that the lime and water be added at least 2 hours prior to the addition of the bitumen emulsion or foamed bitumen. (The treated material must be placed in an air-tight container to retain moisture and the moisture content checked and, if necessary, adjusted prior to adding the bitumen stabilising agent.) Such materials are not subjected to “Preliminary Level 1” tests. Preliminary Level 1 Tests: Where the PI < 10, the need for an active filler and the type of active filler (cement or hydrated lime) that is appropriate for the material must first be determined by carrying out “Level 1” tests on three different mixes. The same amount of bitumen (residual bitumen for bitumen emulsion treatment) is added to all three mixes, determined from the fractions passing the 4.75mm and 0.075mm sieves, as shown in Table 8.7 Suggested bitumen addition relative to key aggregate fractions.

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Page 28

Table 8.7 Suggested bitumen addition relative to key aggregate fractions Percentage passing sieve size (%) 0.075mm

> 50

2.0

5.0 – 7.5

2.25

7.5 – 10.0

2.5

> 10.0

2.75

< 5.0

2.25

5.0 – 7.5

2.5

7.5 – 10.0

3.0

.

< 50

< 5.0

rw .l. l

4.75mm

Bitumen addition (% of dry aggregate)

> 10.0

3.5

ta

The first mix contains no active filler, 1% cement is added to the second mix and 1% hydrated lime is added to the third mix. 100mm diameter specimens are manufactured, cured and tested to determine the relevant ITSDRY, ITSWET and TSR values as described in ‎8.7.12.

as

qa

Where the TSR value for the mix with no active filler added is in excess of 60%, the mix design should be undertaken with no active filler. (This situation is usually confined to materials consisting of good quality crushed stone, often including a high proportion of reclaimed asphalt pavement (RAP) material.)

er

se

Where the TSR value of the mix with no active filler added is less than 60%, the mix with the type of active filler that produces a significantly higher TSR value (> 5%) indicates whether cement or hydrated lime should be used. If the TSR values for both active fillers are of the same order (difference < 5%) then either type of active filler is suitable.

Determination Of The Fluid / Density Relationship The Optimum Fluid Content (OFC) and the Maximum Dry Density (MDD) of the stabilised material is determined using standard compaction effort.

m

8.7.4

et it

o

ov

Note. Should cement and/or hydrated lime be not readily available and tests indicate the need for an active, the use of 15% (by volume) quarry fine aggregate (5mm to 0mm) or similar material with > 10% passing the 0.075mm sieve may be used as a substitute in the mix designs.

Note: For foamed bitumen stabilisation, the OFC and MDD can be assumed to be the same as the OMC and MDD, as determined for representative samples of the untreated material. The OFC for bitumen emulsion treated material is the percentage by mass of bitumen emulsion plus additional moisture required to achieve the maximum dry density in the treated material. As described below, the OFC is determined by adding a constant percentage of bitumen emulsion whilst varying the amount of water added. Step 1: Measure out the bitumen emulsion as a percentage by mass of the air-dried material for each of five prepared samples following the procedure described in ‎8.7.1. The percentage of bitumen emulsion added is normally between 2 and 3% residual bitumen (e.g. for 3% residual bitumen, add 5% of a 60% bitumen emulsion). Step 2: The bitumen emulsion and water is added to the material and mixed until uniform immediately prior to compaction. Step 3: Determine the OFC and MDD for the stabilised material in accordance with the modified moisture-density relationship test procedure (AASHTO T-180).

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8.7.5

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 29

Preparation For Stabilising With Bitumen Emulsion (Bsm-Emulsion) Step 1: Place the required quantity of sample into a suitable mixing container (10kg for the manufacture of 100mm diameter specimens, or 20kg for the manufacture of 150mm diameter specimens). Step 2: Determine the dry mass of the sample using equation 1. Step 3: Determine the required percentage of active filler (lime or cement) using equation 3. Step 4: Determine the required percentage (by mass) of bitumen emulsion using equation 8: = (RBreqd / PBE) x Msample

[Equation 8]

Memu

= mass of bitumen emulsion to be added

[g]

RBreqd

= percentage of residual bitumen required

[% by mass]

PBE

= percentage of bitumen in emulsion

[% by mass]

.

where:

Memul

Mwater

= {((W OFC – W air-dry) / 100) x Msample} – Memul

Mwater

= mass of water to be added

[g]

W OFC

= optimum fluid content

[% by mass]

W air-dry

= moisture content of air-dried sample

[% by mass]

Memul

= mass of bitumen emulsion to be added

[g]

qa

ta

[Equation 9]

as

where:

rw .l. l

Msample = dry mass of the sample [g] Step 5: Determine the amount of water to be added for optimum compaction purposes using equation 9:

er

se

Msample = dry mass of the sample [g] Step 6: Mix the material, active filler, bitumen emulsion and water together until uniform. Immediately manufacture specimens following the relevant procedure for either 100mm or 150mm diameter specimens, as described in ‎8.7.7 and ‎8.7.9 respectively.

ov

Repeat above steps for at least four mixes with different bitumen emulsion contents.

et it

o

Recommended bitumen addition interval for different specimen sizes Difference in amount of bitumen added (%) to Specimen diameter (mm) each mix 100 (Level 1) 0.25 0.1

m

150 (Level 2)

For 100mm diameter specimens, use Error! Reference source not found. as a guideline or the amount of bitumen addition that the material will require for effective stabilisation. For 150mm diameter specimens, use the results of Level 1 tests from ‎8.7.8 as the maximum addition of bitumen (i.e. the three other mixes will be in intervals of 0.1% less than this value). 8.7.6

Preparation For Stabilising With Foamed Bitumen (Bsm-Foam)

1

Determination of the foaming properties of the bitumen: The foaming properties of each bitumen type is characterised by: Expansion Ratio. A measure of the viscosity of the foamed bitumen, calculated as the ratio of the maximum volume of the foam relative to the original volume of bitumen; and Half Life. A measure of the stability of the foamed bitumen, calculated as the time taken in seconds for the foam to collapse to half of its maximum volume.

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Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 30

The objective is to determine the temperature and percentage of water addition that is required to produce the best foam properties (maximum expansion ratio and half-life) for a particular source of bitumen. This is achieved at three different bitumen temperatures (not exceeding 195°C) with the following procedure: Step 1: Heat the bitumen in the kettle of the Wirtgen WLB10 S laboratory unit with the pump circulating the bitumen through the system until the required temperature is achieved (normally starting with160°C). Maintain the required temperature for at least 5 minutes prior to commencing with testing. Step 2: Calibrate the discharge rate of the bitumen and set the timer on the Wirtgen WLB10 S to discharge 500g of bitumen (Qbitumen). Step 3: Set the water flow-meter to achieve the required water injection rate (normally starting with 2% by mass of the bitumen).

rw .l. l

.

Step 4: Discharge foamed bitumen into a preheated (± 75°C) steel drum for a calculated spray time for 500g of bitumen. Immediately after the foam discharge stops, start a stopwatch.

ta

Step 5: Using the dipstick supplied with the Wirtgen WLB10 S (which is calibrated for a steel drum of 275mm in diameter and 500g of bitumen) measure the maximum height the foamed bitumen achieves in the drum. This is recorded as the maximum volume.

qa

Step 6: Use the stopwatch to measure the time in seconds that the foam takes to dissipate to half of its maximum volume. This is recorded as the foamed bitumen’s half-life. Step 7: Repeat the above procedure three times or until similar readings are achieved.

as

Step 8: Repeat steps 3 to 7 for a range of at least three water injection rates. Typically, values of 2%, 3% and 4% by mass of bitumen are used.

ov

er

se

Step 9: Plot a graph of the expansion ratio versus half-life at the different water injection rates on the same set of axes (see the example in graph below). The optimum water addition is chosen as an average of the two water contents required to meet these minimum criteria. Repeat Step 1 to 9 for two other bitumen temperatures (normally 170°C and 180°C).

et it

o

The temperature and optimum water addition that produces the best foam is then used in the mix design procedure described below. Note: The absolute minimum foaming properties that are acceptable for effective stabilisation (material temperature of 25°C) are: Expansion ratio:

10 times

Half-life:

12 seconds

m

 

2

If the minimum requirements cannot be met, the bitumen should be rejected as unsuitable for use.

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Page 31

Prepare the material for foamed bitumen treatment as follows: Step 1: Place 20 to 25kg of sample prepared as described in ‎8.7.1 into the Wirtgen WLM30 pugmill mixer. Step 2: Determine the dry mass of the sample using equation 2. Step 3: Determine the required percentage of active filler (lime or cement) using equation 3. Step 4: Determine the percentage water to be added for optimum mixing moisture content as calculated using equation 10. The amount of water to be added to the sample is determined using equation 11. [Equation 10]

Mwater

= (W add / 100) x (Msample + Mcement)

[Equation 11]

W add

= water to be added to sample

[% by mass]

W OMC

= optimum moisture content

W air-dry

= moisture content of air-dried sample

[% by mass]

Mwater

= mass of water to be added

[g]

Msample

= dry mass of the sample

rw .l. l

.

= 0.75W OMC - W air-dry

ta

where:

W add

[% by mass]

[g]

qa

Mcement = mass of lime or cement to be added [g] Step 5: Mix the material, active filler and water in the mixer until uniform.

er

se

as

Note: Inspect the sample after mixing to ensure that the mixed material is not packed against the sides of the mixer. If this situation occurs, mix a new sample at a lower moisture content. Check to see that the material mixes easily and remains in a “fluffed” state. If any dust is observed at the end of the mixing process, add small amounts of water and remix until a "fluffed" state is achieved with no dust.

= (Badd /100) x (Msample + Mcement)

[Equation 12]

Mbitumen

= mass of foamed bitumen to be added

[g]

Badd

= foamed bitumen content

[% by mass]

Msample

= dry mass of the sample

[g]

o

Mbitumen

et it

where:

ov

Step 6: Determine the amount of foamed bitumen to be added using equation 12:

Mcement = mass of lime or cement to be added [g] Step 7: Determine the timer setting on the Wirtgen WLB10 S using equation 13:

m

3

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

where:

T

= Mbitumen / Qbitumen

[Equation 13]

T

= time to be set on WLB10 S timer

[s]

Mbitumen

= mass of foamed bitumen to be added

[g]

Qbitumen = bitumen flow rate for the WLB10 S [g/s] Step 8: Position the mixer adjacent to the foaming unit so that the foamed bitumen can be discharged directly into the mixing chamber. Step 9: Start the mixer and allow it to mix for at least 10 seconds before discharging the required mass of foamed bitumen into the mixing chamber. After the foamed bitumen has discharged into the mixer, continue mixing for a further 30 seconds or until uniformly mixed. Step 10: Determine the amount of water required to bring the sample to the OMC using equation 14.

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

where:

Page 32

Mplus

= (W OMC – W sample) / 100 x (Msample + Mcement)

[Equation 14]

Mplus

= mass of water to be added

[g]

W OMC

= optimum moisture content

[% by mass]

W sample

= moisture content of prepared sample

[% by mass]

Msample

= dry mass of the sample

[g]

Mcement = mass of lime or cement added [g] Note: This moisture adjustment is to be carried out when 150mm diameter specimens are to be manufactured. Where 100mm diameter specimens are to be manufactured, the moisture content of the material is to be adjusted to 90% of OMC. Step 11: Add the additional water and mix until uniform.

rw .l. l

.

Step 12: Transfer the foamed bitumen treated material into a container and immediately seal the container to retain moisture. To minimise moisture loss from the prepared sample, manufacture the specimens as soon as possible following the relevant procedure for either 100mm or 150mm diameter specimens, as described in ‎8.7.7 and ‎8.7.9 respectively.

ta

Repeat the above steps for at least four mixes with different foamed bitumen contents.

100 (Level 1)

se

150 (Level 2)

Difference in amount of bitumen added (%) to each mix

as

Specimen diameter (mm)

qa

Recommended bitumen addition interval for different specimen sizes

0.25 0.1

er

For 100mm diameter specimens, use Error! Reference source not found. as a guideline or the amount of bitumen addition that the material will require for effective stabilisation.

et it

o

ov

For 150mm diameter specimens, use the results of Level 1 tests in ‎8.7.8 as the maximum addition of bitumen (i.e. the three other mixes will be in intervals of 0.1% less than this value). Manufacture Of 100mm Diameter Specimens

1

For Level 1 mix designs ITS tests are carried out on 100mm diameter specimens. Six specimens are manufactured for each sample at the different bitumen contents. The two primary objectives of undertaking the Level 1 mix design are to determine:

m

8.7.7



the optimum bitumen content for the BSM, and



the need for an active filler.

2

Specimens may be made using either Marshall or vibratory compaction methods.

3

Marshall Compaction shall be carried out as follows: Step 1: Prepare the Marshall mould and hammer by cleaning the mould, collar, base-plate and face of the compaction hammer. Note: the compaction equipment must not be heated but kept at ambient temperature. Step 2: Weigh sufficient material to achieve a compacted height of 63.5mm ± 1.5mm (usually 1150g is adequate). Spade the mixture with a spatula 15 times around the perimeter and 10 times on the surface, leaving the surface slightly rounded.

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Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 33

Step 3: Compact the mixture by applying 75 blows with the compaction hammer. Care must be taken to ensure the continuous free fall of the hammer. Remove the mould and collar from the pedestal, invert the specimen (turn over). Replace it and press down firmly to ensure that it is secure on the base plate. Compact the other face of the specimen with a further 75 blows. Step 4: Take approximately 1kg representative samples after compaction of the second and fifth specimen and dry a constant mass (at 105 to 110°C). Determine the moulding moisture using equation 15:

where:

W mould

= (Mmoist – Mdry) / Mdry x 100

[Equation 15]

W mould

= moulding moisture content

[% by mass]

Mmoist

= mass of moist material

[g]

rw .l. l

.

Mdry = mass of dry material [g] Step 5: After compaction, remove the mould from the base-plate and extrude the specimen by means of an extrusion jack. Measure the height of the specimen and adjust the amount material if the height is not within the required limits.

qa

Vibratory Compaction shall be carried out as follows:

se

as

Step 1: Fix the mounting head and appropriate tamping foot to the vibratory hammer and fit hammer onto guide rods. Place 5kg surcharge weight onto mounting head (total mass of assembly [Hammer + foot + surcharge] = 25kg) and fasten tightly. Using the pulley system raise the vibratory hammer to an adequate height that will allow operator to work safely beneath the vibratory hammer and lock in position.

ov

er

Step 2: Clean the mould, collar and base plate. Fix the mould to the base of the compaction frame. Note: the compaction equipment must not be heated but kept at ambient temperature.

et it

o

Step 3: Weigh sufficient material to achieve a compacted height of 63.5mm ± 1.5mm (usually 1150g is adequate). Spade the mixture with a spatula 15 times around the perimeter and 10 times on the surface, leaving the surface slightly rounded. Step 4: Lower the vibratory hammer into the mould, checking that the vibratory hammer is perpendicular to the base of the mould. Apply 15 seconds of vibratory compaction to the sample in the mould.

m

4

ta

Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in the mould for 24 hours, allowing sufficient strength to develop before extracting.

Step 5: Raise hammer to the safe position, remove mould, invert mould and secure to base. Step 6: Lower vibratory hammer to surface of material in mould and ensure vibratory hammer rests freely on sample and is perpendicular to the base of the mould. Apply further 15 seconds of vibratory compaction to sample in the mould. Step 7: Take approximately1kg representative samples after compaction of the second and fifth specimen and dry to constant mass (at 105 to 110 oC). Determine the moulding moisture using equation 15. Step 8: After compaction, remove the mould from the base-plate and extrude the specimen carefully by means of an extrusion jack. Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in the mould for 24 hours, allowing sufficient strength to develop before extracting.

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 34

5

Curing procedure: Compacted specimens shall be cured by placing the specimens on a steel mesh and curing in a forced-draft oven until a constant mass is obtained (normally 72 hours at 40°C). Remove from oven after curing and allow to cool to ambient temperature.

6

When specimens have cooled to ambient temperature determine the bulk density for each specimen: Step 1. Determine the mass (Mbriq). Step 2. Measure the height at four evenly-spaced places around the circumference and calculate the average height (h). Step 3. Measure the diameter (d). Step 4. Calculate the bulk density using equation 16: x h) x 1000

BD

= moulding moisture content

Mbriq

= mass of specimen

h

= average height of specimen

[Equation 16]

.

= (4 x Mbriq

[kg/m³]

rw .l. l

where:

2

BD

[g] [cm]

qa

ta

d = diameter of specimen [cm] Note: Exclude from further testing any specimen whose bulk density differs from the mean bulk density of the batch by more than 50 kg/m³. The bulk density may alternatively be determined by using the “weigh-in air / weigh-in water” method for those specimens designated for soaked testing.

8.7.8

Determination Of The Strength Of 100mm Diameter Specimens

1

The 100mm diameter specimens are tested for indirect tensile strength under dry and soaked conditions to determine the ITSDRY and the ITSWET values. To prevent moisture loss, specimens should be tested as soon as they are prepared. The results are used to indicate the optimum bitumen content and the need for active filler. In addition, these test results are used as a guide for the classification of the BSM.

8.7.9

Manufacture Of 150mm Diameter Specimens

1

Level 2 mix designs ITS tests are carried out on specimens that are 150mm diameter and 95mm in height. These specimens are cured to simulate the equilibrium moisture content achieved in the field. This method of curing provides more realistic values for classification of the bitumen stabilised materials.

2

The procedures described allow for the manufacture of four 150mm diameter specimens to a compacted height of 95mm. If additional specimens are required, the sample quantity shall be increased.

3

Specimens may be made using either Modified AASHTO (T-180) or vibratory compaction methods.

4

MODIFIED AASHTO (T-180) compaction shall be carried out as follows:

m

et it

o

ov

er

se

as

7

Step 1: Prepare and treat at least 24kg of sample for each selected bitumen content. Step 2: Where required, add sufficient moisture to bring sample to optimum compaction moisture content and mix until uniform. Immediately after mixing, place material in an airtight container.

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 35

Step 3: Take approximately 1kg representative samples after compaction of the first and third specimen and dry to a constant mass (at 105 to 110°C). Determine the moulding moisture using equation 15. Step 4: Compact at least 4 specimens using a 150mm diameter split-mould, applying modified AASHTO (T-180) compaction effort (4 layers approximately 25mm thick, 56 blows per layer using a 4.536kg hammer with a 457mm drop). Step 5: Carefully trim excess material from specimens, as specified in the AASHTO T180 test method. Step 6: Carefully remove the specimen from the spilt-mould and place on a steel mesh. Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in the mould for 24 hours, allowing sufficient strength to develop before extracting.

.

Vibratory compaction shall be carried out as follows:

ta

rw .l. l

Step 1: Fix the mounting head and appropriate tamping foot (150mm diameter) to the vibratory hammer and fit hammer onto guide rods. Place 10kg surcharge weight onto mounting head (total mass of assembly [hammer + foot + surcharge] = 30kg) and fasten tightly. Using the pulley system raise the vibratory to an adequate height that will allow operator to work safely beneath the vibratory hammer and lock in position.

qa

Step 2: Clean the 150mm diameter spilt mould, collar and base plate. Fix the mould to the base of the compaction frame.

2

= ( x d x h / 4) x (MDD) /1000

Mmix

= Mass of mixed material

d

[Equation 17] [g]

= diameter of specimen

[cm]

= required height of layer (4.75cm for ITS)

[cm]

o

h

er

Mmix

ov

where:

se

as

Step 3: Weigh sufficient material to achieve a compacted height of 47.5mm ± 1.5mm. An approximation of the quantity required can be calculated using equation 17. Spade the mixture with a spatula 15 times around the perimeter and 10 times on the surface, leaving the surface slightly rounded.

Apply

et it

MDD = maximum dry density [kg/m³] Step 4: Lower the vibratory hammer into the mould, checking that the vibratory hammer is perpendicular to the base of the mould.

m

5

25 seconds of vibration for bitumen emulsion stabilised materials 35 seconds of vibration for foamed bitumen stabilised materials.

Step 5: Raise hammer to safe position. Step 6: For the second layer, if necessary, adjust for the amount of material to be added such that the final compacted thickness is 95mm. Using a chisel, scarify the entire surface area of the top of the compacted layer to a maximum depth of 10mm. Add the required amount of material and ensure the material is as level as possible. Step 7: Lower the vibratory hammer into the mould, checking that the vibratory hammer is perpendicular to the base of the mould. Apply

25 seconds of vibration for bitumen emulsion stabilised materials 35 seconds of vibration for foamed bitumen stabilised materials.

Step 8: Raise hammer to safe position. Remove mould from base plate and open the split mould to remove the specimen.

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 36

Step 9: Take approximately 1kg representative samples after compaction of the first and third specimens and dry to a constant mass. Determine the moulding moisture using equation 15. Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in the mould for 24 hours, allowing sufficient strength to develop before extracting. Curing procedure: Place the specimens in an oven at 40°C for 24 hours (or until the moisture content has reduced to at least 50% of OMC). Thereafter place each specimen in a sealed plastic bag (at least twice the volume of the specimen) and place in an oven at 40°C for a further 48 hours.

7

Remove specimens from the oven after 48 hours and remove the respective plastic bags, ensuring that any moisture in the bags does not come into contact with the specimen. Allow to cool to ambient temperature.

8

When specimens have cooled to ambient temperature determine the bulk density for each specimen:

rw .l. l

.

6

Step 1: Determine the mass (Mbriq).

qa

ta

Step 2: Measure the height at four evenly-spaced places around the circumference and calculate the average height (h). Step 3: Measure the diameter (d).

as

Step 4: Calculate the bulk density using equation 16:

se

Note: Exclude from further testing any specimen whose bulk density differs from the mean bulk density of the batch by more than 50 kg/m³. The bulk density may alternatively be determined by using the “weigh-in air / weigh-in water” method for those specimens designated for soaked testing.

8.7.10

Determination Of The Strength Of 150mm Diameter Specimens

1

The 150mm diameter specimens are tested for indirect tensile strength under equilibrium moisture content and soaked conditions to determine the ITSEQUIL and the ITSSOAK values. To prevent moisture loss, specimens should be tested as soon as they are prepared. The results are used to refine the optimum bitumen content and amount of active filler that was initially determined from the 100mm diameter specimens. In addition, these test results are used to classify the BSM with additional confidence.

2

Additional ITS tests should be carried out using 150mm diameter specimens to determine the sensitivity of the mix to minor variations in both the amount of added bitumen and active filler.

m

et it

o

ov

er

9

If, for example, Level 2 test results indicated an optimum bitumen addition (OBA) of 2.2% with an active filler addition of 1%, then the following further tests should be undertaken: Step 1: To check the sensitivity of the bitumen addition, follow the Level 2 procedure in ‎8.7.9 to manufacture, cure and test the following mixes:

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials Added bitumen (%) 2.2 (Level 2 OBA) 2.1 2.0 1.9

Page 37

Active filler (%) 1 1 1 1

ITS test results will allow the optimal bitumen addition (OBA) to be refined. Step 2: To check the sensitivity of the amount of active filler added, follow the Level 2 procedure in ‎8.7.9 to manufacture, cure and test the following mixes: Active filler (%) 0.9 0.7 0.5

.

Added bitumen (%) OBA OBA OBA

rw .l. l

ITS test results will indicate the minimum amount of active filler required in the mix. Strength Test Procedures

1

The Unconfined Compressive Strength (UCS) of a cement stabilised material is determined by measuring the ultimate load to failure of a 127mm high and 150mm diameter specimen that is subjected to a constant loading rate of 140kPa/s (153kN/min), as follows:

qa

ta

8.7.11

as

Step 1: Place the specimen on its flat side between the plates of the compression testing machine. Position the specimen such that it is centred on the loading plates.

se

Step 2: Apply the load to the specimen, without shock, at a rate of advance of 140kPa/s until the maximum load is reached. Record the maximum load P in kN, accurate to 0.1kN.

er

Step 3: Immediately after testing a specimen, break the specimen up and take a sample of approximately 1000g to determine the moisture content (W break). This moisture content is used to determine the dry density of the material using equation 21. = (4 x P) / (  x d ) x 10000

[Equation 18]

o

= unconfined compressive strength

[kPa]

P

= maximum load to failure

[kN]

d

= diameter of specimen

[cm]

UCS UCS

2

2

m

et it

where:

ov

Step 4: Calculate the UCS for each specimen to the nearest 1 kPa according to equation 18.

Indirect Tensile Strength (ITS) of a stabilised material is determined by measuring the ultimate load to failure of a specimen (both 100mm and 150mm diameter specimens) that is subjected to a constant deformation rate of 50.8 mm/minute on its diametrical axis, as follows: Step 1: Place the specimen onto the respective ITS jig for the 100mm and 150mm diameter specimens. Position the sample such that the loading strips are parallel and centred on the vertical diametrical plane. Step 2: Place the load transfer plate on the top bearing strip and position the jig assembly centrally under the loading ram of the compression testing device. Step 3: Apply the load to the specimen, without shock, at a rate of advance of 50.8 mm per minute until the maximum load is reached. Record the maximum load P in kN, accurate to 0.1kN.

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 38

Step 4: Immediately after testing a specimen, break it up and take a sample of approximately 1000g to determine the moisture content (W break). This moisture content is used in equation 21 to determine the dry density of the material in the specimen. Step 5: Immediately after testing a specimen, measure the temperature of the broken face using a digital thermometer. Record the temperature, accurate to 0.1°C. Step 6: Calculate the ITS for each specimen to the nearest 1 kPa using equation 19:

where:

ITS

= (2 x P) / ( x h x d) x 10000

[Equation 19]

ITS

= indirect tensile strength

[kPa]

P

= maximum applied load

[kN]

h

= average height of the specimen

[cm]

rw .l. l

.

d = diameter of specimen [cm] Step 7: To determine the soaked ITS, place the specimens under water at 25°C ± 1°C for 24 hours. Remove specimen from water, surface dry and repeat steps 1 to 5. Record the results and determine the following as required:

ITSDRY = average of 3 specimens cured to constant mass ITSWET = average of 3 ITSDRY specimens soaked for 24 hours. 150mm Ø specimens: ITSEQUIL = average of 2 specimens cured at equilibrium moisture ITSSOAK = average of 2 ITSEQUIL specimens soaked for 24 hours Step 8: Determine the Tensile Strength Retained (TSR). The TSR is the relationship between the average soaked and unsoaked ITS values for a specific batch of specimens, expressed as a percentage using equation 20: = Average soaked ITS / Average unsoaked ITS x 100

[Equation 20]

se

TSR

as

qa

ta

100mm Ø specimens:

er

Step 9: Using the moisture content determined in each test described above, calculate the dry density using equation 21:

where:

DD

o

Mbriq

= (Mbriq / Vol) x (100 / (W break + 100) x 1000

ov

DD

et it

Vol

[Equation 21]

= dry density

[kg/m³]

= mass of cured specimen

[g]

= volume of specimen

[cm ]

3

m

W break = moisture content of the specimen [%] Report the results using the template sheet shown in ‎8.7.16 as a guide. 8.7.12

Selection Of The Amount Of Bitumen To Be Added For Bsm

1

Plot the results of the respective soaked and unsoaked ITS test results against the relevant bitumen content that was added. The added bitumen content that best meets the desired BSM classification is selected as the optimum amount of bitumen to be added, as shown in the example below (Figure 7.3 Determination of BSM class and added bitumenFigure 7.3 Determination of BSM class and added)

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 39

Interpretation of ITS Tests BSM1

BSM2

BSM3

Purpose

ITSDRY

100 mm

> 225

175 to 225

125 to 175

Indicates the optimum bitumen content

ITSWET

100 mm

> 100

75 to 100

50 to 75

Indicates need for active filler.

TSR

100 mm

N/A

N/A

N/A

Indicates problem material where TSR < 50 and ITSDRY > 400 kPa

ITSEQUIL

150 mm

> 175

135 to 175

95 to 135

Used for classifying the BSM and for optimising the bitumen and active filler content.

ITSSOAK

150 mm

> 150

100 to 150

60 to 100

Check value on ITSWET

rw .l. l

.

Specimen Ø

et it

o

ov

er

se

as

qa

ta

Test

m

Figure 7.3 Determination of BSM class and added bitumen

2

The TSR value is useful for identifying problem materials. If the TSR is less than 50%, it is recommended that active filler is used. If such treatment does not increase the ITSWET value with a maximum application of 1% lime or cement, then the nature of the material being stabilised should be investigated:

3

Where the material is granular, a TSR value below 50% combined with an ITSDRY value in excess of 400 kPa suggests contamination (normally attributed to clay or deleterious materials). In this situation, it is suggested that material is pre-treated with hydrated lime and the Level 1 tests repeated.

4

Where the material is 100% RAP, a TSR value below 50% combined with an ITSDRY value in excess of 500 kPa indicates that the treated material is partly stabilised and partly continuously bound (cold mix). In this situation, the material probably requires blending with crusher dust to ensure that the stabilisation process dominates the mix.

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 40

5

Level 2 testing using 150mm diameter specimens should be undertaken to verify the relevant ITS values for BSM classification.

8.7.13

Determination Of The Shear Properties Of Bsm

1

Triaxial testing is carried out to determine the cohesion and angle of internal friction of BSM specimens. Testing is normally carried out at the bitumen content selected from the results of ITS tests carried out on 150mm diameter specimens (see above). Additional tests at different bitumen contents can always be carried out to investigate the sensitivity of the shear properties.

2

Specimens for triaxial testing shall be produced as follows:

rw .l. l

.

Step 1: Prepare and treat 50kg of sample (adequate for manufacture of 4 specimens) with either bitumen emulsion or foamed bitumen at the optimum bitumen content. Include any active filler requirements. Step 2: Where required, add moisture to bring sample to optimum compaction moisture content and mix until uniform. Place the mixed material in an air-tight container.

ta

Step 3: Take approximately1 kg representative samples of each specimen to determine the moulding moisture using equation 15.

as

qa

Step 4: Compact at least four (4) specimens using a 150mm diameter split mould with an effective internal height of 300mm, using equation 17 to calculate the approximate quantity for each layer. Specimens may be made using either Modified AASHTO (T-180) or vibratory compaction methods.

4

Compaction using modified AASHTO (T180) shall be in 12 layers, each approximately 25mm thick, compacted with 56 blows using a 4.536kg hammer with a 457mm drop. Carefully trim any excess material from the specimen.

5

Compaction using vibratory compaction shall be in 5 layers, each approximately 60mm thick, using a hammer assembly of 30kg total mass. Each layer is compacted for: 

25 seconds for BSM-emulsion, or 35 seconds for BSM-foam

m



et it

o

ov

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se

3

The height of each compacted layer is measured and, if necessary, an adjustment made for the quantity of material used for the next layer to achieve the required height for the respective layers. 6

The specimens shall be cured using the same procedure for 150mm diameter specimens.

8.7.14

Determination Of Triaxial Shear Parameters Using Simple Triaxial Test

1

This method describes the determination of triaxial shear parameters (cohesion and internal angle of friction) of Bitumen Stabilised Materials by measuring the resistance to failure (monotonic) of a cylindrical 150 mm diameter and 300 ± 2 mm height specimen prepared according to Vibratory Hammer Compaction Procedure.

QCS 2014

Page 41

Apparatus: (a)

Triaxial Cell comprising a galvanised steel casing 5 mm thick comprising a ring handle and simple mechanical clamps top and bottom, a base with bottom platen for sitting specimen, top disk and a latex tube at least 320 mm in height.

(b)

Testing System comprising a Material Testing System (MTS) or its equivalent system must at least comprise of an actuator, reaction frame, a control panel and data acquisition system. The system must be capable of providing ramp loads with minimum loading capacity of 100 kN and a minimum stroke of 40 mm. The actuator should be operated by a servo-controlled hydraulic pressure system with a closed loop feedback system that is capable of both displacement and load controlled testing if required.

(c)

Measuring devices should include but not limited to a load cell (100 kN Capacity) for measuring load, an actuator displacement transducer (> 40 mm stroke) for measuring displacement (deformation) and pressure regulator, gauges, and valves for lateral pressure.

(d)

Additionally air compressor, loading ram and silicon oil or grease.

rw .l. l

.

2

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

The specimen must be prepared and cured according to Vibratory Hammer Compaction Procedure as stated previously.

4

The triaxial testing of the specimens must be planned to take place within 48 – 72 hours after completion of the curing procedure. This delay must be kept as constant as possible. The following steps describe the procedure taken to assemble specimen in the simple triaxial cell and the cell in the loading frame:

se

as

qa

ta

3

Place the specimens, casing with tube, top disk and base plate in a climate chamber and condition them overnight at 25ºC.

(b)

Lightly grease the sides of the top disk and base plate to reduce friction as much as possible.

(c)

Place the specimen in the middle of the base plate.

(d)

Carefully introduce the casing, comprising the tube, around the specimen. Take care not to damage the edges of the specimen during this procedure.

ov

o

et it

Clamp the casing in position on to the base plate using simple mechanical clamps on the casing.

m

(e)

er

(a)

5

(f)

Put the top disk on top of the specimen.

(g)

Place the cell in the hydraulic loading frame; adjust actuator position until visual contact is made with the loading ram.

(h)

Connect the air supply to the cell; open the regulator and valve on the cell pressure port until the cell pressure is stable at the desired level.

(i)

Set monotonic test parameters on the MTS controller including displacement rate of strain (2.1%), full-scale for the loading (10.0V = 98.1 kN) and half-scale for the displacement (10.0V = 40mm), and run the test

Monotonic Triaxial Test: Select four specimens of comparable density, moisture content and conditioned at 25°C. Assemble the specimen in the triaxial cell according to 4 ensuring the tube is air tight.

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 42

Operate the testing system in displacement control mode. Ensure that there is sufficient space between the actuator and the reaction frame to accommodate the triaxial cell. Place the triaxial cell in the hydraulic loading frame.

(b)

Adjust the actuator position until visual contact is made with the loading ram. Monitor the load cell reading to prevent loading of the specimen during this process. Connect the air supply to the cell pressure port. Open the valve on the cell pressure port and open the regulator until the cell pressure is stable at the desired level. The cell pressures for a series of monotonic tests are 0 kPa, 50kPa, 100 kPa and 200 kPa.

(c)

Test the first specimen without confinement pressure (0 kPa). Begin the test by compressing the specimen at a constant rate of displacement of 2.1%. Record the load versus displacement during the test with a minimum sampling rate of 10 Hz, as well as the cell pressure, temperature and specimen identifier.

(d)

Stop the test and the recording when the total displacement exceeds 18 mm (6% strain) or when the specimen bulges excessively before the end displacement is reached.

(e)

Repeat this procedure for other three specimens until all specimens have been tested at the four levels of confinement pressures.

ta

rw .l. l

.

(a)

Remove the specimens after completion of test after completion of a test. Hold the actuator to its current position, close the valve on the cell pressure port and release the cell pressure by disconnecting the pressure supply tube to the cell (if possible speed up the pressure release by applying suction). Return the actuator to a position whereby the cell can easily be removed from the loading frame. Remove the top disk. Clean the top disk and wipe off any grease. Unclamp the casing and lift the casing with tube from the cell base. Clean the tube from possible remains of the deformed specimen (it is not necessary to remove the tube from the casing). Remove the tested specimen from the base plate. Place it in the plastic bag and seal. Clean the base plate and wipe off any grease.

7

When all the specimens have been tested, remove the tested specimens one by one from the plastic bags. Break the tested specimens up and sample between 500 and 1000 gr. of material from the middle of the specimen. Use this sample to determine the moisture content of each specimen.

8

Calculations:

m

et it

o

ov

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se

as

qa

6

(a)

Determine the applied failure load Pa,f for each specimen tested. The applied failure load is defined as the maximum applied load during the test. Calculate the applied failure stress σa,f :

σa,f where:

σa,f

= applied failure stress

[kPa]

Pa,f

= applied failure load

[N]

= end area of a cylindrical specimen at beginning of test

[m ] or mm ??

A

2

2

QCS 2014

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 43

Calculate the major principle stress at failure σ1,f for each tested specimen:

(b)

where:

σ1,f

= σa,f + σdw

σ1,f

= major principle stress at failure

[kPa]

σa,f

= applied failure stress

[kPa]

σdw

= pressure resulting from dead weight of top disk and loading ram

[kPa]

The relationship between σ1,f and confinement stress (σ3)is determined by:

(c)

σ1,f

= A.σ3+B

A where:

rw .l. l

.

B

Values of A and B can be determined by performing a linear regression analysis on the four combinations of σ1,f and σ3 per mix.

ta

where:

Values of φ [°] and C [kPa] can be calculated as follows: φ

qa

(d)

as

C

Report the following in the table format as illustrated in

10

Table 8. 8 Format Report for Simple Triaxial Test below:

er

se

9

Specimen number or identifier;

(b)

Confinement pressure (σ3);

(c)

Applied stress at failure (σa,f);

(d)

Major principal stress at failure (σ1,f);

o

et it

(e)

ov

(a)

Cohesion, C [kPa]; Angle of internal friction, φ [°]; and

(g)

Coefficient of variance, R

m

(f)

11

2

Plot the Mohr Circles and the Mohr-Coulomb failure envelope as shown in Figure 7.4 Example of Mohr Circle Plot, noting: (a)

The centre of Mohr circle must be on the abscissa and is given by (σ1,f + σ3)/2;

(b)

The radius of such circle is (σ1,f - σ3)/2;

(c)

Angle of internal friction is the angle of the Mohr-Coulomb failure envelope (failure line);

(d)

The failure line intersects with ordinate at the cohesion value.

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Page 44

rw .l. l

.

QCS 2014

qa

ta

Figure 7.4 Example of Mohr Circle Plot

m

et it

o

[kPa]

Principle stress at Failure σ1,f

Cohesion

Internal Friction Angle

Correlation Coefficient

[kPa]

[kPa]

[°]

[R ]

se

Applied Stress at Failure σa,f

er

Confining Pressure, σ3

[kPa]

ov

Specimen No.

as

Table 8. 8 Format Report for Simple Triaxial Test

2

QCS 2014

Page 45

et it

Notes:

o

ov

er

se

as

qa

ta

rw .l. l

.

Using Laboratory Test Results For Estimating Structural Layer Coefficients

The minimum Retained Tensile Strength (%) requirement should be 75%. The following minimum compaction requirements are recommended:

m

8.7.15

Section 06: Roadworks Part 08: Recycled and Stabilised Road Materials

Material Type

Percentage of Modified AASHTO compaction T180

BSM3

BSM2

BSM1

> 97%

> 100%

> 102%



The material passing the 0.075mm sieve to be >2% for BSM-emulsion and >4% for BSM-foam.



The maximum recommended addition of cement (active filler) is 1% by mass.



Materials with a Plasticity Index > 10 to be pre-treated with hydrated lime to reduce the PI to 800 % by Mass Passing 100 90 - 100 50 – 80 40 – 70 25 – 60 10 – 40 0 - 15

m

et it

o

ov

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Sieve Size 25mm 20mm 14mm 10mm 5mm 2.36mm 0.300

99% Saturated olefinic and aromatic: PAHs.

C10 to C26 - may contain Polycyclic Aromatic Nydrocarbons -

CAS No. 068334-30-5. EINECS No. 269-822-7, R40. Additives 1. Middle distillate flow improvers (various) up to 1000ppm. (Dispersion of Ethylene vinyl acetate in an organic solvent). 2. Cetane improvers (AlkyI Nitrates) - up to 500ppm. CAS No. 27247-96-7, EINECS No. 269-822-7. 3. May contain dye and chemical marker - gas oil marker concentrate. CAS No. 68334-30-5. 4. Antistatic additive 1-3ppm 5. May contain a multifunctional detergent

January 2006

QCS 2014

Section 11: Health and Safety Page 49 Part 1.02: Occupational Health and Hygiene (Regulatory Document)

Sheet

AUTO DIESEL / DERV

2 of 8

Revision no.

10

Last revision

January 2006

This is an uncontrolled copy

3. Hazard identification Health hazards:

ta

rw

.l. l

.

This product contains amounts of Polycyclic Aromatic Hydrocarbons, some of which are known from experimental animal studies to be skin carcinogens. Prolonged and repeated exposure may therefore cause dermatitis and there is a risk of skin cancer. The risk of skin cancer will be very low, providing the handling precautions are such that prolonged and repeated skin contact is avoided and good personal hygiene is observed. Aspiration of liquid into the lungs directly or as a result of vomiting following ingestion of the liquid can cause severe lung damage and death.

qa

Safety hazards:

as

Product can accumulate static charges, which may be a possible ignition source (see Section 7). However product does contain an antistatic additive.

se

Environmental hazards:

et it

o

4. First aid measures

ov

er

Dangerous for the environment. Toxic to aquatic organisms. May cause long-term adverse effects in the environment.

m

Eyes:

Rinse immediately with plenty of water until irritation subsides. If irritation persists, obtain medical attention.

Skin:

Immediate flush with large amounts of water, using soap if available. Remove contaminated clothing, including shoes, after flushing has begun. If irritation persists, get medical attention.

Inhalation:

In emergency situations use proper respiratory protection to immediately remove the affected victim from exposure. Administer artificial respiration if breathing has stopped. Keep at rest. Call for prompt medical attention.

Ingestion:

DO NOT INDUCE VOMITING, since it is important that no amount of the material should enter the lungs (aspiration). Keep at rest. Get prompt medical attention.

Pressure injection:

ALWAYS OBTAIN IMMEDIATE MEDICAL ATTENTION EVEN THOUGH THE INJURY MAY APPEAR MINOR.

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Product name: AUTO DIESEL / DERV

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5. Fire-fighting measures

Foam, dry chemical powder, carbon dioxide.

Fire and explosion hazards:

Flammable liquid, moderate hazard. Liquid can release vapours that readily form flammable mixtures at or above the flash point.

Static discharge:

Material can accumulate static charges which may cause an incendiary electrical discharge. However, this product does contain an antistatic additive.

Special fire-fighting procedures:

Water fog or spray to cool fire exposed surfaces (e.g. containers) and to protect personnel, should only be used by personnel trained in firefighting.

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.

Extinguishing media:

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Cut off "fuel"; depending on circumstances, either allow the fire to burn out under controlled conditions or use foam or dry chemical powder to extinguish the fire. Respiratory and eye protection required for fire-fighting personnel exposed to fumes or smoke.

et it

o

Hazardous Smoke, sulphur oxides and carbon monoxide in the event ofincomplete combustion products: combustion.

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6. Accidental release measures

Personal precautions: See Section 8 Environmental precautions:

Land spill: Eliminate sources of ignition. Shut off source taking normal safety precautions. Prevent liquid from entering sewers, watercourses or low lying areas; advise the relevant authorities if it has, or if it contaminates soil/vegetation. Take measures to minimise the effects of groundwater. Water spill: Eliminate the spill immediately with booms. Warn shipping. Notify port and other relevant authorities.

Decontamination procedures:

Recover by skimming or pumping using explosion-proof equipment, or contain spilled liquid with booms, sand or other suitable absorbent and remove mechanically into containers. If necessary, dispose of absorbed residues as directed in Section 13.

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7. Handling and storage

.

Store product in cool, well ventilated surroundings, well away from sources of ignition. Provide suitable mechanical equipment for the safe handling of drums and heavy packages.

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.l. l

Electrical equipment and fittings must comply with local Regulations regarding fire prevention with this class of product. Load/unload temperature: Ambient to 40°C

Storage temperature:

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Special precautions:

Ambient to 40°C

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Use the correct grounding procedure. Store and handle in closed or properly vented containers. Ensure compliance with statutory requirements for storage and handling. Check for and prevent potential leaks from containers.

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8. Exposure controls / personal protection

Substance

ov

Workplace exposure limit:

STEL

Source / Other Information

5 mgm-3

10 mgm-3 HSE Guidance: not listed in EH 40

o

Mineral oil mist

8-hour TWA

Personal protection:

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In open systems where contact is likely, wear safety goggles (EN 166), chemical-resistant overalls and chemically impervious gloves (EN 374). Where only incidental contact is likely, wear safety glasses with side shields. No other special precautions are necessary provided skin/eye contact is avoided. Where concentrations in air may exceed the OES approved respirators may be required (EN 405).

Monitoring methods:

Health & Safety Executive (HSE), Methods for the determination of Hazardous Substances (MHDS); MDHS 84 www.hsl.gov.uk/search.htm

Product name: AUTO DIESEL / DERV

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9. Physical and chemical properties

Appearance:

Clear straw-coloured Odour: liquid

Density at 15°C:

0.82 g/ml

Pungent petroleum

Not applicable

Vapour pressure at 20°C: < 0.3 Kpa

Vapour density (air=1):

< air

Boiling point:

Pour point:

-24°C

Flash point (closed cup): > 55°C

Auto-ignition temperature:

250- 270°C

Flammability limit, in air, % by volume:

LEL: 0.5, UEL: 6.0 4.8

2 -1

3.0

Solubility:

.l. l

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Kinematic viscosity at 40°C, mm s

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2 -1

Kinematic viscosity at 20°C, mm s

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180 - 390°C

.

pH:

Negligible

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PLEASE NOTE THAT THESE PROPERTIES DO NOT CONSTITUTE A SPECIFICATION.

Stability:

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Conditions to avoid:

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10. Stability and reactivity

The product is stable and not subject to polymerisation. Avoid exposure to extreme heat. Avoid contact with strong oxidising agents such as liquid chlorine.

Hazardous decomposition products:

Product does not decompose at ambient temperature.

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Materials to avoid:

Product name: AUTO DIESEL / DERV

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11. Toxicological information The following toxicological assessment of health effects is based on a knowledge of the toxicity of the product's components. Slightly irritating but does not damage eye tissue.

On skin:

Low order of acute toxicity. Irritating. Prolonged or repeated contact may also lead to more serious skin disorders, including skin cancer. Certain components present in this material may be absorbed through the skin, possibly in toxic quantities.

By inhalation:

In high concentrations and/or at elevated temperatures, vapour or mist is irritating to mucous membranes, may cause headaches and dizziness, may be anaesthetic and may cause other central nervous system effects. Elevated temperatures or mechanical action may form vapours, mists or fumes, which may be irritating to the eyes, nose, throat and lungs. Avoid breathing vapours, mists or fumes.

By ingestion:

Low order of acute/systemic toxicity. Minute amounts aspirated into the lungs during ingestion or vomiting may cause severe pulmonary injury and death.

Chronic:

Contains Polycyclic Aromatic Hydrocarbons (PAHs). Prolonged and/or repeated skin contact with certain PAHs has been shown to cause skin cancer. Prolonged and/or repeated exposure by inhalation of certain PAHs may also cause cancer of the lung and of other sites of the body.

Acute:

Based upon animal test data from similar materials and products, the acute toxicity of this product is expected to be:

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.

On eyes:

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ORAL LD50 > 5000 mg/kg DERMAL LD50 > 2000 mg/kg

12. Ecological information

Mobility:

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Ecotoxicity:

et it

o

In the absence of specific environmental data for this product, this assessment is based on information developed with other crude oils. Gas oils released into the environment will float on water and spread on the surface; on release to soils, gas oils show some mobility and predominantly absorb. Dangerous for the environment. Toxic to invertebrates and slightly toxic to fish. Some mobility in soils.

Persistence and degradability:

Lighter components volatilise and in air undergo photolysis to give half-lives of less than a day. Photoxidation of liquid hydrocarbons on the water surface also contributes to the loss process. Slow to moderate degradation in water and soil.

Bioaccumulation potential:

Potential to bioaccumulate, but metabolic processes may reduce this tendency.

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13. Disposal considerations

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14. Transport information

Rails cars, tank trucks, tankers, barges, drum.

Shipping name:

Diesel Fuel

Packaging group:

III

Marine pollutant:

See Section 6

ICAO/IATA:

Class 3

ta

Classification for transport:

1202

UN Class:

3

ADR/RID:

Class 3

Emergency action code:

3Y

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as

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UN Number:

ov

15. Regulatory information Hazard label data:

o R40

N Dangerous for the Environment

Limited evidence of carcinogenic effect

et it

R & S phrases:

Xn Harmful

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R51/53 Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment

EC Directives: Statutory information:

S2

Keep out of reach of children

S36/37

Wear suitable protective clothing and gloves

S61

Avoid releases into the environment, see Section 6

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Product name: AUTO DIESEL / DERV

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16. Other information

.l. l

.

The data and advice given apply when the product is sold for the stated application or applications. The product is not sold as suitable for any other application. Use of the product for applications other than as stated in this sheet may give rise to risks not mentioned in this sheet. You should not use the product other than for the stated application or applications.

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If you have purchased the product for supply to a third party for use at work, it is your duty to take all necessary steps to ensure that any person handling or using the product is provided with the information in this sheet.

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et it

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If you are an Contractor, it is your duty to tell your employees and others who may be affected about any hazards described in this sheet and about any precautions that should be taken.

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Construction Site Safety 1.2.3 Appendix 3 COSHH assessment - diesel fuel Auto diesel

Substance hazard classification:

Flammable, harmful/irritant

Trade name(s):

Any auto fuel production company

Substance used for:

Motive power for plant and other diesel powered vehicles

Safety precautions

Emergency procedures Remove to fresh air. Seek medical attention if conditions severe.

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Inhalation: can lead to nausea Avoid inhaling vapour or mist; and headaches. ensure good ventilation. Remove the victim from exposure.

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Potential hazards

.l. l

.

Name of hazardous substance:

Avoid prolonged/repeated contact. Wear PVC gloves. Do not use as a cleaning agent.

Eye contact: will cause irritation.

Wear eye protection if splashing Rinse immediately with plenty of can occur. water until irritation subsides. Seek medical advice.

Remove contaminated clothing. Wash skin thoroughly with soap and warm water.

Do not eat, drink or smoke during use.

Do not induce vomiting. Wash mouth with water. Seek immediate medical attention.

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o

Ingestion: will irritate mouth, throat etc.

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Skin contact: can be irritating and have a defatting effect.

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Fire: products of combustion Do not smoke during use. Avoid Clear the area. Do not inhale are toxic. Vapour/air mixture is heat sources and open flames. vapours, smoke etc. explosive. Spillage: fumes/vapour likely to Do not allow to enter drains. collect in low areas. Eliminate ignition sources. Ensure good ventilation.

Contain with sand or granules. Remove into a container. Dispose of as hazardous waste.

Additional information: Environmentally damaging. Assessment date

Approved for use by (print name and position) Signature

Next date

review

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Construction Site Safety 1.2.4

First Aid at Work

1.2.4.1 Key points Trained first-aid staff and first-aid equipment must be available on site.

2

The level of provision of trained staff and first-aid equipment will depend upon several factors.

3

Everyone working on site should know where the first aiders and the first-aid kits can be found.

4

All accidents causing injury must be recorded in an accident book.

5

In an emergency, assess the situation but do not put yourself in danger.

6

Don't move casualties who are obviously injured unless it is necessary to do so - summon the first aider immediately and contact external emergency services.

7

Cover severe bleeding with a clean pad and apply direct pressure.

8

First Aiders have the potential to save lives.

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1

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The following four factors will influence decisions: workplace hazards and risks

(b)

the nature of the undertaking and its history of accidents

(c)

the size of the establishment and distribution of employees

(d)

the location of the establishment and the locations to which employees go in the course of their work.

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(a)

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2

These Regulations provide a flexible framework within which Contractors can develop effective first-aid arrangements appropriate to their workplace and the size of their workforce.

DANGER

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1

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1.2.4.2 Introduction

Your own safety is your first priority RESPONSE Does the casualty respond to voice/touch? AIRWAY Does the casualty have a clear airway? BREATHING Is the casualty breathing? If you are not there are brief notes to be taken in an emergency.

a in

PROMPT ACTION SAVES LIVES!

trained Appendix

3

first on

aider, actions

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Section 11: Health and Safety Page 58 Part 1.02: Occupational Health and Hygiene (Regulatory Document)

1.2.4.3 Definition of first aid 1

First aid is defined as the follows: (a)

in cases where a person will need help from a doctor or a nurse: treatment for the purpose of preserving life and minimising the consequences of injury or illness until such help is obtained.

(b)

treatment of minor injuries which would otherwise receive no treatment or which do not need treatment by a doctor or nurse.

It should be noted that the definition covers any illness at work and not just accidents. You must, therefore, plan for times when someone has a heart attack or just collapses.

3

Emergency fist aiders can give a restricted range of first aid treatment to someone who is injured or becomes ill at work. Fully trained first aiders can do the above, plus apply first aid to a range of specific injuries and illnesses.

4

Contractors are required to:

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2

provide adequate first-aid equipment and facilities appropriate to the type of work or operations undertaken

(b)

appoint a sufficient number of suitable and trained people to render first aid to employees who are injured or become ill at work

(c)

appoint a sufficient number of suitable people who, in the temporary absence of the first aider, will be capable of dealing with an injured or ill employee needing help from a medical practitioner or nurse, and who are able to take charge of first-aid equipment and facilities

(d)

inform employees of the first-aid arrangements, including the location of equipment and personnel. This will require that notices be posted and signs displayed. Provision should be made for employees with language or reading difficulties.

Shared facilities

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(a)

To avoid the unnecessary duplication of facilities where employees of more than one Contractor are working together, arrangements may be made to share facilities. Whilst there is no requirement for shared facilities to be formally recorded, industry best practice is that the arrangements are recorded in writing, with each Contractor retaining a copy.

6

In such circumstances, it is the responsibility of each Contractor to ensure that the agreed facilities are actually provided, and that all their employees are aware of these arrangements.

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5

Trained and suitable personnel 7

First aiders must have received training and hold a current first-aid certificate issued by a recognised training organisation.

8

Where first aiders have received first-aid instruction relating to special or unusual hazards in the workplace, they should undergo refresher training and re-examination as necessary. The Contractor must keep a written record of such training. Number of first aiders required

9

For construction, which the table categorises as 'higher risk', the recommendation is as follows.

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Number of employees

Number of first aid trained staff

10

Less than 5: At least one appointed person

11

5-100: At least one first aider or emergency first aider per 50 employees or part thereof

12

More than 100: At least one first aider per 50 employees or part thereof

13

In determining the total number of qualified first aiders required, additional factors should be considered. These are: the type of work or operations being carried out

(b)

whether or not employees work alone or in scattered and isolated locations

(c)

whether there are special or unusual hazards

(d)

whether or not there is shift work -first-aid cover will be required at all times that work is being carried out

(e)

the maximum number of people likely to be on site at any one time

(f)

the remoteness of emergency medical services

(g)

cover for first-aiders' holidays and sickness absence - first-aid cover will be required at all times that work is being carried out

(h)

the presence of work-placement trainees.

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(a)

On sites where special or unusual hazards are present, a proportionately larger number of first aiders, having regard to the factors already mentioned, will be needed. Good practice should encourage all the contractor's site personnel to be trained in basic emergency aid.

15

On major construction projects where there is a site nurse, and/or a doctor on call, their advice in connection with first aid should be followed.

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1.2.4.4 Appointed persons

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14

An appointed person is someone who has been nominated by the Contractor to take charge of a situation, e.g. to call an ambulance if there is a serious illness or injury.

2

They will act in the absence of the trained first aider or in situations where it is deemed that a first aider is not required, such as in a small non-hazardous working area, and where there is easy access to professional medical assistance, such as a hospital accident and emergency department.

3

Emergency first-aid training should be considered for all appointed persons.

4

Appointed persons must not be regarded as an alternative to qualified first aiders and they must not be required to render first aid. The appointed person is responsible for first-aid equipment in the absence of the first aider or in the circumstances described above.

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1.2.4.5 Equipment and facilities Location of first-aid facilities 1

It is essential that all employees should have quick and easy access to first-aid facilities on site. Where employees are working in large numbers and in close proximity, facilities should be centralised in that area. When employees are spread over a wider area, it is necessary to distribute first aiders and equipment accordingly. Sometimes, a combination of these arrangements may be appropriate.

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Section 11: Health and Safety Page 60 Part 1.02: Occupational Health and Hygiene (Regulatory Document)

All employees must be aware of the location of first-aid facilities and the arrangements for providing treatment. The location of first-aid facilities should be clearly marked with the appropriate symbol:

.

White symbol and letters on a green background

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First-aid boxes

Every Contractor must provide one or more first-aid boxes. They should be strategically placed, readily accessible and clearly marked with a white cross on a green background. The container should hold first-aid equipment and nothing else, and should protect the contents from dust and damp.

4

It is essential that the contents of first-aid boxes are replenished after use and checked frequently by the first aider or appointed person. Some of the items are prone to deterioration after a certain period. The minimum recommended contents of the first-aid box are listed in Appendix 1, which should be adjusted following an assessment of the first aid needs of a specific site.

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3

who are working alone or in small groups in isolated locations, e.g. maintenance gangs

(b)

whose work involves travel in remote areas

(c)

who use potentially dangerous tools or machinery.

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(a)

The first-aid kit should only contain the items as recommended in Appendix 1.

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6

Special or small travelling first-aid kits should be provided to those employees:

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Travelling first-aid kits

Supplementary equipment 7

Where first aiders are employed, stretchers or appropriate carrying equipment, such as a carrying chair or wheelchair, should be provided in an accessible location clearly identified by a sign. If a site covers a large area, or contains a number of distinct working areas, it will be necessary to provide such equipment at a number of suitable locations.

8

However, it is recommended that, in most incidents, casualties are moved as little as possible before the emergency services arrive.

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First-aid rooms On a large building or construction site, a first-aid room, suitably staffed and equipped, should be provided. The need for such a room cannot be decided purely on the numbers of persons employed, but should be assessed on the type of work being carried out and whether hospital A&E or other emergency facilities are close to hand.

10

The first-aid room will normally be under the control of the first aider who should be nearby or on call, with access to the room when employees are at work. The name of this person should be displayed, together with the names and locations of all other first alders and appointed persons. On some larger sites, the first-aid room will be staffed by a qualified nurse.

11

The room should be clearly identified, available at all times and used only for rendering first aid. It should be of sufficient size to contain a couch with adequate space around it to allow people to work, and provided with an access door to allow the passage of a stretcher or other carrying equipment. Pillows and blankets should be provided and be frequently cleaned.

12

The room itself should be cleaned each working day, have smooth-topped impermeable working surfaces and provision for privacy and refuse disposal.

13

Heating, lighting and ventilation should be effective. In addition to the first-aid materials (see Appendix 1) which should be stored in a suitable cabinet, there should be:

(b)

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9

(c)

soap, nail brush and paper towels

(d)

clean garments for use by first-aid personnel

(e)

a suitable container for disposal of clinical waste (yellow bags).

a sink with running hot and cold water drinking water

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(a)

14

In first-aid rooms that are supervised by the site nurse, other items may be provided on their advice.

15

The room should have a telephone, where possible, and a siren or klaxon to alert personnel on call.

16

A sufficient number of first aiders should be provided in any work area that is not within easy reach (approximately three minutes) of the first-aid room.

1.2.4.6 Training and qualifications 1

The Contractor is responsible for ensuring that those people who have been selected as fully

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qualified first aiders have undergone training and possess adequate qualifications. Additional training may be necessary to cope with any special hazards in a particular working environment. 2

Instruction in emergency first aid, such as resuscitation, control of bleeding and treatment of unconsciousness, is desirable for all staff. Initial selection of first aiders

3

Whilst it is desirable to appoint staff who have already received first-aid training and utilise their skills, in many instances this may not be an option. On most new sites it is unlikely that a trained first aider will be available, and it will be necessary to arrange training for a suitable member of staff.

.l. l

.

In selecting people for this role, the following factors should be considered: friendly, reassuring disposition

5

acceptable to male and female staff

6

able to cope with stressful and physically demanding emergency procedures

7

able to remain calm in an emergency

8

employed on a task which they can leave immediately in order to go to the scene of an emergency

9

capable of acquiring the knowledge and qualifications required.

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The First Aid training course, including examination will: (a)

normally take three full days (18 'classroom' hours), however

(b)

it need not be completed in a period of three consecutive days - 'split courses' will be permitted.

On completion of the course, each student must be able to demonstrate that they are able to:

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Training of fully qualified first aiders

12

(a)

recognise minor and major illnesses

(b)

act safely, promptly and effectively with emergencies at work

(c)

use first-aid equipment, including the contents of the first-aid container

(d)

understand the duties of Contractors and the legal framework

(e)

maintain simple factual records on the treatment or management of emergencies

(f)

recognise the importance of personal hygiene in first-aid procedures.

Students must also be able to deal with a casualty who: (a)

requires cardiopulmonary resuscitation

(b)

is bleeding or wounded

(c)

is suffering from shock

(d)

is unconscious

(e)

is suffering from an injury to bones, muscles or joints

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Section 11: Health and Safety Page 63 Part 1.02: Occupational Health and Hygiene (Regulatory Document)

(f)

has an eye injury

(g)

has been overcome by gas or fumes

(h)

has been burned or scalded

(i)

has been poisoned or exposed to a harmful substance.

13

Students must also be able to manage the transportation of the casualty as required by workplace circumstances.

14

It may be necessary to provide specialised instruction in the use of protective equipment or rescue techniques, where these are important in the trainee's workplace or if special hazards exist there.

.

Expiry of certificates First-aid certificates should be valid for three years. Re-qualification training, with reexamination, will be required before re-certification.

16

First aiders can undertake re-qualification training up to 3 months before the expiry of their current first-aid certificate. The certificate will be dated to 'run on' from the expiry date of the previous one. Ideally, Contractors will take advantage of this period.

17

However, where this is not possible or practical, re-qualification training can be taken within 28 days after the previous certificate expires.

18

Where within the 28 day period, the student:

as

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15

passes the re-qualification training, a certificate will be issued, backdated to the expiry of the previous one

(b)

fails to pass the re-qualification training, the full First Aid at Work course must be taken again, and passed, for a certificate to be issued.

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se

(a)

In effect, these arrangements provide Contractors with a four month window in which to get each first aider re-certificated.

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19

(a) (b)

can be 'split' over a longer period, but

(c)

must be completed within a period of six weeks.

Re-qualification training for fully qualified first aiders including re-examination: must last at least 12 hours (two days)

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Re-qualification training

Refresher training 21

Contractors are strongly recommended that fully qualified first aiders attend a three-hour refresher course each year to brush up on their basic skills and learn about new techniques and developments. Training of first aiders for special or unusual situations

22

First aiders should have completed training in the subjects described for first aiders, and been given any specialised training related to the particular requirements of their workplace and its hazards.

23

Some workers carry their own medication, such as inhalers for asthma or 'Epipens' which contain injectable adrenaline for the treatment of severe allergic (anaphylactic) reactions, for

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example to peanuts. These medications are prescribed by a doctor. If an individual needs to take their own prescribed medication, the first aider's role is limited to helping them do so and contacting the emergency services as appropriate. Training of emergency first aiders 24

Emergency first aiders must undertake a six-hour course, with their certificate being valid for three years. Similar to fully qualified first aiders, the Contractor is recommended that emergency first aiders undertake an annual three-hour basic skills update and refresher course.

25

To requalify and retain their certification for a further three years, emergency first aiders must retake the six-hour course within their three-year qualification period.

what to do in an emergency

(b)

cardio-pulmonary resuscitation

(c)

first aid for the wounded or bleeding

(d)

first aid for an unconscious casualty.

as

Training records

Contractors must keep written records of all training that has been given to employees and the results of that training.

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27

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1.2.4.7 Miscellaneous

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Ambulance

The local ambulance service should be informed about large sites and of any particularly hazardous operations being undertaken. It is helpful to supply a map locating the site and its entrances and, where appropriate, the first-aid room.

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1

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(a)

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Training courses cover the following subjects:

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26

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Training of appointed persons

2

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Induction

Induction training for employees and other persons joining the site should include details of the location of first-aid boxes, qualified first-aid personnel and actions to be taken in cases of injury or illness. Record of treatment

3

First-aid treatment should be recorded. The use of an accident book does not normally allow enough detail to be gathered and an additional treatment book may be necessary, particularly in order to keep a record of the use of first-aid materials.

1.2.4.8 Accident reporting 1

All accidents causing any injury must be recorded and, where necessary, reported to the Administrative Authority.

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Construction Site Safety 1.2.4 Appendix 1 Recommended contents of first-aid boxes First-aid boxes

Travelling first-aid kits

Guidance card*

1

1

Individually wrapped sterile adhesive dressings (assorted sizes)

20

6

Sterile eye pads, with attachment

2

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Individually wrapped triangular bandages

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Safety pins

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Medium-sized, individually wrapped, sterile, unmedicated wound dressings (approx. 12 cm x 12 cm)

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Large, sterile, individually wrapped, unmedicated wound dressings (approx. 18 cm x 18 cm)

Nil

4

2

6

2

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Nil

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Nil

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Individually wrapped, moist cleaning wipes (suggested minimum number) Disposable gloves (pair)

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Where tap water is not readily available for eye irrigation, sterile water or sterile normal saline (0.9%) in sealed disposable containers should be provided.

Travelling first-aid kits Small travelling first-aid kits are designed for use where the workforce is dispersed widely (possibly with hazardous tools), for employees working away from their Contractor's establishment.

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Construction Site Safety 1.2.4 Appendix 2 Health and Safety (First Aid) Checklist First-aid provision How many employees are involved?

2

How is the workforce distributed/grouped? (Widely dispersed, etc.?)

3

Are remote locations involved?

4

Are shirts worked?

5

What is the nature of the work?

6

Does it involve special operations?

7

Can particular hazards be identified, such as falls, electric shock, dangerous substances?

8

How many first aiders are needed -consider holiday and sickness cover? Training

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Which personnel require first-aid training?

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Does the training offered meet foreseeable needs?

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Is there a system to trigger a warning to management when a first aider is within three months of their certificate expiring?

12

Are training records kept?

13

Are individuals working in isolated locations trained to cope with emergencies?

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Where appointed persons are in charge, do they understand their duties?

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Does induction training cover first-aid arrangements?

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Equipment

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Is first-aid equipment placed in locations where it is likely to be needed?

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Does it meet foreseeable needs, special hazards, etc.?

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Are travelling first-aid kits available when required?

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Is a first-aid room needed, or available, and suitably equipped?

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Are information signs provided?

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Are first-aid boxes and kits properly stocked and maintained?

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General 22

Has responsibility for first-aid provision and organisation been assigned to an individual?

23

Are there established procedures for reviewing: (a)

training and equipment needs?

(b)

new work processes?

(c)

special operations?

(d)

changes in work patterns, site locations, size of labour force?

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Construction Site Safety 1.2.4 Appendix 3 Health and Safety (First Aid) Basic advice on first aid at work What to do in an emergency

Assess the situation - do not put yourself in danger.

2

Make the area safe.

3

Assess all casualties and attend first to any unconscious casualties.

4

Send for help - do not delay.

5

Follow the advice given below.

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Priorities

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Check for consciousness

If there is no response to gentle shaking of the shoulders and shouting, the casualty may be unconscious. Your priorities are to:

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shout for help

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open the airway

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check for normal breathing

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take appropriate action.

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The priority is to check the Airway, Breathing and Circulation. This is the ABC of resuscitation.

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A - Airway

To open the airway: (a)

Place one hand on the casualty's forehead and gently tilt the head back. Remove any obvious obstruction from the casualty's mouth.

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(c)

Lift chin with two fingertips.

B - Breathing 13

Look along the chest, listen and feel at the mouth for signs of normal breathing, for no more than 10 seconds. If the casualty is breathing:

14

Place in the recovery position and ensure the airway remains open.

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Send for help.

16

Monitor that the casualty continues to breathe until help arrives. If the casualty is not breathing:

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Send for help.

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Start chest compressions (see CPR below).

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C-CPR To start chest compressions: Lean over the casualty and, with your arms straight, press down on the centre of the breastbone, 4-5 cm, and then release.

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Repeat at a rate of about 100 times a minute (more than one compression per second!)

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After 30 compressions, open the airway again.

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Pinch the casualty's nose closed and allow the mouth to open.

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Take a normal breath and place your mouth around the casualty's mouth, making a good seal.

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Blow steadily into the mouth while watching for the chest rising.

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Remove your mouth from the casualty and watch for the chest falling.

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Give a second breath and then start 30 compressions again without delay.

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Continue with chest compressions and rescue breaths in a ratio of 30:2 until qualified help takes over or the casualty starts to breathe normally.

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Severe bleeding Apply direct pressure to the wound.

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Raise and support the injured part (unless broken).

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Apply a dressing and bandage firmly in place.

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If a broken bone or spinal injury is suspected, obtain expert help. Do not move casualties unless they are in immediate danger.

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Broken bones and spinal injuries

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Burns

Burns can be serious so, if in doubt, seek medical help. Cool the part of the body affected with cold water until pain is relieved. Thorough cooling may take 10 minutes or more, but this must not delay taking the casualty to hospital.

33

Certain chemicals may seriously irritate or damage the skin. Avoid contaminating yourself with the chemical. Treat in the same way as for other bums but flood the affected area with water for 20 minutes. Continue treatment even on the way to hospital, if necessary. Remove any contaminated clothing which is not stuck to the skin.

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Burning clothing 34

To extinguish the burning clothing of anyone involved in a fire, lay, push or knock the person to the floor to reduce the spread of flames. Cover the burning area with a blanket, coat or other items to smother the flames but do not use synthetic materials (for example, polyester). DO NOT REMOVE ANY OF THE VICTIM'S CLOTHES.

35

Apply large amounts of water to the area of the burns as quickly as possible to cool the affected parts, and then keep them wet with more water. Seek medical help urgently. Eye injuries

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All eye injuries are potentially serious. If there is something in the eye, wash out the eye with clean water or sterile fluid from a sealed container, to remove loose material. Do not attempt to remove anything that is embedded in the eye.

37

If chemicals are involved, flush the eye with water or sterile fluid for at least 10 minutes,

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whilst gently holding the eyelids open. Ask the casualty to hold a pad over the injured eye and send them to hospital. Record keeping It is good practice to record in a book any incidents involving injuries or illness that have been attended, including the following information in your entry:

39

Date, time and place of incident.

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Name and job of injured or ill person.

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Details of injury/illness and any first aid given.

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What happened to the casualty immediately afterwards (for example, went back to work, went home, went to hospital).

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Name and signature of the person dealing with the incident.

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This information can help identify accident trends and possible areas for improvement in the control of health and safety risks.

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Construction Site Safety 1.2.5

Food Safety on Site

1.2.5.1 Key points 1

Getting food hygiene wrong can have severe implications for many other people.

2

Anyone who handles food for consumption by others: must have training in basic food handling techniques;

(b)

must report to their supervisor details of any illness that they may be suffering from;

(c)

may have to be suspended from work if they contract an infectious illness.

Premises in which food is handled, prepared and served must conform to certain standards of construction and cleanliness.

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1.2.5.2 Introduction

Food poisoning is caused by bacteria (germs or bugs) which have lain dormant in most uncooked or unprepared foods, whether meat, fish, poultry and some vegetables.

2

Food poisoning keeps people off work through sickness, just as accidents do.

3

Applying appropriate hygiene standards on site are essential because of the potential for:

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time lost through sickness absence being reduced

(b)

avoiding lost production

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1.2.5.3 Definitions

Food - food or drink of any description, or any of the ingredients used in the preparation of food.

2

Food area - any room or food area in which a person engages in the handling of food, including a server, counter or outside grill preparation area.

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The premises

The siting, design and construction of the premises must aim to avoid the contamination of food and harbouring of pests. It must be kept clean and in good repair so as to avoid food contamination.

4

Surfaces in contact with food must be easy to clean and, where necessary, disinfect. This will require the use of smooth, washable, non-toxic materials.

5

Adequate provision must be made for cleaning foodstuffs, and the cleaning and (where necessary) disinfection of utensils and equipment. You must take all reasonable, practical steps to avoid the risk of contamination of food or ingredients.

6

Washbasins must be designated for washing hands, have hot and cold (or appropriately mixed) running water, and be equipped with soap and suitable hand-drying facilities, such as disposable towels. Lavatories must not lead directly into food rooms and they must be kept clean, maintained in good repair and ventilated.

7

Adequate arrangements and facilities for the hygienic storage and disposal of hazardous and inedible substances and waste (whether liquid or solid) must be available. Food waste must not be allowed to accumulate in food rooms and should be deposited in closable containers.

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Adequate facilities and arrangements for maintaining and monitoring suitable food temperature conditions must be available. (See also below.) The food

9

Stored raw materials and ingredients must be kept in appropriate conditions which will prevent harmful deterioration and be protected from contamination likely to make them unfit for human consumption. Water

10

There must be an adequate supply of potable (clean, drinkable) water which must be used whenever necessary to ensure foodstuffs are not contaminated. This includes the use of ice which must also be made, handled and stored in a way that protects it from contamination.

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Foods intended for supply which need temperature control for safety must be held either HOT at or above a minimum temperature of 63°C or CHILLED at or below a maximum temperature of 8°C.

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Temperature control

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Food handlers

Anyone who works in a food handling area must maintain a high degree of personal cleanliness. The way in which they work must also be clean and hygienic. Food handlers must wear clean and, where appropriate, protective over-clothes. Adequate changing facilities must be provided where necessary.

13

Food handlers must protect food and ingredients against contamination, which is likely to render them unfit for human consumption or create a health hazard. For example, uncooked poultry should not contaminate ready-to-eat foods, either through direct contact or via work surfaces or equipment.

14

Anyone whose work involves handling food should:

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observe good personal hygiene

(b)

routinely wash their hands before handling foods never smoke in food handling areas report any illness (like infected wounds, skin infections, diarrhoea or vomiting) to their manager or supervisor immediately.

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If any employee reports that they are suffering from any condition or illness, Contractors may have to exclude them from food handling areas. Such action should be taken urgently.

16

Food handlers must receive adequate supervision, instruction and training in food hygiene. Microwave ovens

17

On sites where microwave ovens are used, the following points must be noted. (a)

Metal containers or utensils must not be placed in a microwave oven.

(b)

Door seals of microwave ovens should be periodically examined to see that they are not damaged.

(c)

Microwave ovens should not be overloaded by trying to cook too many things at the same time.

(d)

Frozen food should be properly thawed.

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(e)

Food should be thoroughly cooked. Follow instructions on the packaging and leave to stand.

(f)

Do not attempt to add anything to or stir any liquid which has just been removed from a microwave oven and has not been allowed to stand, by using a metal spoon or utensil. Such an action may cause the liquid to boil violently.

(g)

Always adhere to the supplier's or manufacturer's instructions.

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Construction Site Safety 1.2.6

Working with Lead

1.2.6.1 Key points 1

Lead can be a major health hazard if exposure is not prevented or adequately controlled.

2

Lead is a cumulative poison that can find its way into the bloodstream and collect in tissues, particularly the bone marrow.

3

The ways that lead is likely to get into the body are through: (a)

the inhalation of fumes or dust;

(b)

the ingestion of lead particles through hand to mouth contact.

All work with lead, or lead-containing products, must be the subject of a risk assessment.

5

Builders, carpenters, decorators etc., who remove old paint, particularly if involved in window renovation, may be exposed to 'significant' quantities of lead without realising it.

6

Where the risk assessment indicates that employees' exposure to lead is likely to be 'significant', certain monitoring actions must be taken with regard to the employees affected and the workplace itself.

7

'Significant exposure' is defined in these Regulations.

8

During health surveillance, employees' exposure to lead is measured by the concentration of lead in their blood or urine.

9

Above a certain level of exposure, Contractors have a legal duty to temporarily suspend the affected worker(s) from further work with lead.

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Exposure to lead, dust, fumes and vapour constitutes a major hazard in the construction industry who work with lead and lead products. Construction workers most at risk include: plumbers working on lead flashing, upstands and gutters

(b)

operatives handling old architectural lead work

(c)

painters rubbing down or burning off old paintwork demolition operatives

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1.2.6.2 Introduction

(e)

anyone involved in structural renovation or refurbishment, including conservation or heritage projects.

1.2.6.3 The Management of Health and Safety at Work 1

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2

Once those hazards have been identified, it is then the Contractor's duty to put control measures into place in order either to eliminate the hazard or, where this is not possible, to reduce the risks of injury or ill health arising from the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks in the workplace and on any control measures in place to reduce those risks.

4

Employees, in turn, have a duty to tell their Contractor of any work situation which presents a

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risk to themselves or to others, or of any matter which affects the health and safety of themselves or other persons. The main consideration will be identifying where lead is present and taking the appropriate actions to protect the health of lead workers and, if necessary, other people who may be affected by the work.

1.2.6.4 Control of Lead at Work These Regulations aim to give greater health protection to people at work by reducing their exposure to lead and thus the concentrations of lead in their blood. Where concentrations are too high, Contractors are required to remove employees from work with lead. This is known as the 'suspension level'.

2

Concentration levels of lead in blood, which are below the suspension level and known as 'action levels', have been set.

3

If these lower levels are breached, Contractors have a duty to investigate and remedy the cause. Contractors are also required to take steps to reduce the concentrations of lead in air to a level not exceeding the occupational exposure limits stated in these Regulations.

4

The main requirements of these Regulations include:

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A Contractor who is working with lead, or a substance or material containing lead, has to protect from exposure anyone who may be affected by the work as well as their own employees. This includes: the workers of other Contractors including those not engaged in work with lead, such as maintenance staff and cleaners

(b)

visitors to the work site

(c)

the families of those who are exposed to lead at work who may become affected by lead carried home unintentionally on the clothing and footwear of the employee are particularly at risk of lead poisoning, and therefore have lower blood-lead action and suspension levels than other people.

(d)

the occupiers of premises, including private dwellings, irrespective of whether the occupiers are present whilst the work is carried out or they reoccupy the premises later.

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Duties under these Regulations

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Assessment of the risks to health Every Contractor is required to make a suitable and sufficient assessment of the risk to the health and safety of employees while at work. This includes other people who are not employees but who may be exposed as a result of the way the Contractor carries out the work concerned. The assessment must be reviewed as often as is necessary and in other certain specified circumstances, and a record made of any significant findings. Such an assessment is to allow the Contractor to make a decision whether the work concerned is likely to result in an employee being significantly exposed to lead, and to identify the measures needed to prevent or adequately control exposure. Control of exposure 7

Every Contractor must ensure that the exposure of employees to lead is either prevented or, where this is not reasonably practicable, adequately controlled by means of appropriate control measures.

8

As the preferred control measure, the Contractor must consider the use of alternative materials or processes as a means of eliminating or reducing the risks to the health of

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employees.

(a)

the design and use of the work process, systems and engineering controls

(b)

control of exposure at source, including ventilation systems, and

(c)

where adequate control cannot be achieved by other means, the provision and use of suitable PPE.

The control measure(s) must include: the safe handling, storage and transportation of lead and waste which contains lead

(b)

suitable maintenance procedures

(c)

reducing to the minimum required for the task in hand, the number of employees exposed, the level and duration of exposure and the quantity of lead present in the workplace

(d)

control of the working environment, including, where appropriate, general ventilation

(e)

appropriate hygiene measures, including washing facilities.

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Where it is not reasonably practicable to prevent exposure to lead, the Contractor must introduce protective measures which are appropriate to the work activity and consistent with the findings of the risk assessment. In order of priority, these must be:

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Irrespective of these control measures, where the exposure to lead is, or is likely to be significant, the Contractor must provide suitable and sufficient protective clothing.

12

Where the inhalation of lead fumes is possible, the control measures will only be regarded as adequate if:

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the occupational exposure limit is not exceeded

(b)

or if it is, the Contractor identifies the reason and takes immediate steps to rectify the situation.

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(a)

Contractors must take reasonable steps to ensure that any control measure provided is properly used or applied.

14

Employees must make full and proper use of any control measure provided, and: take all reasonable steps, where appropriate, to return anything provided as a control measure to its accommodation (storage) after use

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(i)

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report any defect in any control measure provided to the Contractor.

Adequate control of exposure to lead covers all routes of possible exposure, such as inhalation, Absorption through the skin and ingestion. Eating, drinking and smoking

16

Adequate steps must be taken to control the ingestion of lead. A Contractor must ensure that, as far as is reasonably practicable, employees do not eat, drink or smoke in any place which is, or is liable to become, contaminated by lead. In practical terms, employees must be warned against doing so. Furthermore, under these Regulations employees have a legal duty not to eat, drink or smoke in any place that they have reason to believe is contaminated by lead. Maintenance, examination and testing of control measures

17

All control measures provided, including PPE, must be well maintained, kept in a good state of repair and cleaned as necessary. Any defect in the equipment, or failure to use and apply

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it properly, which could result in a loss of efficiency or effectiveness, thus reducing the level of protection, should be identified and rectified as soon as possible. Air monitoring 18

Where employees are liable to receive significant exposure to lead, Contractors must establish a programme of air monitoring including keeping records of the findings of such monitoring. Medical surveillance Where exposure to lead is significant, the Contractor must: (a)

make sure that employees are under medical surveillance by a 'relevant doctor'

(b)

provide suitable facilities for health surveillance to be carried out where the procedures are to be carried out at the Contractor's premises

(c)

maintain health surveillance records and retain them for 40 years

(d)

allow employees reasonable access to their personal health records

(e)

take steps to determine the reasons why any employee's blood sample exceeds the appropriate action level and take appropriate remedial action

(f)

take the necessary actions, including reviewing the risk assessment, where an employee's blood or urine sample reaches the 'suspension level'.

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Employees for whom health surveillance has been arranged must, when required by the Contractor (and at the cost of the Contractor), make themselves available for the necessary health surveillance procedures and supply the relevant doctor with such health-related information as the doctor may require.

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Contractors who undertake work liable to expose employees to lead shall provide such information, instruction and training as is suitable and sufficient to know the risks to health, and the precautions which should be taken.

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Information, instruction and training

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The Contractor, in attempting to protect the health of employees from an accident, incident or emergency, must ensure that procedures, including the provision of first aid facilities and safety drills, have been prepared and can be put into effect should such an occasion arise. The Contractor must also ensure that information on such emergency arrangements has been notified to accident and emergency services and that all such information is displayed within the workplace.

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Arrangements for accidents, incidents and emergencies

1.2.6.5 Training 1

There is a specific requirement to ensure that the information, instruction and training provided for persons working with lead includes: (a)

the type of lead being worked, the potential health hazards and symptoms

(b)

the relevant occupational exposure limit, action level and suspension level (as explained)

(c)

any other sources of information

(d)

the significant findings of the risk assessment

(e)

the control measures that are in place and which must be used to enable work to be

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(f)

the results of any monitoring carried out

(g)

the results of previous health surveillance, in such a way that the confidentiality of individual cases is not breached.

1.2.6.6 Personal Protective Equipment These Regulations require that where a risk of exposure to lead has been identified by a risk assessment and it cannot be adequately controlled by other means which are equally or more effective, the Contractor must provide personal protective equipment (PPE) and ensure it is properly used by employees.

2

Users of PPE must be trained in its use and care as appropriate.

3

In essence, PPE may only be used as a last resort after all other means of eliminating or controlling the risk have been considered and are not reasonably practicable.

In the context of this section the important requirements of these Regulations are for provision of adequate welfare facilities, particularly in respect of personal hygiene. Contractors must provide or make available:

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1.2.6.7 Construction (Design and Management) CDM

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suitable and sufficient washing facilities, including showers if necessary due to the nature of the work

(b)

hot and cold (or warm) water, soap or other cleanser and towels or other effective means of drying

(c)

suitable and sufficient changing rooms

(d)

lockers or other facilities in which to secure work clothing that is not taken home and personal clothing that is not worn at work

(e)

suitable rest facilities where meals may be prepared and eaten.

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1.2.6.8 Provision and Use of Work Equipment These Regulations require that a Contractor only supplies work equipment that is correct and suitable for the job for which the equipment is going to be used.

2

These Regulations also require that users of work equipment are trained in its use, as appropriate.

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1.2.6.9 Control of exposure to lead in the workplace The hazard 1

Lead is a cumulative poison that will find its way into the bloodstream and can collect in tissues, particularly the bone marrow. Lead poisoning may occur through exposure to lead in its pure form or exposure to products containing lead.

2

Lead affects the body's ability to produce haemoglobin, which is the protein in blood that carries oxygen to the tissues.

3

Inorganic lead, the type likely to be encountered during construction activities, can enter the body in one of two ways: (a)

by inhalation of dust or fumes

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Section 11: Health and Safety Page 78 Part 1.02: Occupational Health and Hygiene (Regulatory Document) via the digestive tract from hand-to-mouth transfer of lead particles.

4

Inhalation is by far the most common route of entry.

5

Whilst the control of exposure through inhalation will be largely controlled by actions taken by the Contractor, the control of exposure through ingestion depends upon the good personal hygiene practices of employees working with lead. Risk assessment

6

Contractors must not carry out any work that may expose employees to lead unless a suitable and sufficient risk assessment has been carried out.

7

The purpose of the risk assessment is to enable the Contractor to: assess whether the exposure of employees to lead is likely to be significant

(b)

identify the measures necessary to prevent or control exposure.

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Control measures

Control measures involve substituting lead with less hazardous substances or, if this is not possible, using engineering and organisational methods, similar to those outlined for COSHH, to control exposure.

9

The control of exposure to lead (by inhalation) will only be regarded as adequate:

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if the concentration of lead in air is kept below the OEL (see below)

(b)

if, where the OEL is exceeded, the Contractor identifies the reasons and takes immediate steps to remedy the situation.

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Air monitoring

Where a risk assessment indicates that employees may be liable to significant exposure to lead, the Contractor must arrange for air monitoring to be carried out to establish the levels of lead in the air at the place of work.

11

Air monitoring will involve using specialist equipment, which is fitted to the employee being monitored, to take an air sample from the employee's 'breathing zone' over a set period of time.

12

Using static air-monitoring equipment to take air samples is not acceptable as the results will not be representative of any employee's personal exposure.

13

Generally, depending upon the circumstances, monitoring must be carried out at either three-monthly or yearly intervals. Air monitoring will determine whether the OEL has been breached.

14

The Contractor has a duty to retain records of air monitoring results for a period of five years.

15

Given the temporary nature of construction sites, and the even shorter periods when employees might actually be exposed to lead, the above requirement is considered to be largely academic for the construction industry. With tradesmen such as plumbers and painters being potentially exposed to lead many times but over relatively short periods, it will be for the Contractor to decide how frequently air monitoring should be carried out to confirm whether or not existing control measures are adequate.

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Occupational Exposure Limit (OEL) 16

The standard for inorganic lead in air is 0.15 milligrams of lead per cubic metre of air determined on an eight-hour time-weighted concentration.

17

This quantifies the standard to be met by the control measures for airborne lead under these Regulations. Medical surveillance Medical surveillance to detect exposure to lead involves measuring the concentration of lead in the blood or urine and therefore necessitates the involvement of suitable trained, medical staff.

19

Where a risk assessment indicates that employees' exposure to lead is likely to be significant, the Contractor has a duty to arrange medical surveillance for the affected employees.

20

If medical surveillance detects blood-lead concentrations at or above those outlined below, this will trigger continued surveillance: all employees: 35 micrograms of lead, or greater, per decilitre of blood.

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young persons (aged 16-17): 40 micrograms of lead per decilitre of blood

(b)

all other employees: 50 micrograms of lead per decilitre of blood.

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If medical surveillance detects blood-lead concentrations at or above these action levels, the Contractor must: recognise that the employee's blood-lead level is near the 'suspension level'

(b)

investigate the effectiveness of existing control measures and take the necessary actions to reduce employees' blood-lead levels below the action level

(c)

prevent the blood-lead level of affected employees from reaching the suspension level.

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The action levels for lead are:

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Action levels

Suspension levels 23

24

If medical surveillance reveals that an employee's blood-lead level has reached or exceeded the levels outlined below, a doctor must decide whether to temporarily suspend them from work which exposes them to lead: (a)

young persons (aged 16-17): 50 micrograms of lead per decilitre of blood

(b)

all other employees: 60 micrograms of lead per decilitre of blood.

In such circumstances, the Contractor must: (a)

ensure that a doctor makes an entry in the health record of affected employee(s) as to whether, in the doctor's professional opinion, they should be suspended from further work liable to expose them to lead

(b)

review the relevant risk assessment

(c)

review the actions taken to prevent exposure to lead

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(d)

provide for a review of the health of any other employees who may have been similarly exposed.

25

If the doctor thinks that there is no need to suspend the affected employee(s) from work, the doctor must note in their health records: (a)

the reasons for that decision

(b)

any conditions under which working with lead may continue.

26

A Contractor must act on the doctor's decision and an employee will not be able to work with lead again or be exposed to it until the doctor considers it safe to do so.

27

(Refer to Appendix 2 for an example of a health surveillance record form.)

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Significant exposure to lead can occur where:

any employee is, or is liable to be, exposed to a concentration of lead in the atmosphere exceeding half the occupational exposure limit for lead

(b)

there is a substantial risk of an employee ingesting lead

(c)

there is a risk of contact between the skin and lead alkyls or other substances containing lead which can be absorbed through the skin.

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Significant levels

Contractors must provide employees with protective clothing, monitor lead in air concentration, and place the employees concerned under medical surveillance.

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Personal protective equipment will be required where control measures are not practicable.

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Some types of work with lead carried out as part of construction or decorating activities, have the potential to result in significant exposure to lead unless the Contractor provides adequate controls and ensures that they are used. For example:

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Types of work liable to result in significant exposure to lead

burning off old paint

(b)

dry-sanding old paint

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high temperature lead-work such as lead smelting, burning and welding

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(d)

working with metallic lead and alloys containing lead, for example, soldering

(e)

disc abrasion of lead surfaces and cutting lead with abrasive wheels

(f)

spray painting with lead-based paints

(g)

work inside tanks that have contained petrol

(h)

manufacture of leaded glass

(i)

hot cutting, demolition and dismantling operations

(j)

otherwise removing or disturbing old lead sheet thereby raising contaminated dust

(k)

recovering lead from scrap and waste

(l)

welding galvanised metal and flame cutting steelwork that has been painted with leadbased paint.

Those operations which do not usually produce significant levels include low temperature work, ordinary plumbing, soldering, handling clean sheets or pipes of lead, rough painting.

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How does lead affect your health? 33

If the level of lead in the body gets too high, it can cause headaches, tiredness, irritability, constipation, nausea, stomach pains and loss of weight. Continued uncontrolled exposure could cause far more serious symptoms, such as kidney damage, nerve and brain damage. A developing unborn child is at particular risk from exposure to lead, particularly in the early weeks before a pregnancy becomes known. Prevention of exposure The Contractor has a duty to assess the nature and extent of the exposure to lead and, on the basis of this assessment, to determine the measures necessary to control exposure and comply with these Regulations.

35

Action should be taken to reduce the amount of lead breathed by operatives to below the lead in air standard.

36

The basic need is to prevent the liberation of lead dust, fumes or vapour into the workplace.

37

If surface finishes are to be disturbed, always check for the presence of lead paint or, if this is not possible, assume the worst (that it is a lead-based paint) and take the appropriate precautions.

38

Ways of testing for the presence of lead include:

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a variety of destructive tests for paint sampling, although these result in damage to painted surfaces in order for samples to be taken

(b)

disposable test kits: instant, on-site lead/no lead result with 95% accuracy. (These are an indicator only, not a laboratory-standard test)

(c)

paint-sampling kits which are ready-to-use (for non-lab professionals) for submission of samples for chemical analysis. A laboratory-standard test

(d)

dust-wipe sampling kits which are ready-to-use dust sampling kits (for non-lab professionals) for submission of samples for chemical analysis. A laboratory-standard test

(e)

hand-portable devices that use XRF (x-ray fluorescence) technology to obtain laboratory standard readings instantly, on site.

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1.2.6.10 Personal protective equipment Respiratory protective equipment 1

Where control measures do not reduce the lead in air levels to below the control limits, respiratory protective equipment of a type suited to the hazard or process involved must be provided, and all employees must be properly trained to use it. All such equipment should be serviced, cleaned, maintained and stored correctly, as is appropriate.

2

Depending upon whether the hazard is lead dust or fumes, adequate protection will be given by the use of compressed air-line breathing apparatus, self-contained breathing apparatus, or a full-face positive pressure powered respirator fitted with a high efficiency filter. Protective clothing

3

Wherever exposure is significant, protective clothing must be provided. It must be suited to the hazard or process involved, should resist the permeation of lead dust, and not collect or harbour dust. Employees must be instructed to report any damaged or defective ventilation plant or protective equipment, without delay, to their supervisor or safety representative.

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1.2.6.11 Working with lead-based paints 1

The residues of lead-based paints are a health hazard. Operatives carrying out the removal of old lead-based paint, and anyone else who might be adversely affected, must be adequately protected when applying or removing paints containing lead.

2

Similarly, the occupiers of premises (including the residents of private housing) must be protected by not being allowed to return to their premises (or contaminated parts of those premises) until they have been thoroughly and effectively cleaned (see below).

3

The findings of a risk assessment, carried out before any surface finish is disturbed, will indicate the most appropriate of removal and safety precautions which must be taken.

4

See Appendix 3 for specimen record details.

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Sanding

Unless appropriate RPE and protective clothing are worn, old lead paint should never be drysanded by hand as this activity will liberate lead-rich dust into the air. Again, unless appropriate RPE and protective clothing are worn and effective measures are taken to clear up the residue, mechanical sanding can only be used if the sander is fitted with a dust extraction/ collection unit incorporating a high efficiency particle air HEPA filter.

6

Wet sanding of lead-based paint is acceptable, providing the residue is collected before it dries out with the potential to become airborne dust.

7

As a result, the subsequent dry sanding of apparently 'clean' wood can liberate a significant amount of lead-containing dust into the air.

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Unless appropriate RPE is worn, blow-lamps or gas torches must not be used to burn off old lead paint as these will heat the paint sufficiently to liberate lead fumes into the air.

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Lead paint may be removed by using a solvent or water-rinseable paint remover. If a solvent is used, the work area must be well-ventilated and no smoking or naked flames allowed. Suitable RPE and other appropriate PPE should be used.

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Solvents

Hot-air gun 10

These must not be confused with blow-lamps and gas torches. A hot-air gun will not raise the temperature of the paint sufficiently to allow lead fumes to be created. When using a hotair gun, the old paint must be scraped off as soon as it is sufficiently soft and before it rehardens. Care must be taken to ensure that the paint does not burn as this indicates that it is reaching too high a temperature where fumes may be given off. The use of RPE to protect against lead-containing dust may be necessary. Infra-red heating

11

A product is available that safely lifts the old paint from the base material by heating it to a safe temperature using an infra-red heater. Whilst warm, the paint can be safely scraped off. This method is particularly suitable where large surface areas have to be stripped.

12

The main benefits of using this method, which acts by heating the resins in the wood and breaking the bond between the wood and the first layer of paint, are:

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(a)

all layers of paint are removed in 'a single hit'

(b)

virtually all residual lead is removed from within the grain of the wood

(c)

large surface areas can be safely stripped more quickly than by using other methods.

Spraying 13

Spraying methods should not normally be employed for applying lead-based paints. Cleaning up the work area All surfaces that have been stripped of paint should be washed down thoroughly, either with a proprietary lead-specific detergent or with a solution of dishwasher detergent in hot water, and then wiped down again with clean water.

15

Any residual dust and other debris should be removed using a vacuum cleaner fitted with a HEPA filter. Depending upon the level of contamination, it may be necessary to wear appropriate RPE whilst doing this.

16

Normal vacuum cleaners (domestic or industrial) should not be used as their filters are not sufficiently efficient to retain the lead-containing dust.

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Anyone who works with lead should take simple personal hygiene measures to prevent the inhalation or ingestion of lead during and after work.

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Changing and washing facilities

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1.2.6.12 Personal hygiene

To avoid any risk to health or damage to any clothing concerned, the Contractor must provide separate accommodation for an employee's own clothing and any protective clothing the employee may have to wear at work. This requirement will normally apply for protective clothing worn for work with lead.

3

Adequate and suitable washing facilities are required where operatives are exposed to lead. Where employees are exposed to lead, washing and changing facilities provided should allow them to meet a high standard of personal hygiene so as to minimise the risk of them ingesting or otherwise absorbing lead.

4

The design of the washing facilities should be related to the nature and degree of exposure to lead as indicated by the assessment. Where employees are significantly exposed to lead, and if washbasins alone would not be adequate, the washing facilities should include showers or baths.

5

An example would be where work is carried out in dusty conditions which could result in the whole body being contaminated by lead. Then the provision of showers or baths would be essential.

6

Washing facilities should provide at least:

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(a)

one washbasin for every five persons. Basins should be of sufficient size to permit arms to be immersed up to the elbow

(b)

a constant supply of hot and cold or warm water (running water where reasonably practicable)

(c)

soap or other cleaning materials

(d)

nail brushes

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For certain types of work, such as lead work, carried out at premises or sites where such work is not regularly done (for example, certain tank cleaning and lead burning operations), mobile caravan type washing/showering facilities of suitable design should be provided. Eating, drinking and smoking These Regulations require Contractors to reduce the risk of ingestion of lead by ensuring that employees do not eat, drink or smoke in places which are contaminated, or likely to be contaminated, from lead arising from work activities. Therefore, Contractors should reduce the risk of employees ingesting lead by ensuring that they are given adequate information on the specific areas that might be contaminated by lead and in which they should not eat (including chewing gum or tobacco), drinker smoke.

9

The information should be reinforced by displaying a prominent notice to identify those areas in which employees may, or may not, eat, drink or smoke.

10

The following points should be noted:

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clean areas, canteens or mess rooms should be isolated from lead-contaminated work areas

(b)

protective clothing should be removed before entering these areas

(c)

washing should take place before eating meals or drinking

(d)

the Contractor must advise employees where they may not eat, drink or smoke

(e)

Employees are not to eat, drink or smoke in any place where there is risk of contamination by lead.

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(a)

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Construction Site Safety 1.2.6 Appendix 1 Lead hazards Safety checklist Has a risk assessment been carried out?

2

Have all persons who have to work with lead received adequate information, instruction and training?

3

Has the nature and extent of any exposure to lead been assessed?

4

Is the monitoring of lead in air levels carried out?

5

Is medical surveillance of individuals necessary and, if so, undertaken?

6

If medical surveillance is necessary, are medical records kept as required?

7

Are measures in place to control levels of exposure to lead?

8

Is protective equipment and clothing in use, as necessary and required?

9

Is the correct type of respiratory equipment being used for the hazard being encountered?

10

Are measures being taken to control the spread of any lead contamination?

11

Is there adequate provision of washing and changing facilities?

12

Are separate areas provided for eating and drinking?

13

Are all operatives adequately trained in safe working procedures?

14

Are operatives aware of the risks to health that can arise from not working safely?

15

Are records being kept as required by these Regulations?

16

Are arrangements in place to deal with accidents, incidents and emergencies?

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Construction Site Safety 1.2.6 Appendix 2 Specimen health surveillance record Recorded details of an employee under medical surveillance because of exposure to lead

Employee's details Name:

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Permanent address:

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Place of birth:

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Date of birth:

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Sex:

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Doctor's details

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Name:

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Address:

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Telephone number:

Contractor's details Name: Address: Telephone number:

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Employment details Years exposed to lead before starting of current employment: Date of first exposure to lead in current employment: (Day Month Year)

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Date of end of exposure to lead in current employment: (Day Month Year)

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Additional information

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a) the reason for medical surveillance b) the dates of initial and periodic medical surveillance

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c) the results of clinical assessments

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d) the results of measuring blood-lead concentrations and of any other biological tests in enough detail to allow adverse trends to be identified, and

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e) action taken, including periods moved to work not involving exposure to lead, and periods of suspension.

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Construction Site Safety 1.2.7

Manual Handling

1.2.7.1 Key points 1

Poorly thought out or badly performed manual handling activities are the cause of many injuries to construction workers.

2

'Manual handling' includes lifting, lowering, pulling, pushing or carrying a load by physical effort.

3

Several factors will determine whether it is safe for an individual to manually handle any particular load.

4

Contractors must:

(b)

where that is not reasonably practicable, assess the risks to the employee;

(c)

put in place control measures to prevent such an injury occurring.

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avoid so far as reasonably practicable their employees having to carry out manual handling activities likely to result in an injury;

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Employees must:

make full and proper use of the Contractor’s safe system of work;

(b)

use (lifting) equipment and machinery in accordance with instruction and training given;

(c)

report to the Contractor any situation where it is considered that the system of working is not safe.

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(a)

Where sustaining an injury is a possibility and handling a load cannot be avoided, using a mechanical means of carrying out the activity is the best solution.

Note:

Section 1, Part 9.2 of the QCS covers the manual handling of materials.

1.2.7.2 Introduction

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All construction and building work involves lifting and handling to some extent. Although mechanical equipment should be used whenever practicable, much of the work will inevitably continue to be done manually. The risk of injury can be greatly reduced by a knowledge and application of correct lifting and handling techniques and by taking a few elementary precautions.

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1.2.7.3 The Management of Health and Safety at Work 1

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity, including those that involve manual handling, to identify any hazard to employees which might be encountered during their work, or to any other person who might be affected by their operations.

2

Once those hazards have been identified, it is then the Contractor's duty to put control measures into place, either to remove the hazard or, where this is not possible, to reduce the risk of injury resulting from manual handling activities, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any (manual handling) risks that exist in the workplace and any control measures that are in place to reduce those risks.

4

Employees, in turn, have a duty under these Regulations to inform the Contractor of any work (manual handling) situation that presents a risk to themselves or others.

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1.2.7.4 Manual Handling Operations 1

2

These Regulations specify how Contractors have to deal with risks to the safety and health of employees who have to carry out manual handling in the course of their employment, as follows: (a)

Assess the manual handling task to identify any risk that may be inherent in the operation.

(b)

Avoid the need to carry out manual handling as far as possible.

(c)

Where a risk is identified, implement control measures to reduce that risk.

The requirements relevant to lifting and handling are described below.

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make a suitable and sufficient assessment of all such manual handling operations to be undertaken by their employees.

(b)

take appropriate steps to implement control measures, thereby reducing the risk of injury to those employees undertaking any manual handling operations, to the lowest level which is reasonably practicable

(c)

take appropriate steps to provide any of those employees who are undertaking any manual handling operations with general indications and, where it is reasonably practicable to do so, precise information on:

(d)

the weight of each load

(e)

the heaviest side of the load whose centre of gravity is not positioned centrally.

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(a)

Any assessment that a Contractor has made must be reviewed where: (a)

there is reason to suspect that it is no longer valid, or

(b)

there has been a significant change to the manual handling operations to which that assessment relates.

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Each Contractor shall, so far as is reasonably practicable, avoid the need for employees to undertake any manual handling operations at work, that involve a risk of their being injured; or where this is not reasonably practicable, each Contractor shall:

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Contractor's duties

Where changes to an assessment are required, as a result of any review, a Contractor shall make them.

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When determining for the purposes of these Regulations whether manual handling operations at work involve a risk of injury, and to determine the appropriate steps needed to reduce that risk, particular regard shall be taken to check:

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(a)

the physical suitability of the employee to carry out the operation

(b)

the clothing, footwear and other personal effects worn by the employee

(c)

the employee's knowledge and training

(d)

the results of any relevant risk assessment carried out

(e)

whether the employee is within a group of employees identified by that assessment as being especially at risk

(f)

the results of any health surveillance already carried out

Contractors must additionally: (a)

provide safe systems and places of work

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(b)

ensure the safety of their employees and, where possible, the absence of risks in the handling, storage and transport of all types of articles and substances

(c)

provide the information, instruction, training and supervision necessary to ensure the health and safety of their employees.

Employee's duties It is the duty of each employee, while at work, to: (a)

make full and proper use of any system of work provided for use by the Contractor in connection with manual handling.

(b)

Use any machinery or equipment provided by the Contractor in accordance with any training or instruction received.

(c)

Inform the Contractor, or anyone else responsible for safety, of any dangerous work practice or shortcomings in the Contractor's arrangements for safety.

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Designers have the potential to minimise the amount of manual handling that is necessary during any construction project and therefore the injuries that might arise from it. Examples of how this might be achieved are: designing site layouts such that 'double handling' is eliminated and manual handling distances are minimised

(b)

incorporating mechanical lifting points into components that would otherwise have had to be manually handled into. place

(c)

taking advantage of technological advances by specifying modern components made from lighter material

(d)

ensuring that designs allow for adequate access for construction plant, such as excavators and dumpers, where excavation work and other earth-moving activities are necessary.

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1.2.7.5 Construction (Design and Management) CDM

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Strains and sprains to muscles and joints, torn ligaments and tendons, disc trouble and hernias. These are often caused by sudden and awkward movements, for example, twisting or jerking while lifting, or handling heavy loads. They are also caused by persons attempting to lift loads beyond their physical capabilities. The muscles of the abdominal wall are particularly vulnerable, and excessive strain may lead to ruptures.

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1.2.7.6 Common injuries

(a)

Cuts and abrasions from rough surfaces, sharp or jagged edges, splinters, projections, etc. Personal protective equipment and clothing should be worn as necessary, such as leather gloves to protect the hands.

(b)

Back injuries are most frequently sustained while lifting and handling manually. They may be the cumulative effect of repeated minor injuries, or the result of an abrupt strain. Stoop lifting (see below) should be avoided; it greatly increases the chances of sustaining back injuries.

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The risk of injury is reduced by a knowledge of correct lifting techniques and by not attempting to lift excessively heavy loads without assistance.

3

Crushing of limbs, etc. by falling loads, or by fingers, hands or feet becoming trapped by loads.

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Correct positioning of hands and feet in relation to the movement of the load is essential. Timber wedges or other blocks should be used when beginning to raise or lower heavy loads to enable a secure grip to be achieved and to prevent fingers and hands becoming crushed when lowering the load. Safety shoes with steel toecaps will protect the feet. Soles of footwear should also provide a secure grip.

1.2.7.7 Making an assessment 1

Completing the assessment is the Contractor's responsibility. Expert help may be needed in difficult or unusual cases.

2

Often assessments can be done by a team of people and, although employees should not make their own assessments, their involvement will often be beneficial.

3

A Contractor should make provision for properly trained manual handling assessment teams, but if there are special difficulties and it is decided to call in outside assistance, the Contractor should ensure that the person engaged is competent to make the type of assessments required and that clear instructions are given.

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The wide range of manual handling tasks that arise on every building and construction site need to be fully identified. This should be systematically carried out by looking at individual tasks and the way in which they are carried out.

5

By grading these factors, e.g. low/medium/high, the assessor will be able to more clearly identify the overall risk.

6

Whilst carrying out the assessment, the assessor should consider ways of reducing any risk found.

7

An assessment should not just be a paper exercise but should be used to pinpoint the unsafe features of the work task, so that the Contractor may improve the situation, by implementing control measures.

8

It is quite acceptable to group any manual handling tasks which have common features into a single manual handling assessment, but care must be taken to ensure that the range of risks is common to all tasks covered by the single risk assessment. However, when taking this approach, it can be tempting to make a task fit the assessment rather than make the assessment fit the task. The important thing is to identify any risk of injury, and then point the way to practical improvements.

9

Significant findings should be recorded and kept, but this is not necessary if the findings are obvious and the assessments easily repeated.

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1.2.7.8 Lifting capacities

The weight that can be lifted by any individual will vary according to personal physique, age, condition and practice, and the techniques employed. Lifting capacity declines with age and an older person may not be capable of lifting the same load as a younger person; this, however, can be offset to some extent by employing a better technique.

2

The general rule is that the load should not be lifted if it causes a feeling of strain. Assistance should be available if required, and employees must not be required to lift loads beyond their capacity.

3

Youthful exuberance and bravado often tempt younger employees to attempt to lift loads that are too heavy. While they may succeed in the short term, long-term damage may be done to the ligaments, muscles and back.

4

If single person handling is needed, either blocks or other materials of 20 kg or lighter should be specified and used, or other precautions should be implemented to reduce the risk by, for example, the provision of mechanical handling.

5

With blocks or other materials weighing less than 20 kg, manual handling risks are still significant and suitable precautions should be taken to minimise these risks as much as possible.

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1.2.7.9 Abdominal belts 1

Research has shown that abdominal belts do not necessarily prevent manual handling injuries and may, in some cases, make things worse.

1.2.7.10 Preparing to lift 1

Before lifting and handling any load, the following points should be established: (a)

What has to be moved?

(b)

Does it really have to be moved?

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(c)

What does it weigh?

(d)

Can it be broken down into smaller loads?

(e)

Can the process that requires it to be moved be changed?

(f)

Where is the load's centre of gravity?

(g)

Can it be safely handled by one person?

(h)

Will assistance be required?

(i)

Can the move be carried out more safely with mechanical assistance?

(j)

How far does it have to be moved and from where to where?

(k)

Is the route clear of obstructions?

(l)

Can it be put down safely?

Suitable protective clothing should be worn. This may include gloves, safety footwear, safety helmets, and special overalls if hot or corrosive substances are to be carried.

3

Ensure that the lifting and lowering areas are clear of tripping hazards, and likewise check the route over which the load is to be carried.

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1.2.7.11 The load

Large, heavy loads should, if possible, be broken down into smaller, lighter and more manageable sizes. It is obviously easier to lift 10 kg five times than to try and lift 50 kg once.

2

Where the load has to be moved by a woman, the weight should be reduced by approximately 30%.

3

As a rough guide, where lifting is repetitive, weights should be reduced as follows:

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Special factors in operation

Rough guide Reduce weight by 30%

Operation repeated five to eight times a minute

Reduce weight by 50%

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Operation repeated once or twice a minute

Reduce weight by 80%

'Average' female

Reduce weight by 30%

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Operation repeated more than 12 times per minute

Handler twists through 45 degrees

Reduce weight by 10%

Handler twists through 90 degrees

Reduce weight by 20%

Handler seated and twisting

Less than 5 kg

Handler seated

About 5 kg

About 25 kg for starting or Pushing or pulling a load (assuming that force is applied with stopping a load About 10 kg hands between knuckle and shoulder height) for keeping a load in motion

4

The size and shape of a load may be as significant as its weight in determining whether assistance is required. Large awkward loads, which require the arms to be extended in front of the body, place more strain on the back and abdomen than compact objects carried close to the body.

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The absence of natural or designed handling points can also make it difficult to raise and carry objects without strain and may require barrows or other lifting and handling aids.

6

Not all loads need to be carried, of course. It may be easiest to roll or push them, depending on the contents. Even so, assistance might still be required to avoid the risk of injury.

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1.2.7.12 Kinetic method of lifting

Kinetic handling must be taught by trainers. It cannot be 'picked up'. It is important that postural errors are corrected during training before bad habits are established.

2

The main features of this method are that it: utilises the strong leg and thigh muscles - not the weaker back muscles as in stoop lifting

(b)

maintains the natural shape of the spine throughout the lift. Although the body may be bent over, the spine remains straight

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(a)

uses the momentum of body weight to initiate forward movement.

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The correct posture (such as the position of various parts of the body) in performing a task is essential. Important points are: (a)

correct position of feet

(b)

knees bent

(c)

straight back

(d)

arms close to body for lifting and carrying

(e)

correct grip or hold

(f)

chin in, head up

(g)

use of body weight.

Some lifting and handling techniques employing the kinetic method are described on the next page.

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Bend at the knees (1) 5

The weight to be lifted must be within the lifting capacity of the individual worker and the load should be approached squarely, facing the intended direction of travel. The feet are positioned about a hip's width apart, one foot SLIGHTLY in front of the body. The knees are bent and the body lowered as close to the load as possible while remaining relaxed and balanced. The back should be straight from hips to shoulders, but not necessarily vertical. Grasp the load (2)

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The load is tilted with one hand (if necessary) so that the other hand can obtain a secure grip at the corner nearest the body. The free hand is then transferred to the furthest corner of the load and drawn as close to the trunk as possible. Arms should be well tucked in to provide maximum support to the load.

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Lift, using the legs (3)

The load can then be lifted by straightening the legs so that the body and load move upwards in unison. All movements should be smooth and natural. Jerking, twisting or straining movements should be avoided.

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Lifting should feel comfortable. Lifting movements will remain smooth and natural providing the back and head are kept naturally erect. This is achieved by looking straight ahead when straightening the legs, instead of looking down at the load.

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Carrying the load (4)

The load should be held firmly into the body and carried to where it is to be deposited. The closer the centre of gravity of the load can be kept to the body, the easier and more natural the lift. It is important to be able to see over or around the load so as to avoid tripping hazards.

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When the weight is approaching the maximum lifting capacity of the individual, it will be necessary to lean back on the hips with the load to bring the trunk to the erect position before straightening the legs to lift the load. In this instance the body is being used simply as a counterbalance to keep muscular effort to a minimum.

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1.2.7.13 Changing grip 1

Grips should not be changed while carrying the load. First rest the load on a ledge or other firm support, then change

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the grip if necessary.

1.2.7.14 Stacking 1

Loads should not be lifted above shoulder height. When it is impossible to lift and stack with the elbows tucked into the sides of the body, a platform should be used to stand on. An intermediate platform should also be used when lifting loads down from a higher level.

1.2.7.15 Use of a lifting platform The squat position is adopted as near to the load as possible. Keeping a straight back and using the leg muscles, the load should be lifted onto a platform. The person lifting the load then stands as near to the platform as possible and, bending at the knees and hips (NOT the back), eases the load onto their shoulder, adjusts for balance and straightens at the knees and hips.

2

For lowering the load, the procedure is reversed.

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Carrying a load under one arm, supported on the hip, causes strain and should be avoided.

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1.2.7.16 Hand hook or lifting aids

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Hand hooks or lifting aids should be used if loads are unwieldy or so irregular in shape that a good grip cannot be maintained. If hooks are being used, care must be taken to ensure that the contents of the load are not damaged.

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1.2.7.17 Team lifting

When large or awkward weights are involved, assistance should be sought. The person assisting should be of similar height and build, so that the raised load does not become unbalanced or unevenly distributed.

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Co-ordinating team activity is important in team lifting. One person should give directions during all lifting, carrying and lowering operations.

3

Properly designed lifting aids will enable some tasks to be performed more quickly and easily, and eliminate the risk of injury or damage.

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1.2.7.18 Using rollers to move a load 1

Lengths of steel pipe or proper rollers can be used to roll or slew heavy crates. The load is

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pushed gently forward on two or more rollers, and further rollers are inserted under the front end as necessary. Care must be taken by the person placing the rollers to avoid being trapped as the load moves forward, and to ensure that those pushing do not trip over the rollers that have previously been used.

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Whenever practical, mechanical handling and lifting should replace manual techniques. This will reduce the risk of fatigue, improve efficiency and reduce the risk of accidents.

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Construction Site Safety 1.2.7 Appendix 1 Safety checklist Manual handling and lifting Preparation What is being lifted?

2

Where to and how far?

3

Has a manual handling risk assessment been carried out?

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Would mechanical means be more practical or appropriate?

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Is the operation part of a routine? If so, could it be more effectively planned and executed?

6

How many people will be needed to move the load safely?

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Are they all trained in kinetic lifting and handling?

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Are proper (kinetic) lifting methods being employed?

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What methods and equipment will be required?

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Is the required equipment available?

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Is the lifting and handling area clear of hazards?

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Lifting and handling

Is the proper personal protective clothing in use?

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Is co-ordination satisfactory in dual and team lifting with one person taking charge of the lift?

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Is the necessary equipment in use or to hand?

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Are excessively heavy weights being lifted?

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Are loads being deposited or stacked safely and securely?

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Is adequate supervision employed where necessary?

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After lifting and handling Are any incidents or accidents reported and recorded?

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Where injuries have been sustained, has medical attention been sought?

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Is the damage or loss of equipment recorded?

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Construction Site Safety 1.2.7 Appendix 2 Manual handling of loads: Assessment checklist Section A - Preliminary Task name:

Is an assessment needed? (An assessment will be needed if there is a potential risk of injury, eg if the task falls outside the guidelines) Yes/No*

Task description:

Load weight:

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Frequency of lift:

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Carry distances (if applicable):

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Are other manual handling tasks carried out by these operators? Assessment discussed with employees/safety representatives

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* Circle as appropriate

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If 'Yes' continue. If 'No' the assessment need go no further.

Diagrams (other information including existing control measures):

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Locations:

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Operations covered by this assessment (detailed description):

Personnel involved:

Date of assessment:

Overall assessment of the risk of injury? * Circle as appropriate

Low/ Medium/ High*

Make your overall assessment after you have completed Section B.

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Section B: Lifting and carrying - More detailed assessment, where necessary If yes, tick appropriate level of risk

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Questions to consider:

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Do the tasks involve: holding loads away from trunk?



twisting?



stooping?



reaching upwards?



large vertical movement?



long carrying distances?



strenuous pushing or pulling?



unpredictable movement of loads?



repetitive handling?



insufficient rest or recovery?



a work rate imposed by a process?

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Are the loads:



heavy?



bulky/unwieldy?



difficult to grasp?



unstable/unpredictable?



intrinsically harmful (eg sharp/hot)?

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High

Problems occurring from the task (Make rough notes in this column in preparation for the possible remedial action to be taken)

Possible remedial action e.g. changes to be made to the task, load, working environment etc. Who needs to be involved in implementing the changes?

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Section B: Lifting and carrying - More detailed assessment, where necessary If yes, tick appropriate level of risk

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Questions to consider:

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Consider the working environment - are there: constraints on posture?



poor floors?



variations in levels?



hot/cold/humid conditions?



strong air movements?



poor lighting conditions?

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Consider individual capability - does the job:

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require unusual capability? pose a risk to those with a health problem or a physical or learning difficulty?



pose a risk to those who are pregnant?



call for special information/training?

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Problems occurring from the task (Make rough notes in this column in preparation for the possible remedial action to be taken)

Possible remedial action e.g. changes to be made to the task, load, working environment etc. Who needs to be involved in implementing the changes?

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Section B: Lifting and carrying - More detailed assessment, where necessary Yes/No

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Other factors to consider

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Is movement or posture hindered by clothing or personal protective equipment? Is there an absence of the correct/suitable PPE being worn?

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Protective clothing

Yes/No

Yes/No

Work organisation (psychosocial factors)







Yes/No

Do workers feel that there is poor / communication between managers and employees (eg not involved in risk assessments or decisions on changes in workstation design)?

Yes/No

Are there sudden changes in workload, or seasonal changes in volume without mechanisms for dealing with the change?

Yes/No

Do workers feel they have not been given enough training and information to carry out the task successfully?

Yes/No

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Do workers feel that there has been a lack of consideration given to the planning and scheduling of tasks/rest breaks?

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Problems occurring from the task (Make rough notes Possible remedial action e.g. changes to be made to in this column in preparation for the possible the task, load, working environment etc. Who needs remedial action to be taken) to be involved in implementing the changes?

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Section C - Remedial action to be taken

Remedial steps that should be taken, in order of priority: Person responsible for implementing controls

Target implementation Completed date Y/N

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Date by which actions should be completed: Date for review of assessment: Assessor's name:

Signature:

TAKE ACTION ... AND CHECK THAT IT HAS THE DESIRED EFFECT

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Construction Site Safety 1.2.8

Asbestos in the Workplace

1.2.8.1 Key points All asbestos-containing material (ACM) is hazardous when airborne and dangerous when fibres are inhaled.

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Before any work with asbestos is carried out a written risk assessment must be made.

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The priority for any Contractor is to prevent exposure to, and spread of, asbestos.

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A written, site specific plan of work must be kept on site and followed.

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Anyone who does any work with asbestos must be specifically trained to do it, and this training must be repeated annually.

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Do not forget other hazards besides asbestos, e.g. working at height or in a confined space, when working with/removing asbestos.

Note:

Section 1, Part 9 of the QCS covers manual handling of materials.

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The key is a risk assessment, which needs to be carried out by someone who is competent in terms of: (a)

working with asbestos

(b)

the requirements of these Regulations

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1.2.8.2 Introduction

Asbestos is a risk to health when airborne fibres are breathed in. The greater the number of fibres, and the longer the period over which they are breathed in, the greater the risk of incurable asbestos-related diseases developing. These include cancers in the lungs and chest lining.

3

However, asbestos that is in a good condition, which is not damaged and is not likely to be worked on or disturbed, does not pose any immediate problem.

4

Although asbestos building materials and products have been largely replaced by safer alternatives, there remains the issue of the ongoing and long-term management of existing asbestos where its removal is not practicable.

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Locating and identifying asbestos can be difficult, as its appearance may be changed by surface coatings, heat or ageing. It may also be encapsulated by, or be concealed beneath, other materials. Past uses of asbestos include:

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Insulation and sprayed coatings using moulded or pre-formed lagging 6

boilers, plant and pipework

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fire protection to steel work

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thermal and acoustic insulation of buildings, including loose packing Insulation board

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fire protection to doors

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claddings on walls and ceilings

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partitioning

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ceiling tiles

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fire breaks in ceiling voids

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Asbestos cement corrugated roof sheets

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flat sheets for cladding and partitions

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roof and rainwater drainage goods

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underground pipes

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bath panels

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artificial roof slates

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Other uses vinyl or thermoplastic floor tiles

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insulation of electrical equipment

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some textured coatings

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bakelite sanitary ware, and other products.

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Asbestos-based friction materials were widely used in brake and clutch linings in vehicles and plant, together with gaskets and packing in engines and heating or ventilation systems. Substitute materials have been developed in most cases.

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Asbestos is a naturally occurring fibrous silicate mineral material, which does not burn and is resistant to most acids and alkalis. The fire protection and insulative properties of asbestos were the main reason for its use over the years. Three main types of asbestos have been used in the construction industry:

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(a)

chrysotile (white)

(b)

amosite (brown)

(c)

crocidolite (blue).

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Although the colours are often used to differentiate between the different types of asbestos, the actual colour of a material suspected of being asbestos is not necessarily an accurate indication as to whether or not it is asbestos or an asbestos-containing material, or if it is, of what type.

3

Changes in colour may occur due to: (a)

it ageing or simply becoming dirty

(b)

the effects of heat

(c)

surface coatings being applied

(d)

encapsulation

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(e)

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oil or chemical splashes.

4

The type of asbestos used in the lagging of boilers can be particularly difficult to identify visually. Repairs and modifications can mean that boilers or pipework may be lagged by a mixture of different types of asbestos.

5

Asbestos was widely used as fire protection in building materials, for thermal insulation and also as a sprayed coating to steel structural members. All of these uses now present significant management issues associated with the maintenance of the asbestos over the remaining life span of the building, or the removal of the asbestos during renovation, refurbishment or demolition.

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Working with, among, or alongside asbestos materials demands stringent control, and compliance with recommended precautionary measures and methods of work.

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1.2.8.4 Control of Asbestos

Risk assessment - an assessment of risk carried out by someone with both the theoretical background and practical experience of the intended work with asbestos-containing materials.

2

While a competent construction manager may be able to form an opinion as to whether a material may be asbestos or an asbestos-containing material, the decision as to who can do the work, and the standards that the work should be carried out to, are likely to require specialist advice.

3

If you are a contractor working on someone else's premises, you should be given information about the presence of asbestos and what they expect you to do about it. If you are not given this, you should not start work.

4

Note 1. This requires a survey by a competent person. If representative samples are needed for laboratory analysis, this may well be a task for a competent technician. Where multiple samples are taken, each sample and the sample point should be numbered. If samples are being sent for analysis, it is a requirement that any laboratory carrying out analysis has the necessary facilities, expertise and quality control procedures. Any samples should be well sealed, for example inside two zip lock plastic bags.

5

Note 2. If in doubt presume that the material is asbestos or ACM until you can prove that it is not. It is better to 'overprotect', than to expose employees and others to asbestos.

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Note 3. A plan of the premises showing where the materials are will always be extremely useful, and will be essential in larger premises. Such a plan would form an integral part of the ongoing management of the asbestos or ACM.

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Note 4. A risk assessment should be undertaken by a competent person who has sufficient knowledge of the subject.

8

If the materials are in good condition, not liable to be damaged, and will not be disturbed or worked on, then the risk is probably low. If the materials are flaky, crumbling, in a place where they can be damaged by, for example, forklift trucks, then the risk is high. Given the known ill health caused by asbestos, then a high risk of damage calls for urgent actions.

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Note 5. This could be work by your employees, or any contractors or subcontractors brought in for carpentry, flooring, partitioning, ceiling fixing, plumbing, electrical or other work.

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Note 6. If material is not going to be removed by an asbestos removal contractor, consider how you are going to manage the long-term presence of the asbestos. If it is in good condition and not liable to be damaged, then routine inspection and monitoring may be

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enough if records are kept. A sealing coat may be needed, or other protective works necessary, to lower and to further control the risk. Note 7. Make it happen by putting your plan into action. What is the organisation, what are the arrangements for the implementation of the plan and who has the responsibility?

12

Note 8. A regular review of the action plan will ensure that it is working that the control measures are still effective, and that inspection, monitoring and recording are in fact taking place. It may be the case that procedures, notices and policies that have been in place for a length of time tend to be overlooked. A fresh approach may therefore be needed.

13

Note 9. Part of this information will be the signs that will have been placed to identify the asbestos or ACM. In a large workplace or premises, this may also mean keeping a register that describes every individual room or workplace and the asbestos or ACM that is in there. This means that visiting subcontractors can be told exactly what asbestos or ACMs to expect in the areas in which they will be working.

14

These Regulations also impose duties on Contractors for the protection of employees who may be exposed to asbestos at work, and other persons affected or who may be at risk of being affected by such work.

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1.2.8.5 Representative sampling

To confirm or identify the type of asbestos or ACM on the premises, a series of samples may have to be taken for laboratory analysis. Methods employed in taking samples of asbestos will vary according to its type and location. Guidance on taking samples is available in the UK publication MDHS100.

2

Anyone removing samples for analysis must be competent to do so and use appropriate protective clothing and respiratory equipment, particularly if the work involves cutting, boring, drilling or otherwise creating airborne dust or fibres. Precautionary measures to be observed include:

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no people, other than those taking the sample, to be in the area

(b)

the area from where the sample is to be taken should be dampened using a 'killer spray'

(c)

a knife, core borer or hand drill should be used to place the sample in a suitably labelled, scalable container. Do not use any tools that will create airborne fibres

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(e)

any disturbed or damaged surfaces should be sealed after a sample has been taken.

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other surfaces on which asbestos dust may fall should be covered with an impervious sheet. The area should be subsequently cleaned by using a dustless method, e.g. a damp cloth, which should be disposed of in a sealed polythene bag

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The results of the analysis will determine what action should be included in the management plan.

1.2.8.6 Asbestos surveys 1

All asbestos surveys must be carried out by a competent person who can demonstrate the following: (a)

evidence of their training and experience in such work

(b)

types of survey outlined below they are qualified to carry out

(c)

that they are going to carry out the survey in accordance with the HSE guidance MDHS100

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2

If an individual surveyor is to be appointed, a check should be made as to whether they have personnel certification for asbestos surveys from a certification body which has been approved by a recognised accreditation body under the standard ISO 17024,

3

All surveys should be subject to a quality assurance process. It is important to note that ISO 9000 accreditation is not the correct standard for assessing asbestos surveys. ISO 17020 is the relevant standard.

4

The competence schemes are: The United Kingdom Accreditation Service UKAS. This is accreditation by the United Kingdom Accreditation Service against ISO 17020, and is normally held by an organisation such as the surveying division of a licensed contractor or an asbestos laboratory. www.ukas.org.uk

(b)

National Individual Asbestos Certification Scheme (NIACS) is a scheme jointly run by the Asbestos Removal Contractors Association and the Royal Institute of Chartered Surveyors. It accredits individual surveyors. www.niacs.org.uk

(c)

Asbestos Building Inspectors Certification Scheme (ABICS) is a scheme run by the British Occupational Hygiene Society. It also accredits individual surveyors. www.bohs.org/standardTemplate.aspx/Home/Professional/ABICS

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(a)

A UKAS or equivalent laboratory should have carried out all analysis of asbestos samples.

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Three types of survey are defined within HSE's publication MDHS 100:

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Type 1 - presumptive survey - during which the surveyor does not take any samples. Instead, using their skill and judgement alone, the surveyor identifies materials as containing asbestos or not. The survey is of the asbestos risks that the building poses to its occupants in normal use.

(b)

Type 2 - sampling survey - the surveyor makes use of sampling and subsequent laboratory analysis to confirm whether or not a material contains asbestos. The survey is of the asbestos risks that the building poses to its occupants in normal use.

(c)

Type 3 - invasive survey - the surveyor samples and breaks into the structure and fabric of the building to try to find the asbestos-containing materials, before a contractor does so in the course of their work.

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Anyone applying the results of a survey should initially check if the surveyor has written any caveats on the survey. It is common to exclude access to areas which are over 3 metres above ground level, as it is not possible for a single surveyor to safely use a ladder higher than this because they cannot foot it. There may be other areas that have not been accessed.

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Asbestos surveyors are taught to identify the 'spaces' where asbestos is likely to be found and to survey accordingly. The meaning of 'spaces' can be anything from a boiler room, to a roof void, an office, an underground duct, a cavity between the two leafs of a wall or anywhere else that asbestos or an asbestos-containing material might have been used.

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A 'no access' comment on an asbestos report could be simply because:

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(a)

the door of a room was locked and the surveyor could not gain entry

(b)

the 'space' was an underground duct and a mini digger was required to lift the covers

(c)

a suspended floor had no access other than by destroying the floor

(d)

the electrical system being live during the survey.

To understand the difference between a Type 2 and Type 3 survey, the simplest explanation is to consider a studwork wall which forms a firebreak. It was originally covered in asbestos insulation board and then covered over with plasterboard. In a Type 1 and Type 2 survey,

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the surveyor would correctly identify the outer surface as being plasterboard. During these surveys there would be no need to carry out any invasive testing and therefore the asbestos insulation board lies undiscovered. Type 3 surveys would be invasive and the surveyor would be expected to check under the plasterboard for other materials. In the previous case, if a building contractor only commissioned a Type 2 survey upon which to plan their work, they may find the asbestos insulation board unexpectedly. Invasive checks must be made before invasive work is carried out.

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Just because the surveyor did not find any asbestos does not mean that there is no asbestos present. In all cases it is important to remember that surveying is as much an art as a science and there will be mistakes. There are also some asbestos-containing materials which would only be found by luck rather than judgement, for example, asbestos cement shuttering in a slab, or asbestos insulation board used as packers inside a stud work wall. It is important to be wary of unidentified building products and for everyone to have sufficient asbestos awareness training. There should also be management who are in a position to stop work if necessary and question the presence of any 'funny looking plasterboard' found.

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1.2.8.7 Working with asbestos

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A Contractor who carries out any work in a building or structure is required to: make a suitable and sufficient assessment as to whether asbestos is, or is liable to be, present in the premises where work is being carried out. Under CDM, the client has a duty regardless of the size of the project to provide information such as the presence of asbestos

(b)

note that:

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this information should normally be in the form of Type 3 surveys as defined in the HSE publication MDHS 100 for most invasive construction work

(ii)

any information on the presence of asbestos supplied by the client based upon a Type 2 survey, must be closely scrutinised to ensure that the construction work will not disturb more of the structure than the surveyor checked

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Requirements of the Regulations

identify that the material does not contain asbestos or assume it contains brown or blue asbestos

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ensure that a competent person carries out an assessment to decide the likely exposure for the proposed work methods.

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prepare a suitable written plan of work

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provide adequate information, instruction and training, for employees and others

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ensure that training is repeated on an annual basis for any work with asbestos

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prevent or reduce asbestos exposure to the lowest level reasonably practicable by means other than the use of respiratory protective equipment (RPE), for example use an asbestos H class vacuum cleaner or other fibre suppression techniques

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ensure the proper use of respiratory protective equipment and that face-fit testing is carried out

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maintain respiratory equipment in a clean, efficient state, good order and repair. Regularly examine and test exhaust ventilation equipment

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provide adequate and suitable protective clothing and ensure that it is cleaned or disposed of appropriately

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prevent the spread of asbestos from the workplace

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ensure premises and plant involved in work with asbestos are kept clean

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monitor the air where employees are exposed to asbestos and keep suitable records for a specific period

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ensure that air monitoring is only carried out by a UKAS or equivalent accredited laboratory

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provide washing and changing facilities that are adequate and suitable for employees exposed to asbestos, and storage for protective clothing and personal clothing (not worn during working hours)

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Asbestos areas and respirator zones

Where an asbestos removal contractor is undertaking the removal of asbestos, in order to ensure that people other than those involved in asbestos work are not exposed to asbestos by entering 'asbestos areas', such areas should be designated and clearly identified, using notices.

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Areas where the removal contractors are working, and where control limits for exposure to airborne fibres are liable to be exceeded, will be designated as respirator zones to ensure that only removal contractors wearing respiratory protective equipment are allowed to " enter.

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Contractors with asbestos removal contractors on their premises should strictly prohibit entry into these areas by their own employees.

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Medical surveillance

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Asbestos removal contractors must ensure that their employees, who are liable to be exposed to asbestos, are under regular medical surveillance by an employment medical adviser or appointed doctor.

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Medical examinations should be provided before work with asbestos starts and at prescribed periods thereafter, currently every two years.

21

Health records containing information on medical examinations have to be maintained and kept for 40 years after the date of the last entry.

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Washing and changing facilities 22

Asbestos removal contractors must provide adequate and suitable washing and changing facilities for their employees. Where protective clothing and respiratory equipment are in use, storage must be provided for contaminated items.

23

Separate storage must be provided for personal clothing not worn during working hours. Storage, dispatch, labeling of asbestos waste

24

Asbestos waste is considered to be of two types - combined or fibrous. Combined was previously called bonded and effectively the asbestos is well bound into the material. Roofing felt, vinyl floor tiles and most asbestos cement is categorised as combined. Asbestos insulation board, pipe lagging and sprayed coating are fibrous. Professional advice may be needed to ensure that the waste is correctly categorised.

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25

There is no requirement to bag or wrap asbestos cement sheets, or gutters removed externally, where they can be placed straight into a suitable skip. The skip should be secured if it is left overnight. It is good practice to bag or wrap waste from internal work to guarantee that when the waste is carried outside there will be no asbestos debris dropped. If a van is being used to carry asbestos waste, the material must be double bagged and the bags secured by putting them in a lidded bin, for example.

26

Any fibrous asbestos removed should be sealed in proper containers and correctly marked before despatch. Typically, this will be double-bagged with the inner bag being red and the outer clear.

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Containers should be designed and constructed so as to retain the asbestos without any spillage or loss during normal handling.

.

Labelling of asbestos waste and used protective clothing Where the asbestos removal contractor uses labels on waste or removed asbestos, the label must be clearly and indelibly printed so that the words in the lower half can be easily read. These words must be printed as specified in the diagram.

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The label has to be firmly affixed to the packaging using an adhesive type label, or directly printed onto the packaging (plastic bag).

Labelling requirement

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Disposal of removed asbestos 30

In essence, there is a duty of care put on everyone in the waste disposal chain. Clients, whether they are at work or domestic, have a responsibility to ensure that the waste is disposed of correctly. They can be prosecuted if the waste is fly tipped. Where asbestos has been removed as part of a project, a prudent contractor would ensure that proof of disposal formed part of the information that was given to the client. Other aspects

31

Concerns regarding aspects of health and safety that are often associated with working with asbestos, such as working at height, the risk of fire, working in confined spaces, the use of machinery, burning, cutting and lifting. It is important not to view asbestos as a hazard in isolation.

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Construction Site Safety 1.2.9

The Control of Dust and Fumes

1.2.9.1 Key points The inhalation of dust or fumes has the potential to cause severe respiratory illness.

2

Asbestos fibres and lead dust are particularly hazardous if inhaled.

3

The dust of some types of wood can be irritating to the skin.

4

The creation of airborne dust or fumes should ideally be prevented although this is often not possible in a construction site environment.

5

Where the prevention of dust or fumes is not possible, the extent of exposure must be controlled to a level that is safe.

6

Control of dust can be achieved by the:

(b)

collection of dust in 'collector bags' attached to powered hand tools

(c)

wet cutting of solid materials such as thermal blocks, bricks or ceramic tiles

(d)

where practical, carrying out of work activities in the open air rather than in enclosed spaces.

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Hazardous fumes usually result from:

processes in which materials are heated, such as welding, lead burning or grinding

(b)

uncontrolled use of substances such as solvents and adhesives

(c)

the use of equipment and plant powered by internal combustion engines.

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Section 1, Part 15.2.3 of the QCS covers the control of dust.

1.2.9.2 Introduction

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Note:

The exposure of employees to airborne dust or fumes can result in severe respiratory illnesses, such as occupational asthma. Such diseases can be totally disabling, causing those affected to give up work or change their employment. Exposure of the skin to some hazardous dusts can result in severe irritation and ulceration of the affected areas.

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1.2.9.3 Dust

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extraction of dust and fumes through stand-alone extractor units

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Dust is the name for a mix of tiny solid particles. It consists of a wide mix of components. In the construction context, the mix will reflect the work activities.

2

It is widely known that almost any excess levels of dust can cause health problems. Harmful effects range from simple skin irritation to severe respiratory illness.

3

Not all harmful dusts are visible. Dusts that are too fine to be seen by the naked eye are the cause of many serious health problems. Like most occupational health problems, it can take several years for symptoms of ill health to manifest themselves.

4

Skin irritation, dermatitis and ulceration can be caused by contact with some types of dusts. Other types of dust, being soluble, may be absorbed through the skin via cuts and abrasions.

5

The inhalation of dust can cause wheezing, coughing, breathlessness, bronchitis, nasal and other types of cancer. Dust also contains bacteria and viruses and therefore has the potential to cause stomach disorders. These can result from ingesting airborne dust or from eating food with contaminated hands.

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Such problems are not likely to arise if occupational exposure limits are not exceeded and safe systems of work are maintained.

1.2.9.4 Fumes 1

Hazardous fumes can be produced when some building materials are heated or otherwise worked. A common form of respiratory illness, which has flu-like symptoms, is caused by the inhalation of welding fumes. Other sources of hazardous fumes are: (a)

uncontrolled exposure to liquid substances such as solvents or paints

(b)

the use of equipment and plant which is powered by internal combustion engines.

1.2.9.5 Health and Safety at Work (Construction Sites)

.

Contractors must provide and maintain plant and systems of work that are safe and without risks to health.

(b)

Contractors must make arrangements for safe handling, storage, and transport of articles and substances.

(c)

Contractors must provide adequate information, instruction, training and supervision.

(d)

Contractors have a duty to ensure persons not in their employment are not exposed to risks to their health and safety.

(e)

Persons in control of premises must use the best practicable means to ensure that noxious or offensive substances do not enter the atmosphere

(f)

Contractors must not charge an employee for personal protective equipment that is provided in accordance with statutory requirements relating to health and safety.

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Employees have a duty to:

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(a)

exercise reasonable care for their own health and safety and that of others who may be affected by their acts or omissions; to co-operate with their Contractor in enabling him or her to carry out his or her duties under the relevant statutory provisions

(b)

not intentionally or recklessly interfere with, or misuse, anything provided in the interests of health, safety and welfare.

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The relevant provisions are as follows.

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1.2.9.6 The Management of Health and Safety at Work 1

These Regulations place a legal duty on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2

Once those hazards have been identified, it is then the Contractor's duty to put control measures in place to either eliminate the hazards or, where this is not possible, reduce the risk of injury or ill health resulting from those hazards, so far as is reasonably practicable.

3

Where a hazard is identified that requires it, the Contractor must offer appropriate health surveillance to employees. This must take into account all the risks to their health and safety that have been identified.

4

The Contractor must provide employees with comprehensible and relevant information on the risks that exist in the workplace and inform them of the control measures that are in place to reduce those risks.

5

Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves and to any other

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person who may be affected. 6

These Regulations require that Contractors assess the health risks to their employees arising out of exposure to hazardous dusts and fumes, and, if reasonably practicable, put control measures in place to eliminate the work processes and the use of substances that cause exposure. If this is not reasonably practicable, Contractors must: (a)

control exposure to an acceptable level, and

(b)

inform employees of the hazards involved and the control measures in place

(c)

mitigate the effects of any exposure by providing health surveillance where necessary.

1.2.9.7 Control of Substances Hazardous to Health When dust is inhaled, the body's defence mechanisms can usually deal with the larger particles. However, they struggle to cope with the very small particles. In occupational hygiene terms, dust is divided into two categories:

(b)

the much smaller particles which are called 'respirable dust'.

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inhalable dust, sometimes called 'total dust', and

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Because dust is a mix of very small particles, all dusts have been assigned a concentration in air above which they are considered hazardous. It is important to remember that this applies to all dusts, for example those caused by: sweeping a dusty floor

(b)

clearing out a building

(c)

driving plant on dusty sites

(d)

mixing sand and cement to make mortar

(e)

sanding down Medium density fibreboard (MDF) or timber.

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The technical descriptions of the two types of dust are: (a)

total inhalable dust approximates to the fraction of airborne material that is inhaled and is available for deposition in the respiratory tract

(b)

respirable dust approximates to the fraction of airborne material that is inhaled and penetrates to the gas exchange region of the lung (the alveoli).

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1

Any concentration of an inhalable dust in excess of 10 milligrams of dust per cubic metre of 3 3 air (10 mg/m ) averaged out over eight hours, or any respirable dust in excess of 4 mg/m averaged over eight hours, is deemed to be a substantial concentration of dust and therefore within the definition of a substance hazardous to health.

5

The official list of exposure limits is updated periodically and published in the Health and Safety Executives Guidance Note EH40. The most recent edition is EH40/2005. This has been supplemented by a table on HSE's website, which is updated more frequently and has the up-to-date list of workplace exposure levels:

6

www.hse.gov.uk/coshh/table1.pdf

7

This lists specified workplace exposure limits (WEL) for a number of dusts, in addition to other substances. Dusts are therefore classified as substances that are hazardous to health.

8

Further guidance on the health hazards posed by dust is included on pages 29-31 of EH40/2005.

9

The principal points of these Regulations place requirements on the Contractor to protect

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employees, or any other persons who may be affected by their operations, by: (a)

assessing the health risks created by work involving substances hazardous to health.

(b)

ensuring that the exposure of employees or others is prevented or adequately controlled, by putting in place any measures necessary to control the exposure to risks

(c)

ensuring that any control methods provided are properly used and maintained, and by monitoring the work environment as necessary

(d)

carrying out health surveillance in specified circumstances

(e)

providing information, instruction and training for employees on the risks to health and precautions to be taken regarding any work with substances hazardous to health

(f)

providing procedures for dealing with accidents, incidents and emergencies, including first-aid and safety drills.

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1.2.9.8 Construction (Design and Management) CDM

Designers have the potential to eliminate or reduce the exposure of operatives, and possibly others, to dust or fumes through their designs.

2

Examples of how this can be achieved are:

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specifying construction methods that avoid hot-works and therefore the creation of fumes, particularly in enclosed areas and confined spaces

(b)

specifying that construction materials are cut to size at the point of manufacture, eliminating the need for cutting, planing, sanding and so on, on site

(c)

designing enclosures to contain hazardous dust where its creation is unavoidable.

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(a)

Contractors and sub-contractors have the potential to reduce exposure to dust and/or fumes by co-ordinating work activities, co-operating with each other and adopting work methods.

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1.2.9.9 Personal Protective Equipment These Regulations require that where a risk has been identified by a risk assessment and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment is used by the at risk employees.

2

In essence, personal protective equipment (PPE) may only be used as a last resort after all other means of eliminating or controlling the risk have been considered and are found not to be reasonably practicable.

3

In deciding which type to issue, the Contractor must take into account the nature of the hazard that the PPE is being used to protect against, and ensure the PPE will fit the wearer and allow them to work safely. If more than one item of PPE is being used, the Contractor must make sure that individual items of PPE are compatible and suitable for the task that is to be undertaken.

4

Whenever PPE is to be issued, the Contractor must ensure that employees have been given adequate and appropriate information, instruction and training to enable the employees to understand the risks being protected against, the purpose of the PPE and manner in which it is to be used.

5

Whilst the Contractor must ensure that personal protective equipment is supplied and used, the employee has a duty to properly use the equipment provided, follow the information, instruction and training that they have been given, and know the procedures for reporting loss or defects to their Contractor.

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1.2.9.10 Training 1

It should be noted that these Regulations place a legal duty on the Contractor to provide employees with adequate information, instruction, training and supervision to be able to carry out any work task safely and without risks to their health.

1.2.9.11 Respiratory hazards The following paragraphs describe the main respiratory hazards which may be encountered on site.

2

Dusts are produced when solid materials are broken down into finer particles. The longer that the dust stays in the air then the easier it is to breathe in. Airborne dust is usually respirable dust.

3

Mists are tiny liquid droplets formed by atomisation of the liquid, for example, when spraying or using an aerosol. Mists may be a combination of several hazardous substances.

4

Metal fumes occur when metal is vaporised at high temperatures, for example, when welding and gas cutting. The physical properties of fumes can be confusing, particularly when identifying suitable respiratory protective equipment (RPE). Usually, metal 'fume' is actually a solid particle by the time it is inhaled.

5

When welding is taking place the temperature of the metal at the weld is sufficiently high for the elements in the metal to become gaseous. However, 2-3 mm away from the weld the gases have cooled down sufficiently for the fume to solidify out as small particles.

6

Consequently, when purchasing RPE to protect against fume, a device that protects against solid particles rather than gases is required.

7

Gases are airborne at room temperature and normally mix with the air that we breathe. Examples include propane, butane, acetylene, carbon monoxide and hydrogen sulphide. Gases can spread very quickly.

8

Vapours are the gaseous state of substances that are liquids or solids at room temperature. They usually form when substances evaporate.

9

One example is the vapour from a tin of glue or solvent that has been left open.

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1.2.9.12 Exposure limits 1

Exposure to any unlisted substance or general nuisance dust should be limited by reducing dust levels to the minimum reasonably practicable. These levels should not exceed 10 milligrams of dust per cubic metre of air, when measured over an eight hour period (10 3 3 mg/m 8H TWA). Within that figure, only 4 mg/m should be respirable dust.

2

Generally speaking, if visible dust can be seen in the air, it is highly possible that the 10 mg limit is being approached (or exceeded), and the application of COSHH should be considered.

1.2.9.13 Control of dust 1

Dust in its many forms has been the cause of health problems throughout the history of the building and construction industry. While much attention has been given to newly recognised hazards, the greater part of the dust problem relates to more common substances.

2

Dust is taken here to mean anything that forms a powder or cloud and is a nuisance,

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including cement, wood, stone, silica, fillers and plastics. The high speed cutting and grinding of most materials can produce dust. Dust in confined spaces is a particular hazard, because of the potential risk of explosion. The most obvious example is in coal mines. Flour dust can also be explosive, and whilst that is normally a process industry risk, for companies who may maintain or cut up extraction plant in bakeries and flour/feed mills, it is something that does require consideration.

4

In all cases, knowledge of the hazards associated with materials, processes and operations is required, and of the specific precautions and protective equipment necessary to reduce or eliminate the risk to health and safety.

5

In many cases, the control of dust will not be difficult to achieve. The accumulation of 'general dust' can be controlled by good housekeeping and simple measures, such as 'damping down'.

6

Where the creation of dust is more localised, such as during the cutting, grinding or sanding of solid materials, satisfactory control will often be achieved by the extraction and collection of the dust through attachments fitted to power tools or by 'wet cutting'. Even where the collection of dust is not practical, it will often be possible to create an enclosure around the activity and ensure that the person carrying it out uses appropriate RPE.

7

Conversely, carrying out some dust-generating activities in the open air may be preferable to allow the dust to disperse, depending upon the hazard posed by the quantity and nature of the dust so created.

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Wood dust

Impregnated timber and some hardwoods (such as teak, African mahogany and iroko) are known to be health hazards. The inhalation of hardwood dusts through the nose is a known cause of nasal cancer.

9

A list of some timbers known to present risks is given below. Protection is not normally required when working on these timbers with hand tools in the open, but harmful dusts can be produced when using machine tools (e.g. sanders or saws) in enclosed or poorly ventilated areas. An assessment should be made and, if ventilation or dust extraction cannot be improved to remove or reduce the dust problem, a dust respirator should be worn.

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Medium density fibreboard 10

Medium density fibreboard (MDF) is a commonly used material in the construction sector. It is manufactured from wood dust glued together with a urea-formaldehyde binder.

11

The risks associated with MDF are exposure to dust and dried urea-formaldehyde during use.

12

The primary issue for construction workers is simply the huge amount of dust that any work with MDF generates. Given the makeup of the product this is not really surprising. The 3 exposure level normally used is the same as softwood dust - 5 mg/m on a time weighted average exposure of eight hours Selection of timbers and their irritant effects

13

The severity and frequency of any symptoms will vary with individuals. They are also doserelated. (a)

Camphor wood - asthma, dermatitis

(b)

Red cedar - asthma, bronchial trouble, sneezing, watering of eyes, rhinitis, dermatitis,

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septic wounds from splinters Dahoma - irritation of mucous membranes and chest, sneezing, coughing, running eyes and nose, dermatitis

(d)

Ebony - irritation of nose and throat, dermatitis

(e)

Guarea (also West African cedar) - mild nasal irritation, sneezing, coughing, running eyes; can cause severe vomiting, chest irritation, blisters around the eyes and dermatitis

(f)

Iroko - skin and eye irritation, asthma and symptoms of the common cold

(g)

Machaerium - dermatitis

(h)

Sapele - dermatitis, allergic extrinsic alveolitis

(i)

Mahogany - asthma, dermatitis

(j)

Chestnut - asthma, dermatitis, rhinitis

(k)

Mansonia - irritation of mucous membranes, sneezing, nasal haemorrhage, eyes sore and bloodshot, dizziness, dermatitis

(l)

Satinwood - dermatitis, headache, coughing

(m)

Teak - dermatitis, eye inflammation. Effects are severe once the skin's protective layer has been penetrated

(n)

Walnut - asthma, dermatitis, conjunctivitis, rhinitis

(o)

Yew - bronchial asthma and dermatitis

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(c)

Generally speaking, the greater the amount and the finer the dust, the greater the risk of health problems.

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Both hardwood and softwood dusts have a workplace exposure limit of 5 mg/m on a time weighted average exposure of eight hours. As both are known causes of asthma dust levels need to be controlled to as low a level as possible.

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Other common sources of dust When cleaning stone, brick and concrete facades, or any metal structure with dry or wet grit blasting, control measures will include the use of respiratory protective equipment. This is likely to be a high performance type such as a powered respirator. When cleaning siliceous masonry, air line equipment may be required.

17

Although this type of cleaning operation is commonly called 'sand blasting', sand must not be used for blast cleaning because of the known health hazard caused by airborne sand and silica.

18

Effective preventative measures must be taken if exposure to crystalline silica is possible.

19

Protection is also necessary when using mechanical cleaning methods.

20

Exhaust ventilation devices should be fitted to power tools, or the operative should be provided with high efficiency breathing apparatus.

21

The cutting and chasing of masonry, stone, brickwork, plaster, thermal insulating blocks and concrete, creates a dust hazard. Therefore, extraction equipment should be provided, the process performed wet or respirators worn, depending on the assessment made.

22

Crystalline silica (also known as quartz) is present in sand and rock and can also be found in building materials such as cement, concrete, plaster, bricks and tiles.

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Dust from plastic fillers can damage the lungs if inhaled, as can dust from resin-based fillers, and fibrous particles of glass fibre, rockwool and similar insulation materials.

24

The dry sanding of lead-based paint can result in exposure to hazardous levels of lead dust. Softening with heat guns and scraping, or the use of chemical stripping agents, will usually be effective. If sanding is required, wet and dry paper with a solution of dishwater detergent can be used. A dishwasher tablet dissolved in about 5 litres of water will give the required solution strength. The form of detergent used for dishwashers is effective at binding and stabilising the lead chromate used in paint.

25

The disturbance of asbestos is likely to result in airborne fibres (dust) which can result in cancer, and other respiratory illnesses, if inhaled.

26

Where a work activity involves the creation or disturbance of dust, a COSHH assessment must be carried out.

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1.2.9.14 Control of fumes

Within the wide range of activities carried out in the construction industry there are numerous operations which liberate fumes into the atmosphere and cause risks to the health and safety of people at work. Every effort must be made to minimise these risks. Fumes may be classified as a substance hazardous to health and thereby require an assessment of the risk to health to be carried out.

2

If a risk does exist, control measures such as mechanical extraction systems and adequate natural air ventilation can prevent high concentrations of fumes forming to create a hazard, particularly in confined areas.

3

The HSE publication EH40 'Occupational exposure limits' lists a level of exposure for each type of fume or pollutant. This represents the maximum limit at which it is considered safe for work to take place.

4

EH 40/2005 has been supplemented by a table on HSE's website, which has the up-to-date list of workplace exposure levels:www.hse.gov.uk/coshh/table1.pdf

5

Every reasonably practicable measure should be taken to reduce any exposure as far below the limit given as is possible.

6

If the fume type is listed in EH40, or is otherwise a hazard to anyone's health, the provisions of the COSHH Regulations will apply. Therefore, an assessment of the risk and the provision of any necessary precautions must be made.

7

Some of the more common causes of fumes are listed below and discussed under subsequent headings:

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(a)

welding or flame cutting

(b)

lead burning (both cutting and melting)

(c)

cable burning (this practice must not be carried out on site)

(d)

the use of solvents, paints, adhesives and soon

(e)

internal combustion engines.

1.2.9.15 Welding 1

During welding and flame cutting, toxic fume hazards can arise from: (a)

nitrogen oxide gases

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ozone

(c)

phosgene gas

(d)

carbon monoxide gas.

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These are mainly caused by the very high temperatures and the presence of volatile substances, sometimes as contaminants, but often as shielding agents or flux.

3

The inhalation during welding of freshly formed metal oxides (such as zinc, cadmium, chrome, nickel, copper and mercury) may lead to an acute 'flu-like' illness termed 'metal fume fever'.

4

The fever is most commonly caused by fumes created while working with galvanised or zinccoated metals, especially in confined spaces.

5

Fumes arising from the cutting and welding of cadmium are especially dangerous, even in the open air. Prolonged or recurrent exposure may result in cadmium poisoning.

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Precautionary measures

A risk assessment, including a COSHH assessment, as appropriate.

7

The use of extraction systems and fume hoods to remove fumes from the breathing zone.

8

The use of respiratory equipment, particularly in confined spaces where high concentrations of fumes can be anticipated.

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1.2.9.16 Lead burning

Lead burning is the process whereby lead is heated to its molten state so that it can be poured into joints, or flame cut to shape, or flame heated so that it can be bent and formed into various shapes.

2

This process is employed extensively in sheet lead work by workers in the plumbing trades, in the formation of roof drainage, guttering, chimney flashings and so on.

3

This will mean that the operatives will need to be under health surveillance.

4

The creation of fumes by the heating of lead exposes operatives to risk. The following safety points should be observed:

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(a)

the use of local exhaust ventilation, or other means, to evacuate fumes from the immediate working area where reasonably practicable

(b)

the use of respiratory equipment of an approved type in the appropriate cases

(c)

the provision of protective clothing and storage for that clothing, along with adequate washing facilities.

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Wear respirator

Quite simply this is not an acceptable practice at anywhere other than a specialised processing facility. This method of recovering metal from cables, by burning off the insulation, often results in the creation of fumes which can be very toxic.

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1.2.9.17 Cable burning

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Chlorinated solvents, paints, adhesives and thinners all require precautions to be taken during their use. If they are hazardous to health, they must be handled and used in accordance with these Regulations.

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1.2.9.18 Solvents

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Avoid breathing the vapour

Most solvents are safe when used correctly but, in common with other compounds of hydrocarbons, the inhalation of a high concentration of vapour will cause drowsiness, headaches and giddiness. Severe exposure may lead to unconsciousness or even prove fatal. Extraction or exhaust ventilation may be needed or, where this is not available, respiratory protective equipment must be used.

3

Long term exposure to solvents may affect the central nervous system. Other chemicals may also have adverse effects. An example is isocyanate, which is a component of expanding foams contained in aerosol tins.

4

Some of the vapours are considerably heavier than air and may collect at low levels, particularly in still conditions. This can cause displacement of the oxygen present and lead to the risk of suffocation. It can also lead to a build up of solvent fume at explosive concentrations.

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Other precautions with solvents 5

DO NOT (a)

take solvents internally or 'sniff' any solvent

(b)

smoke when using solvents

(c)

use the solvent in a place which is not well ventilated - but avoid draughts

(d)

lean over any vessel containing the solvent liquid or vapour

(e)

store solvents in buckets or other open storage vessels

(f)

enter vessels which have contained or have been cleaned with solvents, unless proper tests have been made to ensure it is safe to do so

(g)

allow solvent liquid or vapour to come into contact with naked flames or red hot

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surfaces, e.g. welding arcs. Acidic and toxic decomposition products will be formed.

1.2.9.19 Internal combustion engines The nature of the construction industry, the activities carried out and the drive to get a job finished may lead some people into taking unnecessary risks. The majority of people are aware that internal combustion engines should not be used within confined spaces unless the exhaust gases are led directly to the open air. However, when for example the concrete is too hard, or a pipe will not cut by hand and the job is late, people will often ignore such a basic safety requirement and start a petrol engine disc cutter in a cellar. It is an error which could be fatal.

2

There is a potential for excavations to be contaminated by exhaust gases which are heavier than air and could simply roll down into the excavation. On projects with forced ventilation systems such as tunnels and shafts, the additional loading on the system needs to be factored in before petrol or diesel powered equipment is used.

3

In large buildings the use of forklift trucks, and other vehicles with internal combustion engines, can cause carbon monoxide to reach unacceptable levels, if there is no system to extract exhaust pollution. Simply opening the doors may not be enough.

4

In all cases of doubt, a COSHH assessment should be made by a competent person and, where necessary, the appropriate controls introduced.

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The following points are especially important:

the identification of potentially hazardous work processes, materials and substances before work starts

(b)

the provision of information, instruction and training to employees

(c)

the strict observance of all

(d)

recommendations and procedures advised by the manufacturer

(e)

the effective supervision of employees, and the monitoring of work methods and practices

(f)

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the provision of protective clothing and equipment before any work starts the correct disposal of waste materials and containers as recommended by the manufacturers

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1.2.9.20 Precautions

(h)

cleaning, for example, by extracting dust using a vacuum cleaner, rather than stirring it up by sweeping

(i)

personal hygiene, including the cleansing of hands before consuming food, the use of barrier creams, the removal and storage of contaminated clothing during meals, and the correct laundering or disposal of contaminated clothing

(j)

to avoid, where practical, carrying out potentially hazardous work activities in confined areas to lessen the chances of dust concentrations or fumes building up.

1.2.9.21 Protective equipment 1

Given the nature of some work activities, it is not always practical to completely contain the airborne dust or fumes created. In these circumstances, if no other control measure is reasonably practicable, respiratory protective equipment (RPE) and other PPE as necessary, must be provided for each person working with, or otherwise exposed to, airborne dust or fumes.

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There are various types of respiratory protective equipment approved for use. Details of types and permissible uses are available from the manufacturers.

1.2.9.22 Respiratory protective equipment Selection Selecting the wrong type of RPE could have serious, even fatal, consequences. Selection must be carried out by a competent person. Some of the factors that will determine the appropriate type of RPE are: the hazardous nature of the substance

(b)

the airborne concentration of the substance

(c)

the period of exposure

(d)

the wearer's required field of vision

(e)

the provision for communication

(f)

the need to move in cramped or difficult working places

(g)

the prevailing weather conditions

(h)

the suitability of the protective equipment for the individual

(i)

the need for an external source of breathable air.

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Notes:

When selecting suitable respiratory protective equipment (RPE) it may be necessary to seek expert advice from manufacturers/suppliers.

2

Training in the types of, and in the use of, respiratory equipment must be given.

3

A face fit test is required for any tight fitting face piece - this will include all disposable masks, half masks and most powered masks.

4

All masks, other than disposables, require regular examination by a competent person and records to be kept.

2

The following are some types of respiratory protective equipment (RPE) that are used in the construction industry: disposable face mask respirators

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(b)

half-mask dust respirators

(c)

powered respirators

(d)

ventilated visor and ventilated helmet respirators

(e)

compressed air line breathing apparatus

(f)

self-contained breathing apparatus.

Each type of RPE is given an 'assigned protection factor' (APF), which gives the user some idea of the level of protection that the device will provide. For example, a disposable mask marked: (a)

P1

offers a protection factor of 4

(b)

P2 offers a protection factor of 10

(c)

P3 offers a protection factor of 20

The APF assumes that the user has passed a face fit test, is wearing the mask correctly, is clean shaven and there is no other interference in fit such as facial piercing.

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The APF is a simple multiplier that can be used in two ways. An example is: (a)

a particle mask with an APF of 10.

This simply means that for every 10 units of contaminant outside the mask, only one unit will get inside the mask, so the mask filters out 9 of 10 of the units.

7

If there is a time exposure limit, then a mask extends the time by the same factor - so if someone can be exposed to a concentration of a contaminate for 10 minutes without needing to wear a mask, then a mask with an APF of 10 would allow the person to be exposed for 100 minutes (10 x 10).

8

The same protection factors are used for all particle masks. This does create some surprising results such as the highest protection level on half masks and disposable masks are the same, P3 or an APF of 20, and the normal protection factor of a powered mask fitted with a P3 filter is an APF of 40.

9

If there is any doubt regarding the level of protection required, which type of respiratory protective equipment should be provided or which cartridge should be used on a respirator, advice should be sought from a competent person, or advice taken from the respiratory protective equipment manufacturers/suppliers.

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Disposable face mask respirators

These are simple face masks designed to filter out harmful dust and particles. They are lightweight, comfortable and cheap. They should only be worn by one person and for no longer than a single eight-hour shift. They should be disposed of after use.

11

In areas of high dust levels, it may be necessary to dispose of dust masks more frequently, since they may become clogged and, subsequently, breathing will become more difficult.

12

The big advantage of disposable masks is that they do not need any inspection or record keeping as they are designed to be simply thrown away. This may be a major factor in choosing them as a solution, particularly if the wearers of such masks are normally out on different sites.

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Nuisance dust masks It should be noted that nuisance dust masks are not classed as personal protective equipment or respiratory protective equipment. They do not meet any current standards o legal requirements, and are dangerous in the respect that they give the uninformed user a false impression that they are providing a level of protection. The filter size used in their construction is so large that any particles that they manage to keep out would have been safely dealt with by the body's own defence mechanisms.

14

They typically come in two forms which are either a metal plate that holds a piece of gauze over the nose and mouth or a lightweight cup-shaped filter, again fitting over the nose and mouth, and looking like a disposable dust respirator.

15

Nuisance dust masks are often identifiable by only having one strap and the device is not marked with a protection factor (e.g. P1, P2 or P3). They should not be confused with approved disposable dust masks which will bear the appropriate EN number and a protection factor.

16

Nuisance dust masks should not be issued or used in any circumstances where these Regulations (COSHH) apply or may apply.

17

People who work with harmful dusts should always be provided with, and use, the correct type of CE-marked dust mask or respirator to ensure proper and effective protection.

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Half-mask dust respirator 18

This is one of the most common types of respirator used. It consists of a face mask which covers the nose and mouth of the wearer, and a suitable filter through which air is drawn by breathing.

19

The main advantages of this type of respirator are its low cost, easy maintenance, and the fact that it provides the wearer with freedom of movement.

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Half masks

The filtering canisters or cartridges used in these respirators may be round, oval or triangular, and are often colour-coded to indicate the type of contaminant they give protection against. If a 'use by' date or shelf life is specified, it must be adhered to.

21

High efficiency dust respirators provide protection by drawing air in through the filter system by inhalation.

22

The advantage that this type of mask offers over a disposable mask is that it is usually possible to fit filter cartridges of different types, for example, changing from a dust filter to a fume filter.

23

The disadvantage is that as well as face fit testing, the mask needs some form of identification and regular inspection by a competent person, who then records the detail of the inspection. This exercise can be logistically challenging.

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Powered respirators 24

A powered respirator has a filtered air supply provided to the wearer by a small, batteryoperated pump and filter unit which will deliver air continuously for approximately seven hours. The air pressure inside the mask facepiece is slightly higher than normal air pressure, and therefore filtered air leaks out rather than letting potentially contaminated air enter.

25

These respirators are most suitable for specialised applications, as they are relatively comfortable, and they can be worn where long periods of exposure are involved. The users must be face fit tested and the fit test method must be the so called 'quantitive test', which usually involves the use of a computer and test equipment called a portacount.

26

Batteries must be changed or recharged and filters cleaned or replaced at scheduled intervals to maintain peak efficiency. Ventilated visor and ventilated helmet respirators

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In this type of equipment, a small axial fan housed in the back of the helmet draws in dustladen air through a series of filters situated in the crown of the helmet. Filtered air is then passed downwards over the user's face, maintaining a positive pressure in the region of the nose and mouth. The unit is powered by a rechargeable battery pack worn on a belt.

28

This type of respirator is comfortable and combines protection against dust with the protection afforded by a safety helmet (manufactured to BS EN 397) and face and eye protection (to BS EN 166). Advice should be taken from the manufacturer with regard to the substances the mask will protect against. They are quite comfortable to wear. Tunnelers will be familiar with a version that includes hearing protection, lamp and hard hat as an all-in-one headpiece.

29

Efficient maintenance and cleansing procedures are essential. If the flow of air is reduced by clogged filters or low battery power, unfiltered air can be drawn in around the side of the facepiece.

30

This type of mask does not require a face fit test as it does not seal tightly on the wearers skin. It is the only type of commonly used mask that someone with a full beard can wear.

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Compressed air line breathing apparatus With this equipment, air is supplied to the user from a compressed air supply, via a hose to the face mask or hood. The correct air pressure, temperature and humidity must be maintained.

32

The air supplied must be of breathable quality, thus the selection, siting and maintenance of the compressor and filtration of the air supply is vitally important.

33

The presence of an air hose can, on some occasions, restrict the user's movements.

34

As with all types of breathing equipment, operators should be properly and adequately trained and, unless experienced in the type of work to be carried out, should be properly supervised.

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Self-contained breathing apparatus 35

In a set of self-contained breathing apparatus, air is usually supplied from compressed air cylinders carried on the worker's back and is fed to a full face mask via a regulator. As with the air line apparatus, operators must be properly and adequately trained and, unless experienced in the type of work to be carried out, must be properly supervised.

36

A limitation is that the typical duration of a compressed air cylinder is between 20 minutes and two hours. The equipment should therefore only be selected by competent persons with a full knowledge of their use.

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1.2.9.23 Dust sampling Sampling is usually carried out by a specialist using metered pumps with membrane filters. The dust collected is weighed in relation to the amount of air sampled. Dust samples can also be examined for type.

2

There are also some direct-reading dust sampling monitors available. However, there is some doubt as to the accuracy of these instruments. They are very useful for a long-term project where they can be calibrated regularly by comparing their readings against samples taken from membrane filters.

3

They are not recommended as the sole means of measuring a personal exposure to dust. It is also important to be aware that there are a number of different laboratory techniques required for analysis, for example, measuring exposure to silica normally requires X-ray diffraction.

4

Use of Tyndall Beam to identify dust clouds

5

The Tyndall Beam is a useful way to determine whether a problem exists before investigating further. It uses the common phenomenon of dust being highlighted in a shaft of light.

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1.2.9.24 Training and supervision 1

New employees should receive full instruction before starting work and should be familiarised with the following: (a)

the health risks associated with dust and the preventative measures in operation, as identified by the risk assessment

(b)

the correct use and cleaning of protective clothing and equipment

(c)

the reasons for air sampling

(d)

their duties in respect of the correct use of equipment and of safe systems of work in operation

(e)

the procedures for reporting defective or inadequate equipment.

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Construction site Safety 1.2.9 Appendix 1 Control of fumes Safety checklist An assessment must be carried out.

2

All hazardous processes and operations have been identified.

3

All personnel have been fully instructed in the types of hazard likely to be encountered.

4

There is adequate supervision of all work operations.

5

All personnel are competent to carry out the work operations.

6

Correct and adequate protective clothing is provided and used.

7

Respiratory protective equipment is provided and used, as necessary.

8

Face fit testing and records for the RPE are available.

9

Exhaust ventilation or extraction equipment is used, as required.

10

The correct type of eye protection is provided and used, as necessary.

11

Safe working methods are being adhered to.

12

No one under 16 years is employed (lead burning).

13

Chlorinated solvents, paints, adhesives, and so on are: stored safely

(b)

used safely.

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Personnel have been made aware of the hazards that exist when working with chlorinated solvents, paints, adhesives, and so on.

15

Engine exhaust gases are led directly out of confined spaces.

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Safety checklist

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There is adequate supervision of all work operations.

17

Materials, substances and associated hazards have been properly identified.

18

Manufacturers' or suppliers' instructions are available and observed.

19

Power tools are fitted with a dust extraction and collection facility.

20

Local exhaust ventilation is fitted to workshop machinery.

21

The correct protective equipment is supplied and clothing provided.

22

Operatives have been instructed in the use of materials and are aware of the hazards associated with those materials.

23

There is provision for the ongoing training of employees.

24

There is provision for, and operation of, safe systems of work.

25

There is adequate provision of washing facilities, and facilities for storing overalls, and other work wear during meal breaks.

26

Correct procedures for the storage, identification and disposal of waste materials or substances are followed.

27

Adequate arrangements have been made for air sampling, as necessary.

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Construction Site Safety 1.2.10 Control of Noise 1.2.10.1 Key points Contractors and employees have duties under these Regulations.

2

Noise experienced at work, in the home and social environments can cause permanent damage to hearing.

3

There are often early signs that the hearing is being damaged; these should not be ignored.

4

Contractors should seek to control noise by other, equally or more effective, ways before resorting to personal protective equipment.

5

Effective pre-planning of site activities and the active management of noise during the construction process can significantly reduce noise exposure on site.

6

In addition to hearing damage, excessive noise can have other health and safety implications, such as not being able to hear alarms or shouted warnings.

7

Establishing the noise levels on site might not necessarily involve arranging for noise measurements to be taken.

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Note:

Section 1, Part 15.2.3 of the QCS covers noise control.

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1.2.10.2 Introduction

High levels of noise on construction sites often come from machinery used for demolition, excavation or piling, from compressors and concrete mixers, etc. Other operations, such as hammering, riveting and the use of cartridge-operated fixing tools, may also be the source of excessive noise.

2

The degree of nuisance or damage caused by noise is related to the nature of the noise generated as well as its loudness. Intermittent noise is often more disruptive than a continuous noise and high-pitched sounds are more disturbing than low frequency ones. Exposure to high levels of noise can cause permanent damage to hearing in the form of partial or total deafness.

3

Contractors have a duty to control noise and protect their workers and other persons from its effects. Noise is also a source of annoyance and disruption, and may directly or indirectly lead to an increase in the risk of accidents. Every reasonably practicable step should be taken to control it.

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1.2.10.3 The Management of Health and Safety at Work 1

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2

When hazards are identified, it is then the Contractor's duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising from the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

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Employees, in turn, have legal duties under these Regulations to: (a)

tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other persons who may be affected by their work activities

(b)

use all machinery and equipment in accordance with any training provided.

5

These Regulations require that, additionally, the Contractor provides employees with adequate information, instruction, training and supervision to be able to carry out any work safely and without risks to their health.

6

Contractors must assess the risks to employees' health arising from noise and put effective control measures in place.

1.2.10.4 Control of Noise at Work

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These Regulations: place duties on Contractors and employees

(b)

allow personal exposure to noise to be measured over a weekly, rather than an 8hour, period in situations where employees are exposed to widely varying noise levels

(c)

give employees the right to hearing checks where a noise assessment indicates their hearing could be at risk.

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Action and limit values

These Regulations specify the following three levels of exposure to noise, each of which requires that certain actions be taken:

3

Lower exposure action value. This is reached when a daily or weekly personal exposure reaches 80 dB(A) or a peak sound pressure of 135 dB(C) occurs.

4

Upper exposure action value. This is reached when a daily or weekly personal exposure reaches 85 dB(A) or a peak sound pressure of 137 dB(C) occurs.

5

Exposure limit value. This is the maximum level of noise to which anyone at work may be exposed. It is set at 87 dB(A) at the ear, measured on a daily or weekly basis as appropriate or when a peak sound pressure of 140 dB(C) occurs.

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Contractor's duties 6

These Regulations place a duty on Contractors with respect to the health and safety of employees, the Contractor is, so far as is reasonably practicable, also under a similar duty to anyone else at work who may be affected by the noise created by the Contractor's work activities

7

When applying the 'exposure limit value', Contractors may take account of any hearing protection worn; it is the level of noise actually entering the ear. Therefore, the performance characteristics of any hearing protection worn can be taken into account when assessing the noise exposure of individuals. Similarly, it must be taken into account when decisions are taken on the purchase of personal hearing protectors.

8

If employees are likely to be exposed to noise at or above the lower exposure action value, the Contractor must: (a)

carry out a suitable and sufficient assessment of the risks to employees and ensure that it identifies the measures necessary to adequately control the level of noise at work. When carrying out the risk assessment the Contractor must assess noise exposure by:

QCS 2014

observing work practices

(ii)

referring to information on the probable level of noise issued by tool and equipment manufacturers

(iii)

only if necessary, arranging for noise levels to be measured.

If employees are likely to be exposed at or above the 'upper exposure action value' or the 'exposure limit value', the risk assessment must also include consideration of: the level and type of noise and its duration, including any exposure to 'peak sound pressure'

(b)

the effects that the noise might have on the health of employees exposed to it

(c)

so far as is practicable, the effects on the health of employees resulting from an interaction between exposure to noise and any ototoxic substances (mainly commonuse solvents) that are in use or between noise and vibration

(d)

the possibility of warning alarms or other audible systems not being heard

(e)

information provided by the manufacturers of equipment that generates the noise

(f)

the possibility of using alternative, less noisy equipment

(g)

exposure of employees to noise when not actually working, such as in rest areas and canteens

(h)

the results of previous health surveillance and published information

(i)

the availability of suitable personal hearing protectors, taking into account their performance.

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The Contractor must regularly review the risk assessment and immediately if: there is reason to believe that it is no longer valid

(b)

there has been a significant change in the work to which the assessment applies and implement changes to the risk assessment as identified by the review process.

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(i)

The Contractor must inform at-risk employees of the findings of the risk assessment and record: (a)

the significant findings of the risk assessment as soon as is practicable after it has been made or changed the control measures that have been put in place to eliminate or reduce the noise, including the provision of hearing protection and employee training.

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Records may be kept in any form so long as they are easily retrievable and can be printed.

13

The Contractor must also:

14

(a)

generally eliminate at source the risk of hearing damage or reduce it to the lowest level that is reasonably practicable, irrespective of noise levels

(b)

where exposure is likely to be at or above the upper exposure action value, reduce the noise, as far as is reasonably practicable, by implementing organisational and technical measures other than by providing personal hearing protectors.

Contractors must consider the following: (a)

alternative, less noisy methods of carrying out the work

(b)

alternative, less noisy tools for carrying out the work

(c)

the layout of the workplace, including any rest facilities

(d)

providing employees with adequate information and training so that they can minimise

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their exposure to noise the reduction of noise by technical means

(f)

effective maintenance programmes for equipment that can generate noise, the workplace itself and workplace systems

(g)

limiting the duration and intensity of exposure to noise

(h)

adjusting work schedules and ensuring adequate rest periods.

The Contractor must ensure that employees are not exposed to noise above the exposure limit value, or if they are, immediately: (a)

reduce exposure to below the exposure limit value

(b)

identify the reasons for the exposure limit value being exceeded

(c)

take appropriate actions to prevent it occurring again.

Contractors must:

ensure that the level of noise in rest facilities that are under their control is reduced to a suitable level for their purpose

(b)

adjust and adapt any measures taken to prevent exposure to noise to take account of any person(s) whose health is likely to be particularly at risk from exposure to noise

(c)

inform employees of the measures taken to eliminate or control the level of noise in the workplace.

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(e)

Where employees are exposed to noise at or above the lower exposure action value but below the upper exposure action value, the Contractor must make suitable personal hearing protectors available to employees who request them.

18

Where employees are exposed to noise at or above the upper exposure action value, the Contractor must:

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designate the affected part of the workplace as a 'Hearing Protection Zone'

(b)

identify the extent of the area by signs indicating that hearing protectors are to be worn

(c)

restrict access to the area where practicable and it is justified by the level of risk

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ensure so far as is reasonably practicable that all employees entering the hearing protection zone wear personal hearing protection.

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Hearing protectors must be selected, so as to eliminate the risk to hearing or reduce it to as low a level as is reasonably practicable

20

Contractors must: (a)

ensure so far as is practicable that anything provided to comply with these Regulations, except personal hearing protectors, is fully and properly used

(b)

ensure that anything provided to comply with these Regulations is maintained in good working order and in a good state of repair

21

If the risk assessment indicates that there is a risk to the health of employees exposed to noise, the Contractor must ensure that those employees are placed under suitable health surveillance, including providing them with hearing tests.

22

The Contractor must: (a)

ensure that a record is kept and maintained for each employee who undergoes health surveillance and that records are readily available in a suitable format

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(b)

Where, as a result of health surveillance, an employee is found to have identifiable hearing damage, the Contractor must ensure that the employee is examined by a doctor and, if necessary, a specialist. Where the hearing damage is found to be as a result of exposure to noise at work, the Contractor must: ensure that the employee is informed by a suitably qualified person

(b)

review the risk assessment

(c)

review existing control measures, taking into account any advice given by a doctor, occupational health professional or administrative authority

(d)

consider reassigning the employee to other work where there is no risk of further exposure, taking into account any advice given as above

(e)

continue with the health surveillance of affected employees.

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Where employees are exposed to noise at or above the lower exposure action value, the Contractor must provide the employees with suitable and sufficient information, instruction and training, which must include: the nature of the risks arising from exposure to noise

(b)

the control measures taken to eliminate or reduce exposure

(c)

the exposure limit value and the lower and upper exposure action values

(d)

the significant findings of the risk assessment

(e)

the availability and provision of personal hearing protectors and how to use them correctly

(f)

why and how to detect and report signs of hearing damage

(g)

the employees' entitlement to health surveillance

(h)

how to work safely to minimise noise exposure and thereby avoid hearing damage

(i)

the collective results of any health surveillance carried out, anonymised so as not to reveal the personal health record of any individual.

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The information, instruction and training provided as above must be updated by the Contractor to take account of any significant changes of the type of work carried out or method of working.

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allow employees to see their health surveillance records on being given reasonable notice

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Employees' duties 26

Employees must: (a)

make full and proper use of personal hearing protectors if the noise exposure exceeds the upper exposure action value

(b)

make full and proper use of other control measures provided by the Contractor

(c)

report any defects in the personal hearing protectors or other control measures to their Contractor

(d)

make themselves available for health surveillance checks (during working hours) as required by the Contractor, the health surveillance being at the Contractor's expense.

1.2.10.5 The nature of noise 1

Sound is the transmission of air vibrations at different frequencies. Noise is sometimes defined as unwanted sound. The ear is a pressure-sensitive mechanism, detecting small

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changes of air pressure over a wide range of frequencies of 20-20,000 cycles per second. The unit of frequency is the hertz (Hz). Those with impaired hearing due to age or other forms of hearing loss are less likely to be able to hear the higher frequency range. Audiometry is the technique used to determine the capacity of the ear to detect sounds of varying loudness over a range of frequencies. It can be used to measure an individual's hearing capacity against a recognised standard. Successive audiometric checks can confirm whether or not a person is suffering from progressive hearing loss.

3

When judging the level of noise, the 'rules of thumb' are that if you have to raise your voice to make yourself understood at 2 metres from the other person, the background noise is around 85 dB(A). If the distance is only 1 metre, the noise is around 90 dB(A).

4

A peak sound pressure of 137 dB(C) will be produced by many impact tools such as cartridge-operated tools.

5

Two "types' of noise may damage the hearing of the people who are exposed to it:

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2

Continual or periodic noise, which even if varying over the course of time, can be measured and averaged out over an eight-hour (or in some circumstances a weekly) reference period. This is known as the 'daily (or weekly) personal noise exposure' as referred to in these Regulations. This is the common everyday noise that is experienced on many construction sites.

(b)

Sudden, short bursts of loud impulsive noise such as experienced during the driving of piles, the use of explosives or the use of some hand tools. The references in these Regulations to 'peak sound pressure' are to this type of noise.

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1.2.10.6 Effects of noise at work

Noise levels may fluctuate widely or be relatively steady. A reasonably steady sound level is where the level fluctuates through a total of less than 8 dB(A) on a slow response scale.

2

Exposure to noise can have the following consequences:

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It can cause annoyance and irritation.

(b)

It may affect concentration and efficiency.

(c)

It may cause fatigue and the likelihood of accident proneness.

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It can mask out other sounds, preventing a person's ears from registering instructions and warnings.

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(e)

It can result in temporary hearing loss.

(f)

Regular exposure to loud noise can cause damage to the ear and permanent loss of hearing.

There is also growing evidence that continued exposure to noise has consequential effects on some other illnesses. Hearing loss

4

Hearing loss can be temporary or permanent. Temporary deafness is often experienced after leaving a noisy place. It is often accompanied by a ringing in the ears. Although hearing usually recovers within a few hours, this symptom should not be ignored. It should be taken as a sign that further or continued exposure to noise is likely to result in permanent damage. Permanent hearing damage can also be caused immediately by sudden and loud noises, for example from explosives or cartridge-operated tools.

5

Hearing loss due to prolonged exposure to noise is usually gradual. It may only be when

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damage caused by exposure to noise over the years combines with normal hearing loss due to ageing that people realise how deaf they have become. 6

Prolonged exposure to noise can also cause tinnitus, which can be described as a permanent ringing, whistling or buzzing in the ears. This distressing condition can lead to disturbed sleep which, in turn, can lead to fatigue even before an employee arrives at work. Other adverse effects of noise

7

At work, noise can also be a safety hazard, interfering with communication, the understanding of instructions and, most serious of all, making warnings harder to hear. Noise can also cause stress.

1.2.10.7 Establishing noise levels

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Unit of measurement

The unit of measurement for sound levels (noise) is called a decibel (dB). This scale is logarithmic and means that 90 dB is ten times the intensity of 80 dB and one hundred times the intensity of 70 dB.

2

An increase of 3 dB doubles the energy in the sound. This means that, for example, 87 dB is actually twice as damaging as 84 dB, even though the 3 dB difference in sound level is difficult to perceive.

3

Sound level meters, used for measuring noise levels, have standard 'filters' built into them that attenuate or emphasise signals at different frequencies in order to simulate how the sound affects the ear. This is known as 'frequency weighting'.

4

An instrument with a frequency weighting known as an 'A' weighted scale is commonly used on construction sites to measure noise from the working environment. Readings are expressed as dB(A).

5

Sudden impact noises, hammer blows, etc. are measured in terms of maximum pressure. In this case measurements are 'C' weighted and therefore expressed as dB(C).

6

Risk assessments should be based on measurements of the 'Leq', which is an average of the level of noise for the duration of the measurement.

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Risk assessments 7

If any employee is likely to be exposed to noise at or above the lower exposure action value, the Contractor must carry out a risk assessment which may or may not result in the need for a competent person to measure the actual level of noise exposure.

8

Any new tool or equipment that generates a potentially harmful level of noise should state the actual level of noise generated, either on the tool itself or in the accompanying documents. This can be useful in identifying potentially problematic tools, but it is important to remember that the actual noise experienced by the operator depends on many factors, such as the acoustics of the working environment, tool configuration and material being worked. Survey of noise levels

9

If it is necessary to resort to the measurement of noise, someone who is competent in evaluating the type of workplace, the use of the equipment and the interpretation of the results must be engaged. They must be able to draw valid conclusions from the information obtained and advise management on the actions needed to comply with the requirements of

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legislation.

(a)

identify workers who may be at risk of hearing damage to enable an action plan to be prepared to control the noise exposure

(b)

determine the daily personal noise exposure (LEP,d) of workers (including times when not actually working (for example, rest areas) and from non-occupational sources such as personal entertainment systems)

(c)

identify additional information to comply with these Regulations, for example, whether noise control measures or hearing protection are needed and, if so, where and what type.

The Contractor must: keep a record of the noise assessments and the employees exposed to the noise

(b)

regularly review those assessments. This should be done biannually or whenever it is considered that the assessment is no longer valid, for example, whenever there is new equipment or a change to the process that may alter noise levels

(c)

use the assessment to develop an action plan for introducing noise control measures

(d)

deal with the immediate risk by providing personal hearing protectors (this should only be until other controls have been investigated and implemented)

(e)

identify what steps are reasonably practicable to reduce the noise exposure of employees by engineering or other organisational means

(f)

establish priorities for action and consider what changes may need to be phased in over the course of time.

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The aim of the noise assessment is to:

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Ideally, one person, with sufficient authority, will be given the responsibility for ensuring that these Regulations are complied with and for co-ordinating and monitoring the noise reduction programme where necessary.

13

Nomograms (see Appendix 4) can be used to establish the equivalent continuous sound level for an eight hour period or daily personal noise exposure (LEp,d)

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Typical sound intensities

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1.2.10.8 Avoiding exposure to noise

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Attention should be given at the planning stage to developing a noise control strategy that considers the following factors: The design of the project, and of the processes and equipment which will be involved.

(b)

The phasing of differing operations, especially if a number of contractors are working on site.

(c)

The location of the site; or sites if the project involves more than one location.

(d)

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The noise levels that are likely to be produced by the work being carried out. The layout of the site, including the siting of access points, batching plants, etc.

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Planning against excess noise levels

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(f)

The hours of working which are planned.

(g)

The provisions available for controlling noise on site.

(h)

The possibility of disturbance to nearby residents and properties. (If this is likely, the situation and measures to be taken to reduce noise should be explained to persons likely to be affected.)

Failure to plan the control of noise may lead to delay and increased cost later. Where appropriate, noise levels must be a consideration for designers under CDM. Reference BS 5228 Noise and vibration control on construction and open sites Managing noise levels during construction

3

Exposure to noise can be eliminated or reduced by: (a)

controlling noise at source

(b)

employing engineering controls where possible

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(c)

using a purchasing/hire policy for plant, equipment and tools that takes noise into account

(d)

introducing alternative methods and processes that eliminate or reduce noise levels

(e)

giving consideration to the careful siting of noisy plant, and equipment

(f)

where practical, storing bulk materials to form an acoustic screen

(g)

carrying out job rotation for employees to reduce exposure to noise

(h)

providing rest rooms or acoustic refuges for staff during breaks from work

(i)

rearranging work locations for staff, if possible, away from noisy equipment

(j)

as a last resort, providing personal hearing protectors.

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Controlling the noise at its source can be achieved by a variety of means, by: the design and manufacture of the equipment.

(b)

the use of acoustic covers and exhaust silencers for equipment

(c)

the use of alternative, less noisy equipment or methods of working

(d)

enclosing noisy equipment within temporary structures

(e)

regular inspection and maintenance of the equipment being used

(f)

fitting noise-absorbent mountings to reduce the transmission of noise through adjacent structures.

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Measures that can be taken include ensuring that all equipment which has the potential to create excessive noise: is kept well maintained

(b)

is kept in good order, including ensuring that there are no loose panels or casing and that exhaust mufflers are in good condition is not left running when it is not actually in use.

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Engineering controls

Siting or location 6

7

Effective siting or location includes: (a)

Removing the source of the noise to a distance whenever possible (see Appendix 2).

(b)

Orientating plant to direct the noise away from the work area.

(c)

Placing site buildings, stores, etc. between the noise source and noise sensitive areas.

(d)

Screening the noise source with a barrier, wall, acoustic screen, spoil heap, or by locating the source behind partly completed buildings.

The effectiveness of a noise barrier will depend on its dimensions, its position relative to the source and the listener, and the material used in the construction of the barrier. Care must be taken to ensure that barriers do not, by reflecting sound, transfer the noise nuisance from one sensitive area to another and so create a health problem for someone else.

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Effect on working hours 8

The effect on maximum working times of exposures to equivalent continuous sound levels without any hearing protection are listed in Appendix 1 of this section.

1.2.10.9 Personal hearing protectors All hearing protectors produced or imported by reputable companies are manufactured to British or International Standards. As with all PPE for use at work, ear protectors should be selected by a competent person who can ensure, in discussion with the supplier, that it possesses the necessary performance characteristics. Most leading manufacturers and suppliers will offer their own advisory service.

2

Competence in the selection of this type of PPE is particularly important as ear protectors that give good protection against noise at a high frequency may not offer very much protection against low frequency noise, and vice versa.

3

All reasonably practicable methods must be used to reduce noise levels, but where these remain at or above the upper exposure action value, after control measures have been implemented, ear protectors must be made available and worn. Ear protectors are not a substitute for other methods of noise control, they are an absolute last resort.

4

Employees may initially be reluctant to wear ear protection and those who are at risk must be made aware of the potential for hearing loss that can be caused by exposure to excessive noise levels.

Mandatory warning sign: 'Wear ear protectors'

Colour: white symbol on circular blue background

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Other considerations 5

Personal hearing protectors must be provided on an individual basis.

6

A competent person must be responsible for any training that may be necessary in the correct use of personal hearing protectors.

7

Personal hearing protectors should normally be provided as an interim measure while more effective and permanent methods of control are sought.

8

Employees must be trained in the use, care and storage of ear protectors.

9

Ear protectors must be suited to the user and suitable for the type of noise.

10

They must provide an effective seal.

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11

They should be stored in a clean place when not in use, unless disposable.

12

They should be inspected regularly for deterioration or damage and replaced when necessary, unless disposable.

13

Personal hearing protectors should not 'over protect' whereby users can become isolated from their work environment and unable to hear warnings.

14

Note: A check should be made to ensure that hazard warning signals are audible to individuals wearing ear protectors, and the volume, tone, or method of signalling changed if necessary.

1.2.10.10

Types of personal hearing protectors

The two basic types of protector are ear plugs and ear defenders.

2

Disposable ear plugs: These are made of very fine mineral fibre or foam, sometimes ready shaped. They must be inserted correctly and, if taken out, should not be reused. They should only be handled with clean hands.

3

Reusable ear plugs: These are made of rubber or plastic, and need regular, careful washing. The initial supply and fitting should be carried out by trained persons. Different sizes may be required for each ear and must be a good fit. They must be fitted with clean hands as any contamination by dirt, grease or swarf may cause ear irritation. Ear plugs are therefore unsuitable on site for intermittent use, such as can occur when operating a breaker.

4

Ear defenders (or muffs): These completely cover the ear and are sealed to the head with a foam or liquid-filled seal. Badly designed or badly produced defenders may give little or no protection against noise. Other points are as follows: pressure from the seal may cause wearers to complain of tightness, but loose defenders lose most of their protective capability and are ineffective

(b)

damage and deterioration to seals also results in ineffectiveness and loss of protection

(c)

in fitting, account needs to be taken of people with different sized or shaped heads or ears, hair styles and spectacles

(d)

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defenders fitted to safety helmets may cause problems by not fitting tightly to the ear, or by moving as the helmet moves

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(e)

facial hair and the arms of spectacles may interfere with the seal on ear defenders

(f)

defenders must be chosen to deal with a particular noise problem; ones that offer protection against low frequency sound may be ineffective at high frequency, and vice versa.

5

Ear defenders which incorporate a sound enhancement system are available. When noise levels are low, sound detected by a microphone is replayed to the wearer enabling them to communicate normally. When noise levels are high, the sound replay system is automatically cut, such that the defenders act as regular ear protectors. Such products are particularly suitable for those exposed to unpredictable short bursts of noise.

6

Ear protectors are only effective while they are being used. If protectors are worn for only half the shift, only some 10% protection is gained; if worn for 7% out of 8 hours, the protection factor is still only 75%.

7

Contractors providing hearing protectors that perform 4 dB better than the required minimum, in order to take into account 'real world' factors such as poor fitting.

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Construction Site Safety 1.2.10. Appendix 1 The effect on maximum working times due to exposure without protection

Maximum exposure in one working day if 80 dB(A) (LEp,d) is not exceeded

80

8 hours

83

4 hours

86

2 hours

89

1 hour

92

30 minutes

95

15 minutes

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Average noise level dB(A)

98

7.5 minutes

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3.75 minutes

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Increase of protection gained in relation to time if ear protectors are worn

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Construction Site Safety 1.2.10. Appendix 2

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How sound levels vary with distance from source

Notes: 1

This assumes that the sound at the measurement point only comes directly from the source and there are no reflections from the ground or any other objects

2

This is the noise level at the ear and not at the source

3

The graphs on pages 14 and 15 of this module are based on the International Organisation for Standardisation standard where an increase of 3 dB(A) is regarded as doubling the noise level or halving the exposure time.

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Construction Site Safety B10. Appendix 3 Calculating personal noise exposure Nomogram for calculation of equivalent continuous sound level for an eight hour period, so giving the daily personal noise exposure.

2

For each exposure, connect sound level dB(A) with exposure duration t and read fractional exposure f on centre scale.

3

Add together values of f received during one day to obtain total value of f,

4

Read equivalent continuous sound level opposite total value of f, by drawing a line through f9 from the time scale t = 8 to read LEP,d on the L scale.

5

The noise exposure figures on the nomogram are illustrative only and do not represent a legal or safe level of exposure to noise.

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Construction Site Safety 1.2.10 Appendix 4 Some typical sound levels of construction and piling equipment (Levels given are average at source) Construction equipment

95

Hand tools - electric

100 101 102

Hand tools - air Forklifts Hammer drill

103

Dumpers

104

Concrete mixer

105

Hand tools - petrol

106 107 108 109

Tower cranes Circular bench saw Trucks Excavators

110

Crawler cranes

111

Heavy lorries

112 113

Ready mix Hoists diesel

114

Loading shovel

115 116

Rock drill Batching plant

117 118

Generators Loaders

119

Cranes - lorry mounted

120

Compressors - compactors

128 136 138

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6 tonne drop hammer (cased piles)

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Bulldozers - graders

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Piling equipment

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Sound level dB(A)

Trench hammer (sheet piles) Rotary bored piles Screen drop hammer (sheet piles) Impact boring (driving case method) 2 tonne drop hammer (pre-cast concrete piles) Vibration system (sheet piles) Resonant system 'h' section Single acting air hammer (pre-cast concrete) Diesel hammer (sheet piles) Double acting air hammer (sheet piles)

These sound levels are for guidance only. Information should be sought from the manufacturer or the plant hire company regarding machines on site. Noise levels emitted from the machines will be affected by the competence of the operator and the quality of maintenance. For accurate measurement of site noise, a survey is necessary.

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Construction Site Safety 1.2.10 Appendix 5

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Summary of legal requirements

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Contractors' duties

Exposure below the Exposure at or Exposure at or Exposure at or lower exposure above the lower above the upper above the action value of 80 exposure action exposure action exposure limit values of 80 dB(A) values of 85dB(A) values of 87dB(A) dB(A) or peak sound or peak sound or peak sound pressure of pressure of pressure of 140 dB 135dB(C) 137dB(C)

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Assessment of noise exposure







Record of significant findings and control measures put in place



















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Risk assessment to be carried out and reviewed as necessary

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Risk assessment to include extra considerations in higher risk situations General duty to reduce risk Risk of hearing damage to be eliminated or reduced to the lowest level reasonably practicable





Implement organisational and technical control measures, excluding issue of personal hearing protection



Reduce exposure below exposure limit value (ELV), if ELV breached, identify why and modify organisational and technical measures Ensure noise exposure in rest facilities is kept to acceptable level







Adapt control measures as necessary to take account of employee(s) who may be particularly at risk from exposure to noise







Consult with employees on protective measures taken







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Exposure below the lower exposure action value of 80dB(A)

Exposure at or Exposure at or Exposure at or above the lower above the upper above the exposure action exposure action exposure limit values of 80 values of 85 values of dB(A) or peak dB(A) or peak 87dB(A)or peak sound pressure of sound pressure of sound pressure of 135dB(C) 137 dB(C) 140 dB

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Contractors' duties (continued)

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Provision of hearing protection

Ensure that personal hearing protectors are: provided to employees who ask for them



provided to all those exposed



used by all those exposed.

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Create hearing protection zones, designated by appropriate signs and: 

restrict access if justified by the level of risk







ensure as far as is reasonably practicable that all who go into a marked hearing protection zone use hearing protection.





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Exposure below Exposure at or Exposure at or Exposure at or the lower above the lower above the upper above the exposure action exposure action exposure action exposure limit value of 80 dB(A) values of 80 values of 85 values of 87 dB(A) or peak dB(A) or peak dB(A) or peak sound pressure of sound pressure of sound pressure of 135dB(C) 137 dB(C) 140 dB

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Contractors' duties (continued)

























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all equipment provided under these Regulations, except personal hearing protectors, are fully and properly used all equipment is maintained in an efficient state and good working order.

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Maintenance and use of equipment Ensure so far as is reasonably practicable that:

the nature of the risks to hearing from noise the organisational and technical measures taken the action and limit values the significant findings of the risk assessment

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   

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Information instruction and training Provide adequate information, instruction and training and update it as necessary, on: } } } }

 how to obtain a personal hearing protector }  how to detect and report signs of hearing damage }  the entitlement to health surveillance }  the results of any collective health surveillance. } Provide information, instruction and training for anyone who has responsibilities for ensuring the Contractor's legal duties are carried out.

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Exposure below the lower exposure action value of 80dB(A)

Exposure at or above the lower exposure action values of 80dB(A) or peak sound pressure of 135dB(C)

Exposure at or above the upper exposure action values of 85dB(A) or peak sound pressure of 137 dB(C)

Exposure at or above the exposure limit values of 87dB(A) or peak sound pressure of 140 dB









 

 













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Contractors' duties (continued)

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Health surveillance

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Provide as appropriate if the risk assessment indicates there to be } a risk to employees' health resulting from noise at work }

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Keep and maintain records of health surveillance } Enable employees access to their own health surveillance }

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Where employee found to have hearing damage: }  ensure the employee is informed by a suitably qualified person }  review the risk assessment and control measures }  consider assigning the employee to alternative (non-noisy) work }  continue with health surveillance. } Employee's duties Use of equipment Employees must:  make full and proper use of personal hearing protectors  use any other control measures provided by the Contractor 

report any defects discovered in the protective measures to the Contractor. Health surveillance Attend health surveillance procedures as required by the Contractor in working hours and at the Contractor's expense.



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Construction Site Safety 1.2.11 Protection of the Eyes 1.2.11.1 Key points Many eye injuries occur to people at work each year because eye protection is not being worn.

2

These accidents are easily preventable simply by wearing the correct type of eye protection.

3

The loss of sight, even in one eye, will have a profound effect on the sufferer.

4

Given the nature of most construction sites, in many cases protection of the eyes will be achieved by the issue and wearing of appropriate personal protective equipment (PPE).

5

In common with other types of PPE, Contractors must:

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identify the correct type of eye protection necessary;

(b)

provide it at no charge to employees who need it;

(c)

provide adequate information, instruction and training in its use;

(d)

make sure that it is worn.

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Users of eye protection must:

wear it when there is a risk of eye injury as indicated by a risk assessment;

(b)

look after it, particularly with regard to protecting the lenses or face shield;

(c)

return it to any accommodation allocated to it when not in use;

(d)

report to the Contractor any defect, such as scratched or crazed lenses, and obtain a replacement;

(e)

report to the Contractor if it is lost and seek a replacement.

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1.2.11.2 Introduction

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1

A person's eyes are very vulnerable and an accident or injury can completely change that person's way of life.

2

Analysis of the injuries to people's eyes shows that damage is caused as follows:

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(a)

75% by impact

(b)

10% by abrasion following ingress of dust or other foreign body

(c)

15% by burns or chemical contamination.

3

The majority of these injuries would have been prevented if the correct eye protection had been worn.

4

Contractors must make a provision for the protection of the eyes of employees at work.

5

The protection provided must conform to the approved specifications and includes goggles, visors, spectacles, face screens and fixed shields, either free standing or attached to machinery or plant.

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The Management of Health and Safety at Work

1.2.11.3 Personal Protective Equipment

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If a risk assessment identifies that employees may be exposed to a risk of injury to their eyes then, unless the risk can be adequately controlled by other means, the Contractor has a duty to supply eye protection and must take all reasonable steps to ensure that it is worn. Selection of all personal protective equipment should be carried out by a competent person.

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Duties of Contractors

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Eye protectors should be:

issued on a personal basis to the person at risk

(b)

maintained and readily available in sufficient numbers for persons occasionally employed.

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Eye protectors and shields Issue and availability

Eye protectors should be kept available in sufficient numbers so that any which become lost, destroyed or defective can be replaced.

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Replacement of eye protectors

All eye protectors and shields provided must comply with British or International specifications and be:

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Construction and marking

(a)

suitable for the type of work or risk involved

(b)

suitable for the user to give them minimum discomfort and ease of movement whilst working

(c)

marked to identify their type and suitability

(d)

maintained, kept clean and disinfected.

Fixed shields 5

Fixed shields provided must: (a)

conform to the relevant European Standard specification

(b)

be cleaned regularly, disinfected and properly maintained

(c)

be so constructed and kept in position as to protect the eyes.

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Duties of employees 6

It is the duty of an employee: (a)

to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or others

(b)

where there is any risk of injury to the eyes, to use the protection provided in accordance with the instructions and training given (i)

to take care of eye protectors

(ii)

to report any loss or defect to the Contractor.

1.2.11.4 Eye Protection

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Identifying the type of hazard Only when the Contractor has carried out a risk assessment to determine the hazards can the correct type of eye protector be supplied.

2

Some of the types of hazard detailed require eye protectors to have sufficiently strong lenses or shield to withstand the impact of particles or fragments striking them.

3

The effectiveness of the seal made between the eye protectors and the operator's skin is very important in affording protection against the type of hazard where irritant or corrosive materials are involved.

4

The ability to withstand high temperatures or reduce strong light and glare is a main requirement for the other types of eye protector.

5

For further information concerning specific requirements or combinations of different kinds of protection, manufacturers' literature should be consulted.

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1.2.11.5 Types of eye protector

There are several types of eye protector and it is important to select and issue the correct type to give the required protection. The types and their markings are listed in Appendix 1.

2

Examples of the types of work for which the various standards of eye protection might be used, are listed in Appendix 2.

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1.2.11.6 Eye protection safety checklist 1

Have operations requiring eye protection been identified?

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Has the work activity been assessed to determine what, if any, hazards exist?

3

Are appropriate types of eye protection available for the various work activities to be carried out?

4

Does all eye protection comply with the relevant standard?

5

Is the eye protection supplied on a persona] basis to employees?

6

Are there sufficient quantities of eye protectors available for occasional users?

7

Is the use of eye protection satisfactorily monitored?

8

Have employees been informed of work activities requiring eye protection?

9

Have employees been trained in the correct use and maintenance of eye protection?

10

Are employees aware of their

11

responsibilities with regards to the care and reporting of loss or defective eye protectors?

12

Are appropriate safety signs displayed?

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Items of equipment producing light amplification by the stimulated emission of radiation, more normally known as lasers, are widely used on construction sites, mainly for alignment and levelling in civil engineering. Most are of the helium or neon continuous wave type and emit visible light, but some lasers emit in the invisible infrared region of the electromagnetic spectrum, and these require extra caution.

2

The optical radiation produced by a laser is absorbed by the first few centimetres of the body and so the skin and eyes are the tissues most at risk of damage.

3

All lasers should comply with BS EN 60825. This standard groups laser products into five classes (with some subclasses), based on acceptable emission levels, and is intended to ensure that the manufacturer and user of laser products comply with current requirements.

4

Appendix 3 reproduces an extract of information contained in BS EN 60825.

5

The use of Class 1 and 2 products is preferred on construction sites because these represent the lowest risk of eye injury. However, even these lower power lasers can cause eye damage if they are misused, for example, staring directly into the beam or viewing the beam through any magnifying device.

6

Class 3R and 3B lasers, which may sometimes be in use, can involve hazards to both the user and other personnel. Those who maintain, operate and supervise the use of these products must be fully trained, competent and capable of implementing the necessary safety and hazard control procedures.

7

Where lower power lasers are used, the human 'blink reflex' will offer some protection. However, this should not be relied upon and is unlikely to offer any protection from higher power lasers.

8

Appendix 4 outlines the hazards arising out of the uses of the various classes of laser and control measures necessary.

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General procedures Full training and information must be given to persons using lasers.

10

There should be no unauthorised access to any laser equipment.

11

All personnel must be aware of the hazards when working with lasers, the safe working procedures and accident reporting procedures.

12

Any necessary eye protection equipment, hazard signs, barriers, etc. must be available and in use as necessary.

13

Any eye protectors used in conjunction with lasers must be suited to the wavelength of the laser in use. General purpose safety glasses offer no protection whatsoever against lasers and should not be used.

14

All hazard areas must be clearly defined with signs and barriers.

15

The laser beam should only be directed at non-reflecting surfaces. Any adjacent reflective surfaces must be covered, otherwise the beam will diverge and could affect other areas and people not directly involved in the job.

16

Extra care must be taken when working near reflective surfaces (e.g. water, dust, spray) which cannot be marked or covered.

17

Special precautions must be taken when working near roads, airfields and other public areas, where a stray beam could cause a hazard.

18

When work activities require the use of high powered lasers, the work should, when possible, be undertaken when the site is vacated (such as evenings or weekends). If this is not possible, special precautions will be necessary to ensure that unauthorised persons do not enter the work area or any designated area.

19

See Appendix 3 for specific precautions.

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In the event of an eye injury caused by a laser No medication is to be applied to the eye.

21

The eye involved should be covered with a clean, dry material.

22

Immediate medical attention should be sought.

23

A thorough ophthalmic examination should be carried out within 24 hours, with a full biophysical investigation.

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Laser safety checklist Has a risk assessment been carried out?

25

Only competent and trained people must be allowed to operate laser equipment.

26

The hazard area should be defined and clearly marked.

27

Create an 'exclusion zone' when the more powerful classes of laser are being used.

28

When work with lasers is taking place, only authorised people should be allowed in the area.

29

The correct eye protection must be in use during all laser operations.

30

There should be no danger to any other person(s) resulting from stray reflections or from any activity involving the use of lasers.

31

Where necessary, the source and direction of the laser beam should be clearly identified.

32

The laser beam should only be directed at a non-reflecting surface.

33

Any other reflective surfaces should be covered.

34

All laser equipment should comply with British Standard EN 60825.

35

Beam attenuators and any other safety devices must be in use when using Class 3R and 3B products.

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Construction Site Safety 1.2.11 Appendix 1 The standards of eye protection Hazard description

Marking BSEN 166 (1 or 2).S

Low energy impact (45 m/sec)

BSEN 166 (1 or 2).F

Medium energy impact (120 m/sec)

BSEN 166 (1 or 2).B

High energy impact (190 m/sec)

BSEN 166 (1 or 2).A

Droplets and splashes of liquid

BS EN 166 (1 or 2).3

Large dust particles

BSEN 166 (1 or 2).4

Gas and fine dust particles

BSEN 166 (1 or 2).5

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Increased robustness

BSEN 166 (1 or 2).8

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Short circuit electric arc

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Molten metal and hot solids Hard coat (resistance to fine particles)

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Non-mist (resistance to fogging)

BSEN 166 (1 or 2).K BSEN 166 (1 or 2).N BS EN 175

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Face shields (welding)

BSEN 166 (1 or 2).9

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Notes:

The 1 or 2 in the BS EN numbers refer to the optical characteristics of the PPE.

2

Eye protectors manufactured to the British and European Standard are subjected to a number of tests (including temperature, robustness and optical quality) before approval.

3

In the test of robustness, for example, general purpose goggles to EN 166.1 .S must withstand the impact of a 6 mm steel ball travelling at 12 m/sec (43.45 km/h). Impact goggles to EN 166.1.F must withstand the impact at 45 m/sec (160.93 km/h) and for EN 166.1.B they must withstand an impact at 120 m/sec (434.52 km/h).

4

Eye protection to BS EN 166 A is for specialist applications and is only available in the form of a face shield.

5

Safety goggles are marked with a combination of letters and numbers to indicate the standard of protection provided, for example:

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(a)

BS EN 166.1 .F is impact-resistant to a low energy projectile.

(b)

BS EN 166.1.B.3.4 is impact-resistant to medium energy projectiles, droplets, splashes of liquid and large dust particles.

(c)

BS EN 166.1.A.9 is impact-resistant to high energy projectiles, molten metal and hot solids.

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Construction Site Safety 1.2.11 Appendix 2 Selecting eye protection The following hazards are those most likely to be encountered in construction operations. Approved eye protection is required and must be provided for all persons engaged in any of the processes specified below.

2

The protection listed below is recommended as containing good practical value, but should be regarded as the minimum standard required.

3

Eye protection must be selected in the light of the work activity to be undertaken and the assessed level of risk. A suitable and sufficient risk assessment will identify hazards and indicate the control measures required to minimise the likelihood and severity of potential risks. Hazard

Recommended protection

Goggles Face shield

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Use of compressed air with shot or High speed flying other abrasives for blasting or cleaning fragments or particles (1, 2)

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PART I Processes in which approved eye protectors are required

Flying fragments or particles

Use of hand or power tools to strike masonry nails (4)

Flying fragments or particles

BS EN 166.B

Goggles Spectacles Face shield

BSEN 166.S

Goggles Spectacles Face shield

BSEN 166.F

Handling and use of cartridge-operated High speed flying tools (5) fragments or particles

Goggles Face shield

BS EN 166.B

Chipping of metal, chipping; knocking Flying fragments or out or cutting of cold rivets, bolts, nuts, particles lugs, pins, collars etc. using hand or power tools (6)

Goggles Spectacles Face shield

BSEN 166.F

Chipping or scuffing of paint, scale, slag, rust etc. from metal and other hard materials using hand or power tools (7)

Goggles

BS EN 166.4

Goggles Face shield

BSEN 166.B

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Cleaning by means of high pressure water jets (3)

BS specification

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Process to be considered

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Flying particles, dust

Use of power-driven high-speed metal High speed flying cutting saw, or abrasive cutting-off fragments or particles wheel or disc (8)

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Goggles

BSEN 166.3 and 4

Handling in open vessels or manipulation of the substances described above (12)

Flying particles, chemical splash, injurious dust

Goggles

BSEN 166.3 and 4

Pressure injection of liquids or solutions into buildings or structures (14)

Chemical splashes

Goggles

BSEN 166.3

Use of hand or power tools to drive in bolts, pins, collars etc. (13)

Flying fragments or particles

Goggles Spectacles Face shield

BS EN 166.F

Breaking up of metal by use of a Flying fragments or hammer (whether power-driven or not) particles or a tup

Goggles Spectacles Face shield

Use of compressed air to remove swarf, dust, dirt etc. (17)

Goggles Spectacles Face shield

BS EN 166.S

Pouring or skimming molten metal (18) Molten metal, splash, sparks

Goggles Face shield

BS EN 166.9

Goggles Spectacles Face shield

BSEN 166.F

BS EN 166.F

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Breaking, cutting, dressing, carving or Flying fragments or drilling with hand or power tools the particles following materials:(i) Glass, hard plastics, concrete, fired clay, plaster, slag, natural or artificial stone, and any similar materials. Also any articles consisting wholly or partly of these materials(ii) Stonework, brickwork, or blockwork(iii) Bricks, tiles, or blocks (16)

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Flying fragments or particles

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Operation, maintenance, dismantling Flying particles, chemical or demolition of plant which contains splash, injurious dust or has contained acids, alkalis, corrosive materials, or other dangerous substances, whether liquid or solid (11)

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Cutting of wire and related operations (21)

Flying fragments or particles

Goggles Spectacles Face shield

BSEN 166.S

Cutting of wire or metal strapping under tension (22)

High speed flying fragments or particles

Goggles Spectacles Face shield

BSEN 166.B

Processing and handling of glass or cullet (23)

Flying fragments or particles

Goggles Spectacles Face shield

BS EN 166.S

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PART 11 Processes in which approved shields or approved fixed shields are required Electric arc welding (24)

Glare, radiation, heat, spatter

Fixed shield and/or welding Housing BS EN 175 Filters helmet or band screen BS EN 169

PART III Processes in which approved eye protectors or approved shields or approved fixed shields are required

Glare, radiation, heat, splatter

Goggles

Housing BS EN 175 Filters BS EN 169

Cutting, boring, cleaning, surfaceconditioning, or spraying of material using apparatus supplied with oxygen or flammable gas under pressure (27)

Flying fragments or particles

Goggles

Housing BS EN 175 Filters BS EN 169

Processes involving the use of lasers (28)

Radiation and burning

Fixed shield Goggles

BS EN 60825

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Gas welding (25)

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PART IV Process in which approved eye protectors or approved shields or approved fixed shields are required

High speed particles or fragments

Fixed shield and/or goggles

BSEN 166 B

Dry grinding of materials or articles using a power-driven wheel, disc or band, or a portable tool (31)

Flying particles or hot sparks

Goggles Spectacles Face shield

BS EN 166 F

Flying particles

Goggles Spectacles

BSEN 166 S

Flying particles, spatter

Goggles Spectacles Face shield

BS EN 166 S

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Truing or dressing of abrasive wheels (29)

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Machining of metals including any dry grinding process not elsewhere specified (34)

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Welding of metals by an electric resistance process or a submerged electric arc (35)

Cases in which protection is required for persons at risk from, but not employed in, the process Chipping of metal, chipping; knocking Flying fragments or out or cutting of cold rivets, bolts, nuts, particles lugs, pins, collars, etc. using hand or power tools (1)

Goggles Spectacles Face shield Fixed shield

BSEN 166 F

Electric arc welding (2)

Glare, radiation, spatter

Cover Goggles Spectacles

BSEN 166 S Filters BSEN 169

Process involving lasers

Radiation and burning

Goggles Spectacles

BS EN 60825

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Construction Site Safety 1.2.11 Appendix 3

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This table constitutes a quick reference guide for the safe use of lasers. For further authoritative information, consult BS EN 60825:1991. Class 1

Labelling

Hazard warning label Yellow background with black symbol and border, with the words CLASS 1 LASER PRODUCT

Class 2

Class 3R (formerly Class 3A)

Class 3B

Class 4

1) Hazard warning label Yellow background with black symbol and border 2) Explanatory label (black/yellow) LASER RADIATION DO NOT STARE INTO BEAM CLASS 2 LASER PRODUCT

As 1 - 2 except explanatory label to read: LASER RADIATION DO NOT STARE INTO BEAM OR VIEW DIRECTLY WITH OPTICAL INSTRUMENTS CLASS 3R LASER PRODUCT

As 1 - 3 except explanatory label to read: LASER RADIATION AVOID EXPOSURE TO BEAM CLASS 3B LASER PRODUCT

As 1 - 3 except explanatory label to read: LASER RADIATION AVOID SKIN OR EYE EXPOSURE TO DIRECT OR SCATTERED RADIATION CLASS 4 LASER PRODUCT

Key control

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Classification Requirement

Beam attenuator

Not required

Remove key when not in use

Not required

When in use prevents inadvertent exposure

Emission indicator device Not required

Indicates laser is energised

Warning signs

Not required

Follow precautions on warning signs

Beam path

Not required

Specular reflection

Not required

Eye protection

Not required

Required if engineering and administrative procedures not applicable and MPE exceeded

Protective clothing

Not required

Sometimes required

Training

Not required

Terminate beam at end of useful length Prevent unintentional reflections

Required for all operator and maintenance personnel

Specific requirements

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Laser health risks and control

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Construction Site Safety 1.2.11 Appendix 4

Health risks

Class 1M

Potentially harmful to the eye but only if deliberately viewed through an optical magnifying device, such as binoculars.

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Class of laser

No one must be allowed to deliberately look at the beam or to direct the beam into another person's eyes. Magnifying devices such as binoculars must not be used by any person who may be exposed to a laser beam whilst using them.

May be harmful to the eyes if deliberately misused, for example, if someone stares directly into the beam.

As above.

Harmful to the eyes if viewed through an magnifying optical device.

As above.

Class 3R (formerly Class 3A)

These are higher power lasers that can cause eye injuries, generally exposure is no more hazardous than to a Class 2 device because of the human 'blink reflex'.

BS EN 60825 specifies minimum training requirements for the users of Class 3 and 4 lasers. This will include information on the risks from the beam and the advice against misuse.

Class 3B and Class 4

A higher power laser that can cause eye injury, either directly from viewing the beam or from reflections.

Appropriate eye protection (PPE) must be worn whenever Class 3R or more powerful lasers are used. Class 3B and Class 4 lasers. Particular training on these classes of laser is required. The human 'blink reflex' is not likely to offer any protection to anyone accidentally exposed to the beam.

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Class 2

Control measures

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Construction Site Safety 1.2.12 Protection of the Skin 1.2.12.1 Key points Many of the substances used or created during construction activities have the potential to cause severe skin problems.

2

The (COSHH) risk assessment and the information on the accompanying data sheet and a substance's container should indicate the degree of risk and the preventative measures necessary.

3

Ideally, the risk will eliminated by avoiding the substance altogether, although this will often not be practical.

4

Hazardous substances created by work processes will carry no 'health warning' but must be identified in a (COSHH) risk assessment.

5

Skin conditions can be prevented by such simple actions as wearing the appropriate gloves (PPE).

6

Barrier creams offer limited protection against some substances but should not be relied upon.

7

Most substances can enter the body through openings such as cuts and grazes. Other, more hazardous, substances can penetrate unbroken skin.

8

Periodic 'self-checks' or hand-checks carried out by someone trained to recognise the symptoms are an effective form of initial health surveillance.

9

Prompt medical advice should be sought if there could be an emerging health problem.

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1.2.12.2 Introduction

Industrial dermatitis is a major cause of absenteeism.

2

It is an inflammatory skin condition which is neither infectious nor contagious. It is caused by certain irritants contained in many industrial materials. Although dermatitis is not itself an infection, it can lead to infection when the skin's natural barriers break down.

3

There are two general types:

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Irritant dermatitis 4

Irritant dermatitis is usually caused by the skin coming into contact with an irritant substance -usually a chemical, but it can be a mineral.

5

Repeated exposure to extreme heat or cold can lead to physical damage to the skin and make it more likely that irritant dermatitis will occur. Wet work, which involves the hands being wet for long periods (more than two hours a day) or repeatedly getting the hands wet, can also cause dermatitis. Anyone may be affected, and the length of exposure together with the strength of the irritant substance will affect the seriousness of the complaint. Most cases of dermatitis are of this type. Sensitising dermatitis

6

Sensitising dermatitis, also know as allergic contact dermatitis, accounts for about 20% of all work-related dermatitis.

7

Some people develop a sudden allergic reaction following exposure to a specific substance.

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The reaction may be after weeks, months or even years of use or exposure to a substance without any ill effects. However, once that sensitising dermatitis has occurred, any future exposure to the substance will again produce an adverse reaction. The exposure may be to an everyday chemical or mineral, and may be as simple as exposure to nickel in jewellery.

9

The outer layer of skin forms a natural defence against irritants providing it is undamaged by cuts and abrasions, or by solvents (such as hydrocarbons, benzene, tetrachloride, spirits and thinners) that remove the skin's natural protective oils. Reaction of the skin to an irritant varies from one individual to another. The reaction may be only a mild redness or it can develop into swelling, blisters and septic ulcers that are both unsightly and painful.

10

Personal hygiene is particularly important when working with materials which may be irritants, as resistance to an irritant varies with the type of skin. Pores, ducts and hair follicles in the skin may admit irritants to the sensitive inner skin layer and, therefore, washing thoroughly to remove dirt and grime with soap and water is an essential preventative measure.

11

It is equally important that clothing is kept clean. Oil-stained overalls are a known cause of skin problems around the thighs.

12

The best course of action is to prevent skin contact with all potentially irritant substances, even if this is achieved by issuing PPE. When total avoidance of skin contact cannot be guaranteed, it will be necessary in some cases to implement occupational health screening (depending on the hazardous properties of the substance). Initially this should involve establishing whether the persons involved in the job have had any previous adverse reaction to the substance(s) in use.

13

Those people who are found to be allergic to one or more substances should be identified and not be allowed to handle or come into contact with them. Any part of the body that comes into contact with a skin irritant may be affected although it is usually the hands, wrists and forearms that are affected initially. Treatment for dermatitis should be sought as soon as possible because, if neglected, symptoms may spread to other parts of the body.

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Many substances that are used in the construction industry have corrosive properties that can cause severe burns to the skin. These substances have either strong acid or alkali properties.

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1.2.12.4 Abrasion and cuts 1

Manually handling objects with rough surfaces, sharp corners etc. can cause damage to the skin of the hands if appropriate gloves, such as rigger gloves, are not worn. Repetitive manual handling may even make the situation worse. Such damage breaks the surface of the skin making it more vulnerable to absorbing other substances that could potentially have severe health effects. Worn-out gloves must be thrown away and replacements obtained.

2

Where objects with sharp edges such as sheet glass, sheet metal components etc. have to be manually handled, gloves with cut-proof material, such as Kevlar, woven into the fabric must be worn.

3

Ideally, work would be organised so that the manual handling of all such objects could be avoided, however, given the nature of construction activities, total avoidance is usually not possible. For example a roof tiler may now use an inclined hoist to get the tiles up to roof level, but the hoist must still be loaded and the tiles distributed around the roof by hand.

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1.2.12.5 Health and Safety at Work (Construction Sites) 1

Contractors have a duty to ensure that, as far as is reasonably practicable, safe systems of work are used, that adequate welfare facilities are available and that appropriate information, instruction, training and supervision are provided, as is necessary to ensure safety and the absence of risks to health in the use, handling, storage and transport of articles and substances.

2

Employees are required to take reasonable care for their own health and safety, and that of other persons who may be affected by their work, and to co-operate with the Contractor so as to enable them to carry out their legal duties and requirements. In addition, employees must not intentionally or recklessly interfere with anything provided in the interests of health and safety.

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1.2.12.6 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard to employees (or any other persons) that might be encountered as a result of the work having been carried out.

2

When hazards are identified, it is then the Contractor's duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

Where a hazard is identified that requires it, the Contractor must offer health surveillance to employees, taking into account the risks to their health and safety that have been identified.

4

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and control measures that are in place to reduce those risks.

5

Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves and any other persons who may be affected.

6

In the context of this module, the risk assessment must identify any substance to be used that can cause an adverse skin reaction and the control measures that are necessary to ensure that the substance can be used safely.

7

Employees are required to use hazardous substances provided in accordance with any training or instructions that they have received from their Contractor.

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1.2.12.7 Control of Substances Hazardous to Health 1

The principal points of these Regulations place requirements on the Contractor to protect employees, or any other persons who may be affected by their operations, by: (a)

assessing the health risks created by work involving substances hazardous to health.

(b)

ensuring that the exposure of employees or others is prevented, or adequately controlled, by putting in place any measures necessary to control the exposure to risks

(c)

ensuring that any control methods provided are properly used and maintained by monitoring the work environment, as necessary

(d)

carrying out health surveillance in specified circumstances

(e)

providing information, instruction and training for employees on the risks to health and precautions to be taken regarding any work with substances hazardous to health

(f)

providing procedures for dealing with accidents, incidents and emergencies, including

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first aid and safety drills.

1.2.12.8 Personal Protective Equipment at Work These Regulations require that where a risk has been identified by a risk assessment, and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment (PPE) is used by employees.

2

In essence, PPE may only be used as a last resort after all other means of eliminating or controlling the risk have been considered.

3

In deciding which type to issue, the Contractor must take into account the risk that the PPE is being used for, and that the PPE will fit the wearer and allow them to work comfortably.

4

Whilst the Contractor must take 'reasonable steps' to ensure that any PPE supplied is worn, employees in turn must ensure that they wear the equipment provided and know the procedures for reporting any loss or defect to their Contractor.

qa

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(b)

adequate washing facilities (including showers, where appropriate)

(c)

a supply of hot and cold (or warm) water

(d)

soap or suitable cleansers

(e)

towels or other means of drying.

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Use of harmful substances

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Specifically in relation to skin protection, Contractors must ensure that the appropriate assessments have been made on any articles and substances used at work, and that they are:

(b)

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properly stored, transported and handled

(d)

properly marked to indicate any special precautions which need to be taken.

safe and free from any risk to health, when properly used used in accordance with the findings of risk assessments, procedures and conditions stipulated

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They must ensure that persons using such articles and substances are: (a)

suitable and able to carry out the task which is expected of them

(b)

properly and adequately trained in their use and aware of all necessary precautions which must be taken

(c)

provided with appropriate personal protective clothing and equipment

(d)

supplied with all necessary information

(e)

educated in the dangers of skin

(f)

conditions, and in methods to be used to prevent those conditions arising

(g)

able to detect, and be aware of, the need to report any signs of skin infection or dermatitis.

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Adequate washing and first aid facilities must be provided, and barrier and cleansing creams should be available. In addition, the Contractor is responsible for providing supervision to ensure the above procedures, conditions and correct methods of work are maintained and that the proper facilities and equipment are available.

1.2.12.11

Potentially harmful substances and agents

Substances and physical agents which can be potentially harmful to the skin include: pitch, tar and bitumen

(b)

cement or lime

(c)

brick, stone, tile and plaster dust

(d)

paints, varnishes, lacquers and stains

(e)

certain types of timber (see Appendix 2)

(f)

fibreglass

(g)

certain epoxy resins

(h)

acrylic and formaldehyde resins

(i)

chromates (in primers, cement, etc.)

(j)

organic solvents

(k)

petrol, diesel and paraffin oils

(l)

white spirit and thinners

(m)

acids or alkalis

(n)

ionising radiation

(o)

solar radiation

(p)

other materials (depending on individual reactions).

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1.2.12.12

Effects of contact with some materials

Skin contact with certain materials can cause a variety of reactions and some examples are given below. This list is not exhaustive.

2

Mineral oils, including fuel oils and mould oils, can lead to inflammatory skin conditionsdermatitis, oil acne or even skin cancer.

3

These may be caused by constant contact with oil or oily clothes and rags (e.g. when placed in overall pockets).

4

Chemicals, including strong alkalis and certain acids, chromates, formaldehyde, are substances which can penetrate the skin causing ulcers (for example, chrome ulceration) and dermatitis.

5

Cement and lime can also cause chronic dermatitis. Wetted cement and lime become more alkaline, corrosive and therefore potentially very damaging to the skin.

6

Solvents and de-greasers, including paraffin, turpentine, petroleum products, thinners and similar solvents, affect the skin by dissolving the natural oils (de-fatting) which renders it more vulnerable to attack by other substances and bacteria.

7

Tar, pitch, bitumen products, including cresols and phenols like mineral oil, cause inflammation, blisters and oil acne.

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8

Radiation, light and heat radiation, including X-rays, beta and gamma radiation, extremes of radiation, temperature and humidity, make the skin more susceptible to dermatitis and other skin problems.

9

Epoxy resin hardeners, glass fibres, certain woods, fungicides and insecticides may irritate the skin and lead to dermatitis.

1.2.12.13

Reducing risks

Substitute products Every effort must be made to ascertain which substances have the potential to cause dermatitis and, where possible, to substitute other materials that either eliminate or reduce the danger. An alternative, where possible, may be to use a more dilute form of the substance.

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Reducing contact

If the outcome of an assessment is that there are no alternatives, and substances that cause dermatitis have to be used, methods of work should be implemented which eliminate contact between the skin and the substance.

3

The use of mechanical handling equipment may be possible but, if this is not available, simple devices and instruments, including splash guards, drip trays, tongs, and scrapers, will help to reduce the risk.

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Healthy working conditions

It may be possible to use localised ventilation and exhaust systems to deal with dust, fumes and oil spray.

5

Plentiful supplies of clean fresh air and comfortable working temperatures are vitally important, as is the general cleanliness of the working area, the machinery and any other equipment which is in use.

6

Wherever possible and appropriate, the display of warning and information signs should be prominently made, so that all employees are aware of the hazards existing in that area.

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Warning signs (black on yellow background)

Mandatory signs (white on blue background)

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Protecting the worker 7

If a Contractor intends to use any items of PPE (including gloves and barrier creams) as part of their skin protection strategy in the workplace, then it is important that the correct PPE is selected.

8

All PPE for skin protection that is produced or imported by reputable companies is manufactured to British and European Standards.

9

As with all PPE for use at work, skin protection should be selected by a competent person who can ensure, in discussion with the supplier, that it meets the appropriate standards. Protective clothing Protective clothing and other PPE provides one of the most practical ways of limiting contact between the skin and other substances. To be effective, all protective clothing must be the right size, fit for the purpose, maintained in good condition, cleaned regularly and stored carefully when not in use.

11

Protective clothing may include gloves, overalls, eye protectors (such as goggles, face shields), aprons, boots and leggings, depending on the work being undertaken. The protective equipment provided must be suited to the requirements of the job.

12

Regular inspections must be made to ensure it remains sound and adequate.

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Gloves 13

A glove suitable for handling abrasive materials may offer no protection against chemicals. The appropriate glove for sulphuric acid may not be approved for chromic acid.

14

Much care is needed in selecting the right type of glove to be used for a particular hazard. Manufacturers' charts and recommendations should be followed when selecting gloves to

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protect the wearer against specific hazards. A properly selected glove can be useful in the prevention of dermatitis if care is taken to avoid getting contaminants inside the gloves when putting them on and taking them off. 15

The modern materials from which gloves are now made enable them to be effective against hazardous substances whilst generally allowing the necessary amount of 'feel' and dexterity where these factors are an issue. Industrial gloves - some types and uses

Recommended type

Acids, concrete, brickwork, stain removers, solvents, alkalis

Neoprene, nitrile, PVC, rubber

Esters, ethers, ketones (mastic, sealers), aldehydes, petroleumbased products

Medium and heavyweight rubber, neoprene, nitrile, PVC

High and low temperatures

Nitrile, PVC, medium and heavyweight rubber

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Abrasion, unloading bricks and blocks, general materials handling

Asbestos substitute or 'Nomex' gloves

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Bitumen, hot work, etc.

Rubber, nitrile, PVC, neoprene, chrome-leather with reinforced palm

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Barrier substances 16

Where exposure of the skin is unavoidable, the use of barrier creams or other preparations may limit the degree of contact.

17

These substances are applied before starting work and removed by washing after each spell of work. Reapplication is necessary before resuming work.

18

Water-soluble barrier creams are unsuitable where wet work is involved, and some substances are worn off with manual work.

19

There are many types of barrier substances available and it is essential that the right type is used for the work being done.

20

Most barrier substances afford only limited protection and should never be relied on as a sole means of protection.

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Hygiene 21

Personal cleanliness is an important factor in the prevention of dermatitis. The necessary washing facilities and an ample supply of clean warm water, soap and clean towels should be made available near to the workplace, and workers should be encouraged to use these facilities.

22

Facilities for changing out of work-stained or contaminated clothing will also help to promote personal cleanliness.

23

All facilities should be kept clean and inspected regularly. Skin cleansers Soap and water will help restore the skin to its natural state after the use of barrier creams. Skin cleansers may be required where soap and water are not adequate (such as insoluble barrier substances). With some skin cleansers (sanitisers), an additional moisturiser may be needed.

25

Solvents (such as paraffin, turpentine, thinners and petrol) remove the natural oils from the skin and must not be used for skin cleaning. Conditioning creams, designed to replace the natural oils of the skin removed through frequent cleansing, should be used when necessary.

1.2.12.14

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First aid

A healthy, intact skin is an effective barrier against some substances and infection, but the slightest cut or other injury may admit infection.

2

All abrasions to the skin, however minor, should be treated at once. However, be aware that some substances can penetrate unbroken skin.

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Medical advice should be sought as early as possible when there is concern. Any treatment of dermatitis or its symptoms should be left to a doctor.

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Treatment of dermatitis

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Inspections and examinations, educating staff in prevention Regular inspections of the workplace, work methods and precautionary procedures adopted will help ensure that the risk of dermatitis, or other skin complaints, is kept to a minimum. Atrisk employees should be encouraged to carry out 'self checks' for the first signs of dermatitis and, ideally, supervisors should be trained to identify dermatitis. In appropriate circumstances, arrangements should be made for workers to have regular examinations by an occupational health professional to detect early signs of skin complaints, such as dermatitis and skin cancer.

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Active concern for the welfare of employees will encourage their co-operation in reporting skin irritations at an early stage. Workers are more likely to co-operate in preventative measures if they are told positively what dermatitis is and what can be done to prevent it from occurring.

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Health risks from working in the sun 6

A sunny day usually makes most people feel good, but too much sunlight can actually damage the skin. It is not simply sudden exposure while on holiday that is harmful. Even a tan that has been built up gradually can be harmful to health. A tan is a sign that the skin has been potentially damaged.

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Skin damage is caused by ultraviolet rays in the sunlight. People whose jobs keep them outdoors for a long time (such as building, construction and civil engineering workers) may, if their skin is unprotected, get more sun on their skin than is healthy for them. They will then be at greater risk of developing skin cancer. The dangers

8

In the short term, excess exposure of unprotected skin to the sun can cause blistering and peeling. Even mild reddening of the skin is a sign of skin damage. In the long term, too much sun will speed up ageing of skin, making it leathery, mottled and wrinkled. However, the most serious issue is an increased chance of developing skin cancer.

9

Some medicines, and contact with some chemicals used at work (such as bitumen products), can make the skin more sensitive to sunlight (photosensitivity).

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Some people are more at risk than others - and the effect that strong sunlight can have on the different types of skin is explained below. People with white skin are most at risk. Workers should take particular care if they have: fair or freckled skin that does not tan, or goes red or burns before it tans

(b)

red or fair hair and light coloured eyes

(c)

a large number of moles.

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The risks

Type 1: White skin, never tans, always burns. Often person has red or fair hair, blue eyes, pale skin and freckles.

12

Type 2: White skin, burns easily, but may tan eventually. Person may have fair hair, blue eyes and freckles.

13

Workers with skin types 1 and 2 must take extra care to avoid strong sunshine or cover up with tightly woven clothing and a hat.

14

Type 3: White skin tans easily and burns rarely. Person has dark hair and eyes and slightly darker skin.

15

Type 4: White skin, never burns, always tans. Person has dark hair, eyes and skin.

16

Workers with skin types 3 and 4 should still take care in strong sunshine.

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Type 5: Brown skin.

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Type 6: Black skin.

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Workers with skin types 5 and 6 are still at risk from skin cancer. These skin types can still darken and even burn in stronger sunlight.

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To protect yourself 20

Even if their skin is not fair or freckled, workers should be particularly careful whilst working out of doors in summer in the three or four hours around midday when the sun is most intense.

21

Workers should:

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(a)

protect themselves with the type of clothing outlined below

(b)

try to avoid the mild reddening which is a sign of skin damage as well as being a sign of early burning

(c)

try to work and take breaks in the shade if they can. This will reduce the danger of harming the skin

(d)

not be complacent. The skin's most vulnerable areas are the back of the neck and the head. Where possible, keep these areas covered

(e)

not try to get a tan; it might look good but it indicates that the skin has already been damaged.

A suntan does not eliminate the long-term cancer risk, which is associated with prolonged exposure to the sun.

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The main way to avoid the dangers of developing skin cancer is to cover up. Work clothing made from close-woven fabric, such as a long-sleeved shirt and jeans, will stop most of the UV rays.

(b)

Wear a hat. A wide brimmed hat will shade the face and head. A safety helmet will afford protection and the addition of a hanging flap will protect the back of the neck.

(c)

Keep a shirt or other top on.

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Hats and other clothing are the best form of protection, but sun creams and lotions can add useful protection for parts of the body that are not easy to shade from the sun. A sun protection factor rating of 30 or more is recommended.

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Protective clothing 23

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Periodic checking of the skin

The first warning sign is often a small scabby spot that does not clear after a few weeks. Workers should be instructed to look for changed or newly formed moles or any skin discoloration. Workers should pay particular attention to any growths that appear on the face, especially around the eyes and nose, or on the backs of hands.

26

If these signs are noticed, medical assistance should be sought either from the Contractors medical staff or a local general practitioner, drawing attention to any moles that grow, change or bleed.

27

Many of these symptoms may prove to be non-cancerous - but they need to be checked to be absolutely sure.

28

Even if a spot is cancerous, simple modern treatments can usually cure them. This type of cancer very rarely spreads to other parts of the body. The smaller the spot, the easier it is to cure.

29

Don't delay If you think something might be wrong, get it checked out

30

Contractors are strongly encouraged to develop a Sun Safety Policy. An example of such a policy is attached at Appendix 3 to this module.

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Construction Site Safety 1.2.12 Appendix 1 Protection of skin Safety checklist Have the materials or substances in use been correctly identified?

2

Is up-to-date manufacturers' information available on the safe use of the substances?

3

Have the hazardous substances that will be produced by a work process been identified?

4

Have the necessary risk assessments been carried out?

5

Has an attempt been made to control the hazard at source, for example by using a less hazardous substance?

6

Has a COSHH risk assessment been carried out for the substances in use?

7

Have the significant findings of the risk assessment been communicated to those who will be using or otherwise affected by the substance?

8

Are the correct warning and cautionary notices displayed?

9

Are the methods of handling, transport and storage correct for the substances being used?

10

Are there adequate selection and training procedures available for operatives using harmful substances?

11

Is it necessary for workers to have wet hands for long periods or repeatedly get their hands wet?

12

Have operatives been properly trained in the necessary precautions and protective measures required for safe working?

13

Are safe working procedures and methods being properly implemented?

14

Is the correct handling equipment available and in use?

15

Is there adequate ventilation where toxic materials are in use?

16

Are there adequate washing facilities, barrier creams and cleansing agents of the correct type available and in regular use?

17

Are there gloves and protective clothing of the correct type and specification available and in use?

18

Have they been selected by a competent person, who can be the supplier?

19

Is there provision for cleaning protective clothing?

20

Is protective clothing regularly changed?

21

Are there adequate supervision and inspection procedures in place?

22

Is medical surveillance available for operatives when applicable?

23

Have appropriate welfare and first aid facilities been provided?

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Construction Site Safety 1.2.12 Appendix 2 Some timbers known to produce dermatitis and other irritant effects Harmful effects

Severity

Frequency

Afrormosia

Dermatitis, asthma

Can be severe

Quite frequent

African mahogany

Dermatitis

Severe

Infrequent at present

Boxwood

Dermatitis, rhinitis, asthma Mild

Quite frequent

Chestnut

Dermatitis, conjunctivitis, asthma

Usually mild

Infrequent

Dahoma

Irritation of the chest, dermatitis

Severe

East African camphor wood

Asthma, dermatitis

Fairly severe

Ebony

Irritation of nose and throat, Fairly severe dermatitis

Fairly frequent

Guarea (also West African cedar)

Nasal irritation, severe vomiting, chest irritation, blisters and dermatitis

Quite frequent

Iroko

Skin and eye irritation, asthma, symptoms of the common cold

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Commercial name

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Machaerium

Effects vary from mild to severe depending on sensitivity

Usually mild, occasionally Very infrequent serious

Dermatitis

Severe

Infrequent at present

Irritation of mucous membrane, nasal haemorrhage, sore eyes, dizziness, dermatitis

Severity varies with individuals

Frequent

Dermatitis, headache, coughing

Quite severe

Infrequent

Teak

Dermatitis, eye inflammation

Can be severe

Not frequent

Western red cedar

Asthma, bronchial trouble, dermatitis, septic wounds from splinters

Severe

Fairly frequent

Yew

Bronchial asthma and dermatitis

Quite severe

Infrequent

Satinwood

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Mansonia

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Construction Site Safety 1.2.12 Appendix 3 Model Sun Safety Policy This Contractor is committed to protecting and educating its workers about the risks to health arising from excessive exposure to strong sunlight. The policy will be implemented as appropriate for all workers who are at risk. Sun protection advice will be provided as part of routine health and safety training for all.

2

All new employees will be made aware of the Sun Safety Policy.

3

Wherever possible, working hours and tasks will be scheduled to avoid the midday sunshine. Wherever possible, work that can be carried out indoors or in the shade will be scheduled during periods of strong sunshine.

4

All workers who are liable to be at risk will receive appropriate training on how to protect themselves from prolonged exposure to strong sunlight, regardless of their skin type or hair colour.

5

Workers who are at risk will be encouraged to wear full-length trousers and long-sleeved shirts throughout the year. They will be made aware that, ideally, clothing will be loose fitting and made from a close-weave fabric.

6

In most circumstances, the mandatory wearing of a safety helmet will provide the necessary protection for the head. In the rare circumstances where a safety helmet need not be worn, workers at risk will be advised to wear a hat.

7

Workers at risk will be given information on the appropriate use of sunscreen creams, including advice on the minimum recommended level of protection.

8

Drinking water will be provided in the shade and all workers will be encouraged to drink plenty of water to avoid dehydration.

9

Rest areas in the shade will be provided and workers at risk will be encouraged to use them for their rest breaks.

10

All contractors working on the site will be made aware of the contents of the Sun Safety Policy and will be required to adhere to its guidelines.

11

The effectiveness of this policy will be monitored and it will be reviewed and updated as necessary.

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Signed ..................................................................... Date .................................................................... Position ...................................................................................................................................................

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Construction Site Safety 1.2.13 Control of Vibration 1.2.13.1 Key points Exposure to hand-arm vibration has the potential to cause disabling injuries.

2

Exposure to whole-body vibration can cause severe back pain.

3

Contractors have a legal duty to reduce the risks to the health of employees by either eliminating exposure to vibration or reducing it to an acceptable level.

4

Contractors have various means at their disposal of estimating exposure to vibration before resorting to having measurements carried out.

5

If it is necessary to have vibration measurements taken, it is essential that the person doing so is trained and competent.

6

Some of the things that can be done to control the potentially harmful effects of exposure to hand-arm vibration are:

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adopting alternative (non-vibrational) work methods;

(b)

ensuring that tools are either low-vibration by design and/or well-maintained;

(c)

adapting work patterns;

(d)

ensuring that ergonomic factors are taken into account;

(e)

preventing those person(s) exposed to vibration from becoming cold and/or damp;

(f)

training workers how to minimise the risks from vibration.

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Exposure to whole-body vibration can be controlled by, for example, improved technology in mobile plant (e.g. improved suspension and driver's seat), operator training, smooth operation of machines and job rotation.

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1.2.13.2 Introduction Hand-arm vibration A wide range of tools commonly used during construction and demolition activities, particularly those with a rotary or percussive action, have the potential to cause serious health problems. The seriousness of the situation will depend largely on how frequently and for how long vibrating tools are used although, as will be explained elsewhere in this module, other factors contribute to the potential for ill health.

2

The most common forms of ill health resulting from exposure to vibration of hands and arms are known as hand-arm vibration syndrome (HAVS) and vibration white finger (VWF), which is also known as Secondary Raynaud's Syndrome.

3

VWF, which is sometimes called 'dead finger' or 'dead hand', is most common in people whose hands are regularly exposed to damaging levels of vibration. Damage to the nerves and blood vessels in the fingers can lead to permanent loss of feeling and eventual disability. At worst, VWF can eventually lead to ulceration or gangrene, possibly resulting in the loss of one or more fingers. There is no effective treatment for the disorder. Exposure to vibration can also cause damage to muscles, joints and bone, which may also contribute to pain and stiffness in the hands and wrists.

4

If the symptoms of VWF can be seen in an employee's hands or fingers, it is clear evidence that any protective or control measures that are in use have not been effective. The damage has already been done.

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The symptoms or effects of vibration white finger are usually triggered when the hands are exposed to the cold. Early indications are the fingertips rapidly becoming pale or white (blanched), with loss of feeling and perhaps also numbness and 'pins and needles'. This phase is sometimes followed by a red flush that signals the return of blood circulation to the fingers and is usually accompanied by a very uncomfortable or painful throbbing. Continued work with vibrating tools will cause the affected area to increase in size and for attacks to become more frequent over time.

6

Vibration damage to the fingers, hands or body is very much dose-related. The greater the exposure to vibration, the more likely there is to be damage. Increased exposure could be due to being exposed to greater magnitudes of vibration or being exposed for longer durations.

7

Other factors that can influence the risk of developing hand-arm vibration syndrome include: the grip, push and other forces used to guide and apply the vibrating tools or pieces of work equipment. The tighter the grip, the more vibration energy is transferred to the hands

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(b)

tools with blunt cutting edges usually require more time to complete the task, higher grip and push forces, and often result in greater vibration emission

(c)

the exposure pattern, length and frequency of work and rest periods

(d)

how much of the hand, and other parts of the body, is exposed to the vibration

(e)

factors that potentially affect blood circulation, such as workplace temperature, smoking and individual susceptibility

(f)

the hardness of the material being worked

(g)

tool maintenance is important in order to keep it running smoothly and efficiently.

1.2.13.3 Whole-body vibration 1

Whole-body vibration, as its name suggests, is vibration or jolting of the whole body through the surface that is supporting the body, such as a machine seat or floor.

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Whole-body vibration, which often results from driving or operating some types of construction plant or vehicles, has the potential to cause back injury or make an existing back condition more painful.

1.2.13.4 1.2.13.5 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2

When hazards are identified, it is the Contractor's duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

4

Employees, in turn, have legal duties under these Regulations to:

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tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other persons who may be affected by their work activities

(b)

use all machinery and equipment in accordance with any training provided.

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(a)

These Regulations require that, additionally, the Contractor provides employees with adequate information, instruction, training and supervision to be able to carry out any work safely and without risks to their health.

6

The Contractor must assess the risks to employees' health arising from hand-arm vibration and whole-body vibration and put effective control measures in place.

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1.2.13.6 Control of Vibration

They impose duties on Contractors to protect employees (and others) who may be exposed to risk of ill health because of vibration at work.

2

These Regulations place legal duties on Contractors and employees with regard to the control and management of employees' exposure to vibration.

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Definitions 3

These Regulations give a number of definitions, knowledge of which will help readers better understand the requirements of these Regulations. (a)

Hand-arm vibration (HAV) means mechanical vibration which is transmitted into the hands and arms by a work activity.

(b)

Whole-body vibration (WBV) means mechanical vibration which is transmitted into the body through the supporting surface when a person is seated or standing during a work activity.

(c)

Mechanical vibration means vibration occurring in a piece of machinery, equipment or vehicle as a result of its operation.

(d)

Daily exposure means the extent of the mechanical vibration to which a worker is exposed during a working day, which takes account of both the magnitude and duration of the vibration.

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(e)

Exposure action value (EAV) means the level of daily exposure that, if exceeded, requires specific action to be taken to reduce the risk.

(f)

Exposure limit value (ELV) means the level of daily exposure for any worker that must not be exceeded.

(g)

Working day means a daily working period, irrespective of the time of day, when it begins or ends, or whether it begins or ends on the same day.

(h)

Health surveillance means an assessment of the state of health of an employee as related to their exposure to vibration.

4

Exposure limit and action values

5

For hand-arm vibration: 2

the daily exposure action value is 2.5 metres per second squared (2.5 m/s A(8))

(b)

the daily exposure limit value is 5 metres per second squared (5 m/s A(8)).

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For whole-body vibration:

2

(a)

the daily exposure action value is 0.5 metres per second squared (0.5 m/s A(8))

(b)

the daily exposure limit value is 1.15 metres per second squared (1.15 m/s2 A(8)).

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Note: The 'A(8)' notation after each value indicates that the measurement of exposure to vibration is 'time weighted' over an 8 hour period.

See flowchart at Appendix 1.

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1.2.13.7 Duties of Contractors

Where these Regulations place a duty on Contractors with respect to the health and safety of employees, the Contractor shall so far as is reasonably practicable, also be under a similar duty to anyone else, whether at work or not, who may be affected by the vibration created by the Contractor's work activities, except for the provision of:

information, instruction and training unless the non-employees are at the same place of work as where the noise is being created.

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Contractor's duties to non-employees

Contractor's duties to employees 3

If employees are likely to be exposed to risks from vibration in the course of their work the Contractor must: (a)

carry out an assessment of the risks to the health and safety of the employees exposed to vibration. The risk assessment must identify the measures that need to be taken to meet the requirements of these Regulations

(b)

as part of the risk assessment, assess the daily exposure of employees to vibration by:

(c)

(i)

observing work practices

(ii)

referring to information on the probable level of vibration corresponding to the equipment used in those particular conditions

(iii)

if necessary, arranging for vibration levels to be measured.

assess whether any employee is likely to be exposed to vibration at or above the

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exposure action value or the exposure limit value. 4

The risk assessment must include consideration of: (a)

the magnitude, type and duration of exposure to vibration, including intermittent vibration and repeated shocks

(b)

the effects that the vibration might have on employees whose health is particularly at risk from exposure

(c)

any effects that vibration might have with regard to work equipment, such as: (i)

the proper handling of controls (ii) the reading of indicators (iii) the stability of structures

(e)

the availability of alternative equipment that is designed to reduce exposure to vibration

(f)

exposure of employees to whole-body vibration when not actually working, such as in rest areas and canteens

(g)

specific working conditions, such as working in low temperatures

(h)

the availability of appropriate information obtained from health surveillance.

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any information provided by the manufacturers of the equipment that creates the vibration

The Contractor must regularly review the risk assessment and immediately if: there is reason to believe that it is no longer valid

(b)

there has been a significant change in the work to which the assessment applies

(c)

implement changes to the risk assessment as identified by the review process.

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The Contractor must record: (a) (b)

the measures taken to eliminate or control exposure to vibration the measures taken to provide information, instruction and training for at-risk employees.

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(c)

the significant findings of the risk assessment as soon as is practicable after the risk assessment has been carried out or changed

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(iv) the security of joints.

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The Contractor must: (a)

ensure that exposure to vibration is eliminated at source or reduce it to the lowest level that is reasonably practicable

(b)

where exposure is likely to be at or above the exposure action value, reduce exposure to vibration to as low a level as is reasonably practicable, by implementing organisational and technical measures which are appropriate to the work activity being carried out

(c)

Contractors must take in to consideration the following general principals of prevention: (i)

alternative work methods which eliminate or reduce exposure to vibration

(ii)

alternative work equipment or an appropriate ergonomic design which, taking account of the work to be done, produces the least vibration

(iii)

the design and layout of the workplace including any rest facilities

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(iv)

the provision of extra equipment that has the effect of reducing injuries caused by exposure to vibration

(v)

the effective maintenance programmes for equipment that can create vibration, the workplace itself and workplace systems

(vi)

the provision of information and training for at-risk employees such that they are aware of how to use work equipment correctly and safely in order to minimise exposure

(vii)

limiting the duration and intensity of exposure to vibration

(viii)

adjusting work schedules and ensuring adequate rest periods

(ix)

the provision of work clothing to protect at-risk employees from cold and damp.

.

The Contractor must ensure that employees are not exposed to vibration above the exposure limit value or, if they are, immediately: reduce exposure to below the exposure limit value

(b)

identify the reasons for the exposure limit value being exceeded

(c)

take appropriate actions to prevent it occurring again.

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The above paragraph does not apply where the exposure of an employee to vibration is usually below the exposure action value but varies markedly from time to time and may occasionally exceed the exposure limit value, provided that: the exposure to vibration averaged over one week is less than the exposure limit value

(b)

there is evidence to show that the risk from the actual pattern of exposure is less than the corresponding risk from constant exposure to the exposure limit value

(c)

the risk from exposure is reduced to as low as level as is reasonably practicable

(d)

the employees concerned are subject to increased health surveillance, where appropriate.

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Any measures taken to comply with these Regulations must be adapted where necessary to take account of any employee(s) who is/are particularly at risk from exposure to vibration.

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If the risk assessment indicates that: there is a risk to the health of employees who are exposed to vibration

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(b)

those employees are likely to be exposed to vibration at or above the exposure action value;

(c)

the Contractor must ensure that those employees are placed under suitable health surveillance, where appropriate.

The health surveillance will be appropriate if: (a)

a link can be established between exposure to vibration and an identifiable disease or any other adverse effect on health

(b)

it is probable that the disease or other effect on health may occur under particular working conditions

(c)

there are valid ways of detecting the disease or other effect on health.

The Contractor must: (a)

ensure that a record is kept and maintained for each employee who undergoes health surveillance and that records are readily available in a suitable form

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(b)

Where, as a result of health surveillance, an employee is found to have an identifiable disease or other adverse effect on health, which is considered by a doctor or other occupational health professional to be the result of exposure to vibration, the Contractor must: ensure that the employee is informed by a suitably qualified person, including advice regarding a need for further health surveillance

(b)

ensure that the Contractor is informed of any significant findings of the health surveillance, allowing for medical confidentiality

(c)

review the risk assessment

(d)

review existing control measures, taking into account any advice given by a doctor.

(e)

consider reassigning the employee to other work where there is no risk from further exposure, taking into account any advice given as above

(f)

ensure that the health of any other employee(s) who has been similarly exposed is reviewed, including the provision of a medical examination where recommended by a doctor, occupational health professional or the administrative authority.

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Where the risk assessment shows a risk to the health of employees who are (or are liable to be) exposed to vibration at or above the exposure action value, the Contractor must provide the employees and their representatives with suitable and sufficient information, instruction and training, which must include:

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allow employees to see their health surveillance records upon being given reasonable notice

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the organisational and technical measures taken to eliminate or control exposure to vibration

(b)

the exposure limit value and the action values

(c)

the significant findings of the risk assessment, including details of any measurements taken, with an explanation of the findings

(d)

why and how to detect and report signs of injury resulting from exposure to vibration

(e)

the employees' entitlement to health surveillance

(f)

how to work safely to minimise exposure to vibration

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the collective results of any health surveillance carried out, anonymised so as not to reveal the personal health record of any individual.

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The information, instruction and training provided as above must be updated by the Contractor to take account of any significant changes in the type of work carried out or method of working.

17

The Contractor must ensure that any person, whether an employee or not, who has been given the responsibility to ensure that the Contractor's duties are carried out, for example a site manager or project manager, receives suitable and sufficient information, instruction and training to enable compliance with these Regulations.

1.2.13.8 Duties of employees 1

Under these Regulations, employees have a legal duty to make themselves available for health surveillance checks (during working hours) as required by the Contractor, the health surveillance being at the Contractor's expense.

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1.2.13.9 The Provision and Use of Work Equipment These Regulations require that Contractors only provide work equipment that is suitable for the job and ensure that it is maintained and kept in good working order.

2

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to competent and specified workers.

3

Employees must be provided with information, instruction and training in the use of work equipment, where necessary for their health and safety.

4

These Regulations require Contractors to provide serviceable and suitable work equipment that will, in conjunction with other vibration management techniques, by virtue of its design or adaptability, eliminate exposure to vibration or reduce it to an acceptable level.

Tools and plant used in the Qatar construction industry that could cause exposure to risks from vibration include:

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Tools likely to cause harmful levels of vibration

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1

(b)

concrete vibro thickeners

(c)

concrete pokers

(d)

plate vibrators

(e)

chisels

(f)

demolition picks

(g)

compressor guns

(h)

pneumatic drills

(i)

angle grinders

(j)

percussive (hammer) drills

(k)

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sanders, and similar reciprocating tools abrasive wheels (e.g. bench grinders)

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road and concrete breaking drills

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HAV

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cutting-off wheels and discs

(n)

power hammers and chisels, including 'Kango' hammers

(o)

needle guns

(p)

chainsaws

(q)

woodworking machinery.

This is irrespective of the tools' power source. Other equipment that may occasionally be used and that is a source of vibration includes rotavators, lawnmowers, brush-cutters and leaf blowers. WBV (a)

rough-terrain forklift trucks and tele-handlers

(b)

vibratory rollers

(c)

mobile crushers

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(d)

dumper trucks and other forms of earth-moving machinery

(e)

delivery vehicles if required to travel on rough terrain.

1.2.13.11

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Managing vibration, vibration risk assessment in practice

A general risk assessment can be briefly defined as a systematic examination of a work process, carried out by a competent person on behalf of a Contractor.

2

A vibration risk assessment follows the same principle but with the emphasis solely on vibration and its potential to cause ill health in employees.

3

The principle of risk assessment is not new. In fact, it is quite likely that many Contractors have been carrying out risk assessments, including vibration risk assessments, during the day-to-day course of their business activities, possibly without thinking of the process in terms of a risk assessment.

4

A survey of what work activities are carried out, using what tools and equipment, and by whom, will establish who is at risk. If there is any doubt as to whether a particular job has the potential to cause vibration-induced health problems or injury, it is better to assume that it has, initially at least.

5

Having established who could be at risk it is necessary to examine work activities in detail to determine which work activities are of genuine concern. As outlined in the summary, only when all other investigative methods have been exhausted should it be necessary to carry out vibration measurements.

6

There are many sources of information available to Contractors, such as:

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the users of vibrating tools themselves; they are the ones who may have experienced the early symptoms of HAVS

(b)

free online vibration measurement databases which are based on the actual vibration measurements achieved during the testing of hundreds of tools of different types in different conditions

(c)

tool manufacturers' published vibration data, although this should be treated with caution as it can be based upon laboratory testing rather than 'field trials' and usually underestimates exposures under real work conditions.

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In construction, it is likely that those exposed to WBV will exceed the exposure action value if they operate machines for several hours per day. The exposure limit value should only be exceeded if the machine is operated very aggressively or with non-approved attachments.

8

For HAV, the guidance is that an employee is probably at risk from HAVS if they are using:

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(a)

hammer action equipment for more than 15 minutes each day.

(b)

rotary equipment for more than one hour each day.

9

Employees who fall into these categories, as well as other at-risk employees, should be asked to complete a short health surveillance questionnaire (details in Appendix 2).

10

An important factor in establishing who is at risk is the actual time that someone is using a vibrating tool, commonly referred to as the 'trigger time'. When asked, it is usual for users to overestimate the length of time that they actually use the equipment. Their response may be 'I use the equipment all day' when in fact what they mean is that they use it on-and-off all day with, for example, a total 'trigger time' of less than 60 minutes per day.

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The elimination or control of exposure to vibration in the workplace

On the basis of the general principles and hierarchy of control measures, Contractors must ensure that employees' exposure to vibration is either eliminated or reduced so far as is reasonably practicable.

2

Where it cannot be eliminated the Contractor must introduce a programme of organisational and technical measures (control measures) consistent with their risk assessment. This must include consideration of: alternative methods of carrying out the work that eliminate or reduce employees' exposure to vibration, for example, stripping off surface coatings by chemical treatment rather than 'power-sanding'

(b)

choice of work equipment that, because of its design or features, or the nature of the work to be done, produces the least possible vibration

(c)

the provision of ancillary equipment that reduces the risk of injury being caused by vibration, for example, manufacturer approved vibration absorbent handles for handheld equipment

(d)

proper maintenance arrangements for the work equipment, workplace and workplace systems, for example, maintaining ground surfaces over which vehicles regularly travel

(e)

the design and layout of workplaces, workstations and rest facilities

(f)

suitable and sufficient information and training for employees so that they may use the equipment safely and correctly in order to minimise their exposure to vibration, such as training mobile machine operators how to correctly adjust their seats and the benefits from driving less aggressively

(g)

limitation of the duration and intensity of the vibration, for example by job rotation

(h)

appropriate work schedules with adequate rest periods

(i)

the provision of clothing to protect employees from cold and damp

(j)

arranging for operatives to stay warm by providing heating for the workplace where needed and possible, together with suitable clothing and gloves

(k)

ensuring that any new tools have vibration control measures built in

(l)

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by adopting a 'buy smooth'/'hire smooth' policy, in which a commitment is made to choose tools that incorporate low vibration technology the reduction of vibration transmission in the path between the source and the handles or other surfaces gripped by operatives' hands

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the minimisation of the amount of force required to apply and control the tools, and keeping them in good order.

3

A 'points' system has been developed by the UK Health and Safety Executive (HSE) which allows for quick estimates of the hand/arm vibration exposure for a worker. Each process is assigned a number of points per hour. Adding the points from each process carried out (calculated by multiplying the points per hour by the number of hours use) provides an estimate of the total exposure. For HAV the exposure action value corresponds to 100 points and the exposure limit value corresponds to 400 points. For WBV the exposure action value corresponds to 100 points and the exposure limit value corresponds to 529 points. Points from HAV and WBV should not be combined.

4

Further guidance on estimating exposure is contained in Appendix 5.

5

A further benefit gained as a result of controlling vibration can be the reduction in noise levels; in some circumstances reducing noise will also reduce vibration, hence many noise

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control techniques also involve techniques for controlling vibration. See: www.hse.gov.uk/vibration/hav/vibrationcalc.htm

1.2.13.13

If the risk assessment shows that there is a risk to the health of employees because of vibration, or they are exposed to vibration in excess of the exposure action value, then the Contractor must give employees information, instruction and training on: how the Contractor is 'managing' vibration in the workplace

(b)

the exposure limit values and exposure action values

(c)

the significant findings of the risk assessments, including details of any measurements taken

(d)

what employees should look for in themselves as regards HAVS, VWF and low back pain and how they should inform their Contractor

(e)

the entitlement to health surveillance

(f)

the safe working practices in place to minimise employees' exposure to vibration

(g)

the collective (as opposed to individual) results of any health surveillance undertaken.

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Information and training for employees

Work equipment Selection of tools and equipment

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1.2.13.14

All equipment that is liable to vibrate, and that is manufactured for use as work equipment, should be designed to have low vibration operating characteristics.

2

Manufacturers are required to provide information on all aspects of their equipment, including details of any vibration that may be expected. In particular, suppliers must provide information on vibration levels if the tool or machine is likely to subject workers to levels of vibration exceeding the exposure action value of 2.5 metres per second squared.

3

However, as some manufacturers may base their vibration figures on laboratory simulation rather than field trials, the figures quoted may be unrealistically low. In many cases information is also available from independent real or simulated work measurements.

4

Vibration emission is one of many important factors to consider when selecting a tool. For example, a very heavy tool might not emit much vibration but could cause manual handling risk. Similarly, some tools might emit less vibration than others but be relatively inefficient, resulting in increased exposure times, higher grip and push forces. Always select the right tool for the job.

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Regular maintenance of tools 5

Correctly installed and smooth running machines will, in time, vibrate as the machinery parts become worn.

6

The parts of machinery that contribute to vibration are: (a)

worn bearings

(b)

dirty fan blades (unbalanced fans)

(c)

worn mountings or worn anti-vibration pads

(d)

misaligned shafts

(e)

unbalanced rotating parts

(f)

loose bolts

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(g)

damaged gear teeth

(h)

blunt cutting tools and blades

(i)

worn suspension components

(j)

incorrect tyre pressures

(k)

damaged seats

(l)

damaged tyres/tracks.

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The lack of correct maintenance and lubrication will produce increased vibration magnitudes.

8

Machines should, therefore, be maintained at regular intervals and any detected faults rectified as soon as possible, thus reducing the risk of vibration problems. Cutting tools or blades should be kept sharp by maintenance or replacement, as appropriate.

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1.2.13.15

Health issues

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Health surveillance

If the findings of the risk assessment, feedback from employees or other sources of information show that there is a risk to the health of employees because of their use of vibrating tools, or that employees are exposed to vibration in excess of the exposure action value, then the Contractor must ensure that the employees are under suitable medical surveillance where it is appropriate.

2

A recommended five-stage system of health surveillance for HAV:

1

An initial questionnaire to be answered when employees first move into any job that involves exposure to vibration (see Appendix 2).

2

A short questionnaire answered annually by employees exposed to vibration (see Appendix 3).

3

A formal HAVS health assessment carried out by a qualified person, for example, an occupational health nurse.

4

A formal diagnosis made by a doctor who is qualified in occupational health, and who will assess fitness for work

3

Contractors who consider that their employees are at a potential risk from HAVS should

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appoint a person to manage the health surveillance programme and be actively involved in the initial stages. 4

This person: (a)

does not need to be medically qualified (i)

should not attempt diagnosis or be judgemental as to the causes of HAVS with regard to individual cases

(ii)

should receive training from an occupational health professional

(iii)

must be able to describe the symptoms of HAVS.

The person should have experience of the working environment, be able to gain the trust and co-operation of employees, and understand the importance of confidentiality.

6

For WBV, detailed health surveillance is not possible, as there are many non-vibration causes of back pain. An example of a health monitoring questionnaire is given in Appendix 4.

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Keeping records

Health surveillance records should be stored 'in house' in a way that retains their confidentiality, possibly under the control of the person nominated to manage the health surveillance system.

8

Contractors should create a health record for each individual who is exposed to vibration and keep them for at least as long as they are under health surveillance and possibly longer.

9

Health records should be kept up to date and should include full details of the employee's exposure to vibration and any questionnaires that have been completed.

10

It is considered to be good practice if employees are offered a copy of their health records when they leave the Contractor.

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Maintaining blood circulation Keeping the hands and body warm is essential to help maintain good blood flow to the fingers and reduce the risk of injury due to HAV.

12

Specific measures might include:

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(a)

wearing gloves

(b)

using proprietary heating pads for the hands

(c)

using tools with heated handles

(d)

avoiding tools that have pneumatic exhausts that discharge towards the hands

(e)

allowing operatives to warm up before starting work, and helping them to stay warm

(f)

wearing warm, weatherproof clothing in cold, wet areas

(g)

advising those who smoke to stop or cut down (smoking reduces blood circulation)

(h)

massaging and exercising fingers during work breaks.

Work patterns 13

One of the most simple but also one of the most effective ways of minimising risks arising from vibration is by reducing the time when operatives are actually exposed to vibration.

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14

If the use of a vibrating tool is shared between a team of employees, as opposed to it only being used by one person, the tool may be kept in productive use for the day.

15

Moving any employees not operating the tools at that time onto other areas of work will considerably lessen the effects of vibration on users, by splitting and rotating the work. This will also assist the maintenance of blood circulation, thus lessening the chances of injury or ill health being caused to users by the vibrating tool. Personal protective equipment Some retro-fit products are available that are designed to protect operators from vibration.

17

Only those approved by the machine manufacturers should be used.

18

The wearing of anti-vibration gloves is not recommended. Problems with anti-vibration gloves include:

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reduced flexibility at the hands resulting in higher grip and push forces and loss of precise tool control

(b)

the possibility of gloves amplifying the tool vibration in some cases (these cases are very difficult to predict)

(c)

anti-vibration gloves are only tested in one direction and vibration occurs in three directions

(d)

field trials of gloves have shown that the vibration isolation materials are not always durable.

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(a)

However, if anti-vibration gloves are to be tried, it is essential that they carry the CE-mark and are selected by a competent person. One benefit from gloves is that they keep the hands warm and offer other protection.

20

Therefore, if a Contractor intends to provide items of PPE as part of their strategy to reduce the risks from vibration in the workplace, it is important that the correct PPE is selected. All PPE produced or imported by reputable companies is manufactured to British and European Standards. As with all PPE for use at work, gloves or anti-vibration protection should be selected by a competent person who can ensure, in discussion with the supplier, that they meet the appropriate standards. Most leading manufacturers and suppliers will offer advice on the selection of different types of gloves and other PPE.

21

Ear defenders should be worn to lessen the effects of the noise created by vibrating tools, and eye protection should be worn to avoid the risks from dust or flying particles.

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1.2.13.16

Summary

1

The control of vibration at work makes good business sense for Contractors. Employees who are able to work are of far greater benefit to the Contractor than those who are off sick as a result of work-related ill health, or those who cannot work to maximum effect due to HAVS, VWF or back pain.

2

In summary, these Regulations require that the Contractor should: (a)

assess the risks to the health of your employees from vibration, and to effectively plan for its control

(b)

properly manage the risks

(c)

provide suitable work equipment for your employees, having regard for technical developments in tool design and vibration suppression

(d)

maintain equipment fully and correctly

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give employees and supervisors information and training on the risks to health caused by vibration, and on the safe use of the work equipment that is provided

(f)

provide health surveillance/health monitoring where risks cannot be completely eliminated

(g)

consult employees on your proposals for dealing with vibration.

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Construction Site Safety 1.2.13 Appendix 1 Vibration - actions by Contractor

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Construction Site Safety 1.2.13. Appendix 2 Initial hand/arm vibration screening questionnaire Medical in confidence - when completed Initial screening questionnaire for workers using hand-held vibrating tools, hand-guided vibrating machines and hand-fed vibrating machines. Date .......................................................................................................................................................... Name ........................................................................................................................................ Occupation ................................................................................................................................................ Address .....................................................................................................................................................

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Date of birth ..............................................................................................................................................

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Contractor name ......................................................................................................................................... Y/N

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Have you ever used hand-held vibrating tools, machines or hand-fed processes in your job?

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If YES:

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a) list year of first exposure ........................................................................................................

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b) when was the last time you used them? ........................................................................... (detail work history overleaf) Y/N

2 Do you have tingling of the fingers at any other time?

Y/N

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1 Do you have any tingling of the fingers lasting more than 20 minutes after using vibration equipment?

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3 Do you wake at night with pain, tingling, or numbness in your hand or wrist?

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4 Do one or more of your fingers go numb more than 20 minutes after using vibration equipment?

Y/N

5 Have your fingers gone white* on cold exposure?

Y/N

6 If YES to 5, do you have difficulty re-warming them when leaving the cold?

Y/N

7 Do your fingers go white at any other time?

Y/N

8 Are you experiencing any other problems with the muscles or joints of the hands or arms?

Y/N

9 Do you have difficulty picking up very small objects, e.g. screws or buttons or opening tight jars?

Y/N

* Whiteness means a clear discoloration of the fingers with a sharp edge, usually followed by a red flush.

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10 Have you ever had a neck, arm or hand injury or operation? If so, give details .......................................................................................................................

Y/N

11 Have you ever had any serious diseases of joints, skin, nerves, heart or blood vessels? If so, give details .......................................................................................................................

Y/N

12 Are you on any long-term medication? If so, give details ...................................................................................................................

Y/N

Occupational history

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Job title

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……………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………………

Signed:

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I certify that all the answers given above are true to the best of my knowledge and belief.

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Return in confidence to:

Date:

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Construction Site Safety 1.2.13. Appendix 3 Annual hand/arm vibration screening questionnaire for health surveillance Screening questionnaire for workers using hand-held vibrating tools, hand-guided vibrating machines and hand-fed vibrating machines. Date .......................................................................................................................................................... Employee name ........................................................................................................................................ Occupation ................................................................................................................................................

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Address .....................................................................................................................................................

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Date of birth .............................................................................................................................................. National insurance number .......................................................................................................................

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Contractor name .........................................................................................................................................

Y/N

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Date of previous screening ........................................................................................................................ Have you been using hand-held vibrating tools, machines or hand-fed processes in your job, or if this is a review, since your last assessment? (detail work history overleaf)

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If NO or more than 2 years since last exposure, please return the form - there is no need to answer any further questions.

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If YES:

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1 Do you have any numbness or tingling of the fingers lasting more than 20 minutes after using vibrating equipment?

Y/N

3 Do you wake at night with pain, tingling, or numbness in your hand or wrist?

Y/N

4 Have any of your fingers gone white* on cold exposure?

Y/N

5 Have you noticed any change in your response to your tolerance of working outdoors in the cold?

Y/N

6 Are you experiencing any other problems in your hands or arms?

Y/N

7 Do you have difficulty in picking up very small objects, e.g. screws or buttons or opening tight jars?

Y/N

8 Has anything changed about your health since the last assessment?

Y/N

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2 Do you have numbness or tingling of the fingers at any other time?

* Whiteness means a clear discoloration of the fingers with a sharp edge, usually followed by a red flush.

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10 Have you ever had a neck, arm or hand injury or operation? Y/N If so, give details ..................................................................................................................... 11 Have you ever had any serious diseases of joints, skin, nerves, heart or blood vessels? Y/N If so, give details ..................................................................................................................... 12 Are you on any long-term medication? Y/N If so, give details .....................................................................................................................

Occupational history Dates

Job title

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………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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………………………………………………………………………………………………………………………

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……………………………………………………………………………………………………………………… I certify that all the answers given above are true to the best of my knowledge and belief.

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Signed:

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Date:

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Construction Site Safety 1.2.13 Appendix 4 Sample health monitoring questionnaire Date of assessment................................................................................................................................... Employee No/Payroll No ........................................................................................................................... Name ........................................................................................................................................................ Date of birth .............................................................................................................................................. Job title ..................................................................................................................................................... Yes

No

.

Any change in duties since last questionnaire?

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Recent experience

Yes

No

Yes

No

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Is there currently any movement or activity that causes you pain in your back?

No pain

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Please describe the severity of the pain experienced:

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Have you suffered any back/neck/shoulder pain in the last 12 months

Pain as bad as

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3

4

5

6

7

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it could be

Yes*

No

Yes*

No

Yes*

No

Yes*

No

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Note: If severity above 5 indicated, refer on for further advice. However if rank less than 5, but for three consecutive assessments, then refer for further advice. *

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Have you had to take any medication to deal with the pain experienced?

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Have you had to seek medical advice regarding this pain?

Has this back/neck/shoulder pain resulted in time off from work?

Have you had any accidents or injury to the back in the last two years? Action/advice Referral for further advice? Other advice provided? * Further advice should be sought from an occupational health professional or GP in these cases.

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I certify that all the answers given above are true to the best of my knowledge and belief. Signed:

Date:

Return to:

Hand-arm vibration syndrome (HAVS): is a disorder which affects the blood vessels, nerves, muscles and joints of the hand, wrist and arm.



can become severely disabling if ignored; and



its best known form is vibration white finger (VWF) which can be triggered by cold or wet weather and can cause severe pain in the affected fingers.

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Signs to look out for in hand-arm vibration syndrome:

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tingling and numbness in the fingers



in the cold and wet, fingers go white, then blue, then red and are painful



you can't feel things with your fingers



pain, tingling or numbness in your hands, wrists and arms



loss of strength in hands.

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Job title

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Construction Site Safety 1.2.13 Appendix 5 Estimating exposure to hand arm vibration You may be able to get suitable vibration data from the equipment handbook, or from the equipment supplier. See Table 1 for guidance examples of vibration levels which have been measured on equipment in use. There are also some databases on the internet which may have suitable vibration data.

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If you plan to use the manufacturer's vibration data you should check that it represents the way you use the equipment (see 'Duties of manufacturers and suppliers') since some data may underestimate workplace vibration levels substantially. Ask the manufacturer for an indication of the likely vibration emission of the tool when your employees are using it. If you are able to get vibration data from the manufacturer which is reasonably representative of the way you use the equipment, it should be suitable for you to use in estimating your employees' exposure. However, if the only information available to you is the vibration emission declared in the equipment's handbook, it may be safer to double this figure before using it for estimating daily exposures. You also need to check, by observing them, how long employees are actually exposed to the vibration (i.e. the total daily 'trigger time' with the equipment operating and in contact with the employee's hand(s)). Employees are unlikely to be able to provide this information very accurately themselves. You could observe and measure the trigger time over, for example, half an hour and then use the result to estimate the trigger time for the full shift. Alternatively, where the work task is repetitive, e.g. drilling large numbers of holes in masonry, you could measure the trigger time when drilling several holes and multiply the average by the number of holes typically drilled in a shift

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Table 1 Some typical vibration levels for common tools Lowest

Typical

Highest

5m/s

2

12 m/s

2

20 m/s

2

8m/s

2

15 m/s

2

25 m/s

2

Hammer drills/combi hammers

6m/s

2

9 m/s

25 m/s

2

Needle sealers

5 m/s

2

-

18 m/s

2

-

40 m/s

2

-

8m/s

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Demolition hammers

Scabblers (hammer type)

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Angle grinders

4 m/s

2

2

Clay spades/jigger picks

-

16 m/s

2

-

Chipping hammers (metal)

-

18 m/s

2

-

Stone-working hammers Chainsaws Brushcutters Sanders (random orbital)

10 m/s

2

2 m/s -

6m/s

2

2

30 m/s 2

-

2

-

4 m/s

7-10 m/s

2

2

-

If the employee is exposed to vibration from more than one tool or work process during a typical day, you will need to collect information on likely vibration level and 'trigger time' for each one. Workplace vibration measurements If you want to obtain vibration measurements for your own tools you will need to arrange for a competent person to carry out measurements for you using specialised equipment. Measurement

QCS 2014

Section 11: Health and Safety Part 1.02: Occupational Health and Hygiene (Regulatory Document)

Page 198

results can be highly variable, depending on many factors, including the operator's technique, the condition of the work equipment, the material being processed and the measurement method. The competence and experience of the person who makes the measurements is important so that they can recognise and take account of these uncertainties in producing representative vibration data.

2

Tool vibration (m/s )

3

4

5

6

7

10

12

15

Points per hour (approximate)

20

30

50

70

100

200

300

450

.

Multiply the points assigned to the tool vibration by the number of hours of daily 'trigger time' for the tool(s) and then compare the total with the exposure action value (EAV) and exposure limit value (ELV) points.

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100 points per day = exposure action value (EAV)

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400 points per day = exposure limit value (ELV)

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Table 2 Simple 'exposure points' system

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Page 199

Construction Site Safety 1.2.14 Compressed Air

it can enter body orifices such as the mouth, ears and anus, causing severe and often fatal injuries;

(b)

at high pressure it can penetrate the skin;

(c)

particles or oil carried in an air jet can damage the eyes;

(d)

oil-coke deposits in a system can spontaneously ignite and cause an explosion;

(e)

vessels containing compressed air, even at comparatively low pressure, can explode violently once their integrity is lost; and

(f)

dirty or 'wet' air can lead to corrosion and blocked valves which may make the system unsafe.

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(a)

This section explains how to minimise the likelihood of such problems, but it does not give specific advice on air separation plant, the pneumatic transportation of materials through pipelines or the supply of respirable air. Reference in this section to a particular standard does not preclude using an equally effective alternative standard.

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This section provides for the safe use of compressed air by giving advice to designers, manufacturers, installers, users and others concerned with or responsible for health and safety at work (Note: Section 9, Part 14 of the QCS covers air blowers and compression equipment). There are many ways in which compressed air can be dangerous, for example:

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a blocked outlet or some other restriction to flow;

(b)

failure of automatic controls combined with low air consumption;

(c)

compressor malfunction, e.g. overspeeding;

(d)

an external fire near the pressure system; and

(e)

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The major hazard associated with compressors is over-pressurisation, which may arise from:

overheating and the build-up of carbonaceous deposits, both of which can lead to fires or explosions. Although they are rare, fires and explosions can also occur as a result of oil or oil vapour being ignited in the pressure system.

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Hazards

To mitigate the risks of the hazards listed above occurring, a structured and audited equipment maintenance plan must be implemented (see standards such as HSG 139). Furthermore in the use of compressed air for activities other than for respiratory purposes, the user must make every effort to avoid the risk of harm to themselves or their colleagues. To this end, compressed air nozzles must be directed away the users and care must be taken to ensure that they are not directed towards other individuals.

END OF DOCUMENT

QCS 2014

Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

Page 1

REGULATORY DOCUMENT ...................................................................... 1

1.3

WORKING AT HEIGHTS ............................................................................ 1

1.3.1

Work at Height ........................................................................................................................... 4

1.3.2

Ladders, Steps and Lightweight Staging ................................................................................. 18

1.3.3

Working Over or Near to Water including Liquid Bodies ......................................................... 32

1.3.4

System Scaffolds and Mobile Towers ...................................................................................... 50

1.3.5

Tube and Fitting Scaffolds ....................................................................................................... 63

1.3.6

Safe Working on Roofs and at Heights .................................................................................... 93

1.3.7

Fall-arrest and Suspension Equipment .................................................................................. 110

1.3.8

Safety with Steelwork ............................................................................................................. 135

1.3.9

Roofing and Fragile Surface Practices .................................................................................. 146

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QCS 2014

Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

Page 2

FORWARD

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This Section of the Regulatory Document (RD) was produced as a project deliverable under Ministry of Municipality and Urban Planning Contract Number P2009/3, entitled “Consultancy Services for the Preparation of Codes and Standards for Safety and Accident Prevention on Construction Sites”. During the latter stages of the project, the Committee responsible for the administration of the project decided that the RD and the associated Safety and Accident Prevention Management/Administration Systems (SAMAS) would be best delivered to stakeholders via the portal provided by the Qatar Construction Standards (QCS). The QCS includes references and certain sections which address occupational health and safety. To ensure that that users of the RD/SAMAS are fully aware of the where occupational health and safety issues are addressed in the QCS, the following table summarises where potential overlaps may occur. For consistency, it is recommended that in matters relating to occupational health and safety reference is made first to the RD/SAMAS. For the purpose of clarity, however, references are made in the relevant section of the RD/SAMAS to their comparable sections in the QCS and vice versa.

QCS 2014

Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

Page 3

Sr. No

QCS 2014 Section No.

Part No.

Part Name

1

1

7

Submittals

8

7.5.2

Health and Safety Organization Chart

2

1

7

Submittals

9

7.6.1

Health and Safety Plan

3

1

10

Health and Safety

All

All

All

4

1

11

Engineer's Site Facilities

10

11.4.6

Safety Equipment and Clothing

5

1

14

Temporary Works and Equipment

3

14.4

Test Certificates for Cranes and Lifting Tackle

6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1

General Requirements for Piling Work

7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

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42

Item Name

.

Page No. Item No.

Safety and Management

4.9.1.13 Protection of Testing Equipment 1.6

Temporary Fencing

15

7.8.13

Safety Requirements

Works in Relation to Services

4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

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4&5

8

1

17

8

8

Painting and Protective Coatings

6

8.1.9

Safety

18

8

9

Trenchless Pipeline Construction

7

9.2.5

Safety Requirements

19

8

10

Pipeline Cleaning and Inspection Survey

4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

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16

Sewer Rehabilitation

9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16

Noise Levels and Vibration

1

23

m

11

19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1

General Provisions for electrical Installation

7&8

1.1.11

Fire and Safety Precautions

25

21

1

General Provisions for electrical Installation

14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5

Fire Resistance Period

28

29

3

Geotechnical Specifications

4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4

Safety Measures and Systems

32

29

7

Concrete Structures

6

7.1.10

Safety Railing

QCS 2014

Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

Page 4

Construction Site Safety 1.3.1

Work at Height

1.3.1.1 Key points 1

Falls from height are the main source of fatalities and injuries to construction workers.

2

Falls from 'low heights' (below 2 metres) are the cause of many deaths and injuries.

3

Working at height is defined as working at any height from which a fall could cause personal injury.

4

Work at height requires that such work is:

carried out using appropriate equipment to prevent falls

(c)

organised so that the distance and possible consequence of any fall are minimised

(d)

risk-assessment based

(e)

properly planned and supervised by a competent person(s)

(f)

carried out by competent operatives.

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(b)

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Accidents that occurred through working at height show that common factors include the failure of: all parties to recognise that there was a problem

(b)

management to provide a safe system of work

(c)

management to ensure that the safe system of work was followed

(d)

management to provide adequate information, instruction, training or supervision

(e)

the victim to use appropriate equipment

(f)

management to provide safe plant and equipment.

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(a)

Section 14 of the QCS covers roofing and roofworks and Section 24, Part 1 relates to scaffolding.

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Note:

avoided if it is reasonably practicable to do the job another way

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1.3.1.2 Introduction

The intent of these Regulations is to reduce the number of deaths and injuries resulting from falls, and so improve the safety performance of the industry.

2

They cover all circumstances where a person:

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(a)

is working at height or

(b)

is gaining access to or egress from such a place of work, either above or below ground and

(c)

'could fall a distance liable to cause personal injury', that is, any distance whatsoever.

Common examples of tasks carried out within the construction industry classified as work at height include: working on a scaffold; working from a mobile elevated working platform; being on the back of a lorry; using cradles or ropes to gain access; working close to an excavation or a cellar opening; painting at height; working on staging or trestles, and using ladders or stepladders for cleaning and maintenance tasks. Many other jobs in the construction industry also involve working at height and are covered by these Regulations.

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Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

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1.3.1.3 Requirements of these Regulations 1

The key provisions of these Regulations are that Contractors should: (a)

where it is reasonably practicable, avoid the need to carry out work at height

(b)

where such work cannot be avoided, select the most appropriate equipment for the work and to prevent falls

(c)

reduce the distance of, and potential consequences of, any fall

(d)

ensure that the work is properly planned, risk assessment-based and that it is carried out safely.

(e)

ensure the work is carried out by trained and competent persons who are adequately supervised.

The use of a ladder or stepladder is not prohibited by these Regulations; however, a greater degree of consideration must be given to using an alternative means of access before selecting a ladder or stepladder for use. A decision to use this type of access equipment must be justified by the findings of a risk assessment that clearly shows that, given all of the circumstances, it is reasonable to use such equipment rather than safer types of access equipment.

3

It is to be hoped that these Regulations will be a further stimulus to architects and designers to 'design out' work at height for the construction and ongoing maintenance of buildings, or at least make safe working at height easier to further contribute to safety in the Qatar construction industry.

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2

'Access and egress' includes ascent and descent.

(b)

'Fragile surface' means a surface which would be liable to fail if any reasonable foreseeable load were to be applied to it. This will obviously include the weight of a person or any work equipment or materials.

(c)

'Ladder' includes any fixed ladder or stepladder.

(d) (e)

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Below are the most important definitions from within these Regulations.

'Personal’ fall protection system' means: a fall prevention, work restraint, work positioning, fall arrest or rescue system other than a system in which the only safeguards are collective safeguards, or

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1.3.1.4 Definitions

(f)

rope access and positioning systems.

(g)

'Suitable' means suitable in any respect which it is reasonably foreseeable will affect the safety of any person.

(h)

'Work at height' means work in any place, including a place at or below ground level, along with access there to and egress there from (except by a staircase in a permanent workplace) where, if the measures required by these Regulations were not taken, a person could fall a distance liable to cause personal injury.

(i)

'Working platform': (i)

means any platform used as a place of work or as a means of access to or egress from a place of work

(ii)

includes any scaffold, suspended scaffold, cradle, mobile platform, trestle, gangway, gantry and stairway which is so used.

QCS 2014

Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

Page 6

1.3.1.5 Reasonably practicable 1

The term reasonably practicable is used in these Regulations. Therefore a Contractor can look at what the risks in a task involving work at height actually are, and what it would cost to avoid them. If it would cost a great deal of money or use of other resources to avoid a very small risk, then it may not be 'reasonably practicable' to avoid it.

1.3.1.6 Contractors Duty The requirements of these Regulations are: on a Contractor to apply to work carried out by their employees and by any other person(s) under the Contractor's control, to the extent of that control.

(b)

to self-employed persons, together with persons under their control, to the extent of that control.

(c)

to persons who are not self-employed, in relation to work being carried out for them and under their control, to the extent of their control.

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1.3.1.7 Duty of employees

These Regulations also apply to employees in that they have duties.

2

Employees must:

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report any activity or defect relating to work at height which they know is likely to endanger the safety of themselves or that of any other person

(b)

use any work equipment or safety device provided for work at height in accordance with any training and/or instructions which they have received.

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Failure by an employee to comply with the above is an offence which could, in the appropriate circumstances, be dealt with by company discipline procedures.

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1.3.1.8 Organisation and planning of work It is the responsibility of every Contractor to ensure that all work at height is properly planned, appropriately supervised and carried out in a safe manner, taking into account adverse weather conditions that could jeopardise the health and safety of employees. Planning must include the selection of appropriate work equipment, and planning for any emergencies or any rescue.

2

A Contractor will probably meet most of the requirements of this regulation if they have carried out and properly implemented a suitable and sufficient risk assessment.

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1.3.1.9 Competence 1

Contractors must ensure that no person engages in any activity concerning work at height (including the organisation and planning of the work, and selection of the work equipment), unless they are trained and competent to do so or, if they are being trained, it must be by a rd 3 party accredited company, trainees must be supervised by a trained and competent person.

2

The level of supervision is important. The supervisor will need to be able to intervene, physically or by virtue of their authority, if an unsafe situation begins to develop and thereby rectify the situation or stop the work in progress. The less experience an employee has of working at height, the greater will be the appropriate level of supervision required.

QCS 2014

Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

Page 7

Competence may be taken to mean: 3

A person who has practical and theoretical knowledge of the appropriate aspects of work at heights, together with actual experience of what they are to do, which will enable them to ensure that all necessary planning and assessments have been prepared, and safety precautions taken, so that the work may be carried out safely, or that they may work safely.

If they will be inspecting work equipment then 'competence' may be taken to mean: A person who has practical and theoretical knowledge together with actual experience of what they are to examine, which will enable them to detect errors, defects, faults or weaknesses that it is the purpose of the examination or inspection to discover; and to assess the importance of any such discovery.

5

Training is an element of the competence necessary to work at height. Similarly, those who deliver such training must also be competent to do so. To assist trainers in this respect British Standard BS 8454:2006 is to be used. The title of this standard is:

6

'Code of practice for the delivery of training and education for work at height and rescue.'

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1.3.1.10 Avoidance of risks from work at height

Contractors to ensure that risk assessments are carried out.

2

In addition, these Regulations require that:

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'every Contractor shall ensure that work is not carried out at height where it is reasonably practicable to carry out the work safely otherwise than at height.' This clearly requires the Contractor to carry out a detailed study or assessment of all the ways in which the work could be carried out. If a way can be found to carry out the work other than at height, then the Contractor should do so, provided that it is reasonably practicable.

4

A good example of how this can be achieved was demonstrated during the construction of an over-bridge. The bridge deck was completed on flat ground before the spoil was excavated from below it, thus virtually eliminating the need for working at height and reducing the height at which people had to work when constructing the upper parts of the structure.

5

Ground-level fabrication is another way of eliminating or at least reducing some tasks that have been traditionally carried out at height.

6

The fact that falls from height often result in fatal injuries should weigh heavily in any risk assessment and 'cost versus risk calculation' in deciding if an alternative to working at height is reasonably practicable.

7

Where work at height has to take place because there is no reasonably practicable alternative, these Regulations require the Contractor to take suitable and sufficient measures, so far as is reasonably practicable, to prevent any person falling a distance likely to cause injury.

8

The measures include, but are not limited to:

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(a)

ensuring that the work is carried out from an existing (safe) place of work

(b)

ensuring that any means of access to or egress from a place of work using an existing

QCS 2014

Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

Page 8

means it is reasonably practicable to do so safely, and under appropriate ergonomic conditions. 9

Where these control measures do not eliminate the risk of a fall occurring, then the Contractor must: (a)

use suitable and sufficient measures, including the provision of work equipment, to minimise the distance and consequences of any fall

(b)

or, if it is not reasonably practicable to minimise the distance of a fall, then to minimise the consequences of a fall

(c)

provide additional training and instructions, or other suitable and sufficient measures, to prevent, so far as reasonably practicable, any person falling any distance likely to cause them personal injury.

In order to minimise the distance and/or consequences of any fall, suitable and sufficient measures may include the use of safety harnesses, safety nets, safety mats and air bags.

11

Where safety harnesses or safety nets are used, a plan must be developed to rescue anyone who has fallen and must allow for the fact that they may be injured or unconscious. This is particularly important if someone is suspended in a safety harness. Suspension trauma can occur very rapidly and result in severe discomfort or even death if the casualty is not rescued quickly.

12

Ideally, safety nets will be rigged immediately below the place of work and rescue should not be a problem. Anyone who has fallen into the net should be able to simply clamber out of it, or an injured/unconscious person easily rescued. However, if any recovery would prove to be unduly difficult, an alternative method of work which does not involve the use of a safety harness or nets would be more appropriate.

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1.3.1.11 Selection of equipment for work at height In selecting work equipment for use in work at height there is a requirement for the Contractor to select work equipment or other measures which will give collective protection to employees as a whole, rather than just individual personal protection for one person.

2

For example, a guard-rail will protect everyone, whereas a safety harness only protects the wearer.

3

These Regulations require that Contractors follow current best industry practice when selecting equipment for work at height. In particular, Contractors are required to take account of:

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(a)

working conditions and risks to the safety of the persons at work

(b)

access and egress and distances to be negotiated

(c)

distance and consequences of any potential fall

(d)

duration and frequency of use of the work equipment

(e)

need for and ease of evacuation and rescue in any emergency

(f)

any additional risks posed by the installation, use, or removal of the work equipment, and any evacuation or rescue from it, and

(g)

Any work equipment which is selected must:

(h)

be appropriate for the work intended to be carried out

(i)

have dimensions and load-bearing characteristics

(j)

allow passage of persons and materials without risk

QCS 2014

(k)

Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

Page 9

be the most suitable equipment for avoiding risks while working at height.

Requirements for particular work equipment These Regulations cover the provision of: guard-rails, toe-boards, barriers and similar means of protection

(b)

working platforms such as scaffolds and trestles

(c)

nets, airbags and other collective means of arresting falls

(d)

personal fall protection systems

(e)

work positioning systems

(f)

rope access and positioning systems

(g)

fall arrest systems

(h)

work restraint systems

(i)

ladders.

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Guard-rails must be installed to at least 950 mm above the work surface or the edge from which a person may fall.

6

Although there is no statutory minimum height for toe-boards, both BS EN 13374 and TG20:08 recommend a minimum of 150 mm. They must be suitable and sufficient to prevent the fall of persons or materials. In line with current industry practice it is anticipated that scaffold boards on edges will continue to be used in most circumstances.

7

The maximum distance or gap between the top of a toe-board and the mid guard-rail, or between the mid guard-rail and the top guard-rail is 470 mm.

8

Where brick guards or similar items are used as a 'means of protection', then they must be:

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placed so as to prevent the fall of persons or materials

(b)

of a suitable size and strength

(c)

placed or secured so that they do not become accidentally displaced.

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(a)

Guard-rails may be removed on a temporary basis for the movement of materials, provided that suitable and effective alternative fall protection measures are put in place for the duration of the work, and that the guard-rails are replaced as soon as possible after the work is completed.

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1.3.1.12 The use of scaffolds 1

All scaffolding works must be conducted in accordance with BS EN 12811-1:2003. Temporary work equipment. Part 1. Scaffold -Performance requirements and general design.

2

Additional guidance is produced by the UK National Access and Scaffolding Confederation (UK NASC), which sells TG20:08 A guide to good practice for scaffolding with tubes and fittings' 'SG4:05 Preventing falls in scaffolding and falsework” and NASC User Guide SG4: You. Preventing Falls in Scaffolding & falsework 2006. The use of fall arrest equipment whilst erecting, altering and dismantling scaffolding.

1.3.1.13 The use of ladders, stepladders and trestles 1

Ladders may be used for access to and egress from the place of work, and ladders, stepladders and trestles may be used to work from, provided that all of the requirements are properly complied with.

QCS 2014

Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

Page 10

The primary objective of these Regulations is to eliminate work at height (and so the possibility of falls) and where that is not possible, to ensure that all work at height is carried out safely and that the work equipment being used, such as ladder or stepladder, is appropriate, suitable and safe for the work.

3

In deciding to use a ladder for access or egress, or a ladder, stepladder or trestle for work at height, the Contractor must have carried out an assessment and found that it is not reasonably practicable to use any safer means, and that a risk assessment has shown that the risks from using the ladder, stepladder or trestle are low.

4

Ladders should be used in accordance with manufacturers' instructions. They must be the right ladder for the job, positioned at the correct angle, placed on a firm level surface, and secured or otherwise prevented from slipping or moving. Users should face the ladder at all times when climbing up or down, have both hands free, and not carry anything that would interfere with their safety or balance.

5

Ladders may be used as a place of work, subject to the above, and if it is light work of short duration. Users should be trained in how to work safely on ladders, for example not to overreach.

6

When stepladders are to be used to carry out work they should be of a suitable size and type. Generally, stepladders should be placed facing the work. They should not be used side-on to the work in any situation where a sideways load could be applied. Again, the work should be light and of short duration.

7

Trestles should be of sound construction, and properly set up on a surface which will bear their weight as well as any loading of persons or materials. If they are adjustable using telescopic adjustment, they should have high tensile pins in the adjusters.

8

If they are fitted with wheels or castors, they should have brakes or other suitable devices on the wheels or castors.

9

Trestles should be fitted with guard-rails and toe-boards, where appropriate.

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1.3.1.14 Fragile surfaces

Contractors must ensure that no person passes across or near, or works on, from or near, any fragile surface when it is reasonably practicable to carry out the work safely without their having to do so.

2

Where this requirement cannot be met, then the Contractor must:

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(a)

provide and ensure that there are suitable and sufficient platforms, coverings, guardrails or other similar means of support or protection, which must be capable of supporting any foreseeable load or loading

(b)

where the risk of a fall still remains, take suitable and sufficient steps to minimise the distance and consequences of any fall should it occur

(c)

place prominent warning notices at the approach(es) to any fragile material

(d)

where such notices cannot be used, ensure that employees (and others as appropriate) are made aware of the fragile materials by other means.

1.3.1.15 Falling objects 1

Contractors must take suitable and sufficient steps (including prohibiting the throwing down of materials) to prevent, so far as is reasonably practicable, the fall of any materials or objects which are likely to cause any injury to any person. 'Suitable steps' will include the use of such items as brick guards, toe-boards and debris nets.

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2

Where such falls cannot be prevented, or in the interests of safety, suitable and sufficient measures must be taken to prevent persons from being hit by falling objects or materials. This will cover the use of protective fans, boarded or roofed walkways and 'exclusion zones' at ground level.

3

Materials on scaffolds and working platforms must be stored so that they cannot fall or pose a risk of injury to anyone by their collapse, overturning or unintended movement.

1.3.1.16 Danger areas 1

In any workplace where there is a risk of any person falling or of persons being struck by falling objects, then Contractors must take all reasonably practicable steps to prevent any unauthorised access to that area, and appropriate warning signs must displayed.

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1.3.1.17 Inspection of work equipment Where the safety of work equipment used for working at height, for example a scaffold, depends upon how it has been installed or assembled, then it must not be used in that place or elsewhere until after it has been inspected by a competent person. Throughout these Regulations, 'inspection' means any visual or more rigorous inspection, and any appropriate testing that a competent person decides is necessary.

2

All work equipment exposed to conditions causing deterioration that may result in dangerous situations must be inspected. This will ensure that it remains safe and that any deterioration can be detected and remedied.

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Inspections must take place: at suitable intervals

4

after each time that exceptional circumstances have occurred that are liable to have jeopardised the safety of the work equipment.

5

In addition to these requirements, any working platform that is used for construction work, and from which a person could fall more than 2 metres, must not be used unless it has been inspected in that position within the previous seven days. A mobile working platform (such as a mobile scaffold tower or a mobile elevating work platform) must have been inspected within the previous seven days.

6

Contractors must ensure that no work equipment is used unless they have evidence that the last inspection required by these Regulations was carried out.

7

If there is no evidence of the last inspection then the work equipment cannot be used on site until an inspection is carried out.

8

These formal inspection(s) should not be regarded as a substitute for any routine pre-use checks that should be carried out by the user.

9

What is a 'suitable interval' should be decided by a competent person, based on the results of risk assessments, and then be reviewed in the light of experience.

10

The purpose of an inspection is to identify if the work equipment is safe to use, and that any defect or deterioration is detected and repaired. If this is not possible, the work equipment should be removed from service and its re-use prevented before it becomes an unacceptable risk.

11

The results of every inspection must be recorded and kept on site until the construction work is completed, and after that they must be kept at one of the company offices for three

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months. 12

Any computer-based system should be secure and cannot be interfered with. Systems may also be in the form of a 'register'.

1.3.1.18 Inspection of places of work at height 1

So far as is reasonably practicable, every Contractor must ensure that the surface of every place of work at height, every parapet and any permanent rail or other such fall prevention measure be inspected visually prior to each use. While there is no requirement to record such inspections, a simple record would provide evidence that they have been carried out.

1.3.1.19 Schedules Much of the information contained in the schedules detailed below is virtually identical to current requirements and/or guidance so if Contractors are actively working to current standards and guidance then there is little extra for them to do.

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Schedule 1

The requirement in this schedule is for existing places of work at height and means of access or egress to and from such places to be stable, of sufficient size and strength and with edge protection as necessary. Ladders in particular must rest on stable, strong surfaces.

3

A place of work is to be properly constructed, used and maintained so as to prevent the risk of tripping, slipping or being trapped between it and adjacent surfaces. It should have no gaps through which materials could fall and injure someone.

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2

This covers the requirements for guard-rails, toe-boards, barriers and similar means of protection. The top guard-rail must be at least 950 mm above the edge from which any person might fall.

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Schedule 3

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Schedule 2

This covers the requirements for working platforms. Part 1 deals with requirements for all working platforms, and Part 2 covers the additional requirements for scaffolding.

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Part 1 Working platforms must be erected and used so that components cannot become displaced and cause danger to anyone. They must be suitable for the work, and of sufficient strength and rigidity. If they are altered or modified (by a competent person) they must remain safe and stable.

7

Any supporting structure for a working platform must itself be suitable and of sufficient strength and stable while being erected, used or dismantled. It must be prevented from slipping or moving, and if it has wheels or castors, they must be capable of being locked or similar. Working platforms and supporting structures must not be overloaded.

8

Part 2 As regards the additional requirements for scaffolding, strength and stability, calculations must be carried out unless it is being assembled in conformity with generally recognised standard configurations. Design calculations will probably only affect manufacturers and scaffolding companies, and if prefabricated scaffolding materials are being used, then following the manufacturers' erection instructions will probably cover 'recognised standard configurations'.

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9

Depending on the complexity of the scaffold, detailed plans may be needed for its erection, use and dismantling. This may be a standard or generic plan, supplemented with specific details as appropriate. A copy of the plan must be kept for the use of any persons concerned with the erection, use or dismantling of the scaffold.

10

The size and layout of the scaffold must be appropriate and suitable for the work to be performed, and it must also permit the work and passage of persons to happen safely (although no explicit dimensions or requirements are given in these Regulations). It is suggested that following the industry guidance on the size and width of working platforms and the provisions of TG20:08, together with any future guidance produced by the UK NASC, should be sufficient to demonstrate compliance.

Schedule 4 This schedule covers the requirements for collective safeguards for arresting falls. Collective safeguards include safety nets, airbags, landing mats and any similar devices or arrangements. All must be suitable and of sufficient strength to be able to safely arrest or cushion a fall.

12

These safeguards may only be used:

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where a risk assessment has shown that the work which is to be done can be carried out safely while the safeguard is being used, and without influencing its effectiveness

(b)

where the use of safer work equipment is not reasonably practicable

(c)

if a sufficient number of employees (or others) have received adequate training specific to the safeguard, including rescue procedures.

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(a)

A key requirement is that if the safeguard is designed to be attached to a building or a structure then the safeguard, the structure and all anchorages must be suitable and of sufficient strength for any foreseeable load that a fall might impose on it.

14

Airbags and landing mats must be suitable for the purpose intended, and they must be stable.

15

If a safeguard is designed to distort when arresting a fall, it must give sufficient clearance from the ground or adjacent structures to avoid injury to a person whose fall is being arrested.

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16

This schedule covers the requirements for personal fall protection systems (Part 1), work positioning systems (Part 2), rope access and positioning techniques (Part 3), fall arrest systems (Part 4), and work restraint systems (Part 5).

17

Important note. Much of the information in this schedule is quite technical and it is of paramount importance that employees are, or have been, fully trained on and are competent in the use of any of the fall protection systems available to them. There is not sufficient detail within this brief explanation of the schedule to train a person on the requirements, or for them to gain sufficient knowledge to be regarded as competent.

18

All safety harnesses, lanyards and other fall prevention or fall arrest equipment must comply with the appropriate British or International Standard.

19

Part 1 deals with the requirements for all personal fall protection systems. See Interpretation of these Regulations on page 2 of this module for the definition of 'personal fall protection systems'.

20

Regulations apply to all rope-based activities for work at height, including industrial rope

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systems and any other similar activity when carried out as a work activity. The schedule requires that: a personal fall protection system shall only be used if a risk assessment has shown that the work can be done safely while it is being used, and that the use of other, safer work equipment is not reasonably practicable

(b)

the user and a sufficient number of others have been trained in its use and in rescue procedures

(c)

it shall be suitable and of sufficient strength for the purpose for which it is to be used and will withstand any foreseeable loading

(d)

it fits the wearer and is correctly fitted or worn

(e)

it is designed to minimise injury to the user in the event of a fall, and is such that the user will not fall or slip out of it should they fall

(f)

it is designed, installed and used so as to prevent unplanned or uncontrolled movement of the user.

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Any anchorage point must be suitable and of sufficient strength to support any foreseeable loading. If designed to do so, the equipment must be securely attached to at least one such anchorage point when in use.

23

Part 2 deals with the additional requirements for work positioning systems, which may only be used if:

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the system includes a suitable backup system for preventing or arresting a fall, or

(b)

the system includes a line as a back up system and the user is connected to it, or

(c)

where it is not reasonably practicable to do either of the above, then other suitable measures are taken to prevent or arrest a fall.

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Part 3 deals with the additional requirements for rope access and positioning techniques, which may only be used if: it has two separate lines: the working line and a safety line

(b)

the user has a safety harness which is connected to both the working line and the safety line the working line has safe means of ascent and descent, and a self-locking device to prevent falling

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(d)

the safety line has a mobile fall protection system which is connected to and travels with the user

(e)

subject to the type and length of work, and the findings of a risk assessment, it has a seat with appropriate accessories.

25

However, if a risk assessment has demonstrated that a second line would entail a higher risk to the user, then, provided that appropriate safety measures have been taken, a single rope may be used.

26

Part 4 deals with the additional requirements for fall arrest systems. It requires that they must have a suitable energy absorber (often called a shock absorber and which is usually either a folded metal strip that deforms, or 'tear away' stitched webbing), or other suitable means of limiting the force applied to the user's body if they fall. In addition, a fall arrest system must not be used if there is any risk of a line (a rope or a lanyard) being cut, or where there is no safety zone or clear zone to allow for any swinging or pendulum effect after a fall, or in a way which hinders the system's safety performance or makes its use unsafe.

27

Part 5 deals with the additional requirements for work restraint systems (often a safety

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harness with a very short lanyard), and requires that they are designed so that they are used correctly to prevent the user from getting into a position where they could fall. Schedule 6 Requirements for ladders 28

Contractors must ensure that a ladder or stepladder is only used for work at height if a risk assessment has shown that the use of more suitable work equipment is not justified because of the low risk and the short duration of the work, or because of existing features on site that cannot be altered.

29

The remainder of the schedule is in line with current industry best practice and does not contain any further new or changed requirements.

30

The requirements are:

(b)

the ladder to be strong enough for loads which may be put on it

(c)

the ladder to be placed so that it is stable during use

(d)

the suspended ladder to be attached in a secure manner so that it does not swing

(e)

portable ladders to be prevented from slipping by being secured at or near their top or bottom, or with anti-slip or stability devices, or other effective means

(f)

access ladders to be long enough to provide a handhold when getting off at the top, unless other handholds have been provided

(g)

sections on interlocking or extension ladders to be prevented from movement while in use

(h)

mobile ladders to be prevented from moving before being stepped on

(i)

where reasonably practicable, rest platforms to be provided where a run of ladders rises a vertical distance of more than 9 metres

(j)

ladders to be used in such a way that a secure handhold and secure support are always available to the user

(k)

the user can maintain a safe handhold while carrying a load.

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the surface on which a ladder rests to be stable and of sufficient strength

This last point is qualified for stepladders in that:

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(a)

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'in the case of a stepladder the maintenance of a handhold is not practical when a load is carried, and a risk assessment has demonstrated that the use of a stepladder is justified because of the low risk and the short duration of the work.' Schedule 7 32

This schedule states the details to be recorded.

33

The details are: (a)

The name and address of the person for whom the inspection was carried out.

(b)

The location of the work equipment inspected.

(c)

A description of the work equipment inspected.

(d)

The date and time of the inspection.

(e)

Details of any matter identified that could give rise to a risk to the health or safety of any person.

(f)

Details of any action taken as a result of any matter identified in 5.

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(g)

Details of any further actions considered necessary.

(h)

The name and position of the person making the report.

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Reports of inspection have to be kept on site until construction work is completed and then at the Contractor's offices for three months.

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Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document)

Construction Site Safety 1.3.1 Appendix

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Work at height flowchart

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Construction Site Safety 1.3.2

Ladders, Steps and Lightweight Staging

1.3.2.1 Key points Ladders, stepladders and lightweight staging are all easily transported means of access to work at height. They can all be used safely in certain conditions.

2

The danger comes when any of them is used for a job for which it is not suitable; this particularly applies to ladders and stepladders.

3

Although newer and safer equipment is available, these still present serious risks if not used correctly.

4

The nature and duration of the job will be significant factors in determining the most appropriate type of access equipment to use.

5

Falls from low heights, that is from a height below 2 metres, are the cause of many fatalities and major injuries.

6

All work at height must be subjected to a risk assessment.

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1.3.2.2 Introduction

Ladders, stepladders and trestles (or lightweight staging) are among the most commonly used pieces of access equipment on site and, perhaps, the most misused. Many construction workers have used them at some time and it is essential that safe working practices should be followed if accidents are to be avoided.

2

Most ladder accidents occur because the ladder has not been secured correctly at the top or bottom and then slips. A person climbing the ladder while carrying a load or overreaching and overbalancing often makes an unsecured ladder unstable. Ladders that are badly placed, or set on an uneven or unstable base, are also a contributory cause of accidents.

3

There are many proprietary devices designed to stabilise the top or bottom of a ladder and uneven ground can be accommodated with adjusters bolted to the stiles.

4

Contractors are to provide safe access and a safe system of work. In certain circumstances particularly where work at height is prolonged, difficult or requires freedom of movement and the use of both hands - scaffolding, as opposed to ladders or stepladders should be used. At the same time it must provide both safe access and a safe workplace.

5

All ladders, stepladders and trestles are 'work equipment' for the purposes of these Regulations and, as such must be safe, suitable for the job and well-maintained. Before any work at height is carried out, a risk assessment should be made.

6

Guard-rails and toe-boards are required on all working platforms where a risk assessment indicates that any person would be injured as a result of the fall.

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1.3.2.3 Work at Height 1

These Regulations require that Contractors should: (a)

where it is reasonably practicable, avoid the need to carry out work at height

(b)

where such work cannot be avoided, select the most appropriate equipment for the work and to prevent falls

(c)

reduce the distance of, and potential consequences of, any fall

(d)

ensure that the work is properly planned, risk assessment-based and that it is carried

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out safely (e)

ensure the work is carried out by trained and competent persons who are adequately supervised.

1.3.2.4 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity so as to identify any risks which might be encountered during the work, and which might affect the health and safety of employees or of any other persons.

2

When hazards are identified, it is the Contractor's duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with clear and understandable information on any risks that exist in carrying out the work and on any control measures that are in place to reduce those risks.

4

An employee, in turn, has a duty under these Regulations to follow any instructions or training given and to tell their Contractor of any work situation that presents a risk to themselves or others, or of any matter which affects the health and safety of themselves or any others.

5

If carrying out work at height cannot be avoided, the risk assessment must determine the most appropriate type of access equipment for the job to be carried out.

6

Factors that will enable this decision to be made include:

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the nature of the work to be carried out

(b)

the time that it will take to complete the work

(c)

keeping the risk of anyone falling low.

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1.3.2.5 The Provision and Use of Work Equipment These Regulations require that Contractors supply work equipment that is safe and suitable for the job, ensures that the equipment is maintained and kept in good order, and that employees are properly trained in its use.

2

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to specified, trained and competent workers.

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1.3.2.6 Manual Handling Operations 1

These Regulations require that Contractors, as far as reasonably practicable, avoid the need for employees to carry out any manual handling operations which involve a risk of their being injured. Where this is not possible, the Contractor must make an assessment of the work to be carried out and take appropriate steps to reduce the risk of injury to employees.

2

All employees must follow any safe system of work, including using any work equipment (or personal protective equipment) that is provided by the Contractor.

1.3.2.7 General 1

Contractor must provide employees with adequate information, instruction, training and

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supervision so that they can carry out their work safely and without risk to their health,

1.3.2.8 General guidelines for the safe use of ladders 1

A ladder must not be used as an access to, or egress from, a workplace unless it is reasonable to do so taking into account the work being carried out, its duration, and the risks to the safety of any person arising from the use of the ladder.

2

Schedule 6 requires that a ladder should only be used in a low risk situation when a risk assessment has shown that the use of alternative equipment is not justified. This is when:

(b)

the work is of a light nature

(c)

there are aspects of the site that cannot be changed.

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the ladder is to be used for a very short time, or

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A ladder must be of the correct class for the intended use, of sufficient strength, suitable for the job that is to be done, and be so erected that it does not become displaced. Ladders should be set on a firm, level base, strong enough to support the ladder and any load that may be placed upon it.

(b)

There should be no makeshift use of bricks, blocks or timber packing, etc. to gain extra height or to level up the stiles.

(c)

Ladders should be sited clear of any excavation, and in such a position that they are not causing a hazard, or placed anywhere they may be struck or dislodged. Barriers should be placed around the foot as added protection where necessary.

(d)

Ladders should not be placed on or leant against any fragile surface or fitting.

(e)

Proprietary stand-off devices should be used where the point of rest would otherwise be unsuitable, for example, against plastic gutters.

(f)

Ladders should be set, as near as possible, at an angle of 75° (a ratio of 1 unit of length out to 4 units of length up).

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(a)

(g)

Ladders must not be secured by their rungs; lashings should be around the stiles, or proprietary ladder ties should be used.

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Lashing or clamping, at the mid-point of a ladder, will make it safer and help to prevent sway, particularly with ladders that are over 6 metres in height.

(i)

A ladder must not be placed in such a position that any adjacent scaffold tubes interfere with the footing of the person on the ladder.

(j)

If the vertical height of a ladder is over 9 metres, safe landing areas or rest platforms should be provided at suitable intervals.

(k)

Only one person should be climbing a ladder at any one time.

(l)

Always face the ladder when climbing or descending it.

(m)

Footwear worn by persons using a ladder must be suitable for maintaining a satisfactory grip.

(n)

When climbing or descending a ladder, both hands must be kept free for holding onto the ladder and free of any other items.

(o)

Tools and materials required for work can be carried in a shoulder bag, on a special belt, or be hoisted up or lowered afterwards.

(p)

When using a ladder, secure handholds and secure support must always be available.

(q)

Tools not in use should be hooked or otherwise secured to the ladder.

(r)

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The top of the ladder must not be repositioned, by jumping, while standing on the rungs.

(s)

When a ladder must be left standing after working hours, a board should be lashed between the rungs to prevent unauthorised access; ideally, they will be removed.

(t)

Ladders must extend at least 1 metre (approximately 5 rungs) above the landing place, unless an alternative, secure handhold is available.

(u)

As far as possible, ladders must be placed so that there is adequate space behind each rung for a proper foothold.

(v)

Overreaching leads to overbalancing. The most satisfactory method for working safely on a ladder is for both thighs and hips to be kept between the stiles, and one hand always holding the ladder. The working position should be not less than five rungs from the top of the ladder.

(w)

Ladders must be properly maintained, of sound construction and materials, free from any defects and kept in good repair. If a rung is missing or damaged, the ladder must not be used.

(x)

Ladders must be supported on each stile and prevented from sagging or swaying.

(y)

All ladders should, in the interests of safety, be securely fixed or lashed to prevent

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slipping, either near the top or, if this is not possible, at the bottom. Ladders must not be painted or otherwise treated in any way that would hide or conceal any defects. They may be treated with a transparent coating such as varnish, shellac or clear preservative. It should be remembered that some timber preservatives might not be compatible with aluminium fittings.

(aa)

Ropes or lashings which are used to secure a ladder must be in good condition.

(bb)

Ladders should only be used as a working place for light work, e.g. maintenance or painting for short periods. Where longer periods of work are anticipated, other access equipment, such as trestles or scaffolds, should be used.

(cc)

No part of a building should be used to support a ladder unless it is safe to do so and strong enough for the purpose.

(dd)

BS EN 12811-1 Scaffolds. Performance requirements and general design (Schedule 6) and good practice

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'Footing' ladders:

is generally ineffective in preventing most types of ladder incidents

(ff)

must only be used as a last resort, for example when initially climbing a ladder to tie it off, and only if a risk assessment shows a low risk of a fall

(gg)

is only effective on short ladders.

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The person on the ladder must keep their weight between the stiles (no over-reaching or straddling onto adjacent structures).

5

Depending upon circumstances, it may be possible to improve ladder stability by using antislip, stand-off devices towards the top and/or anti-slip feet under the stiles.

6

If possible, seek manufacturer's guidance with regard to extra loading imposed by the weight of two persons on the ladder.

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1.3.2.9 Types of ladder 1

Note: Whichever of the following types of ladder is to be used, it should be Class 1 (suitable for industrial use.

2

Standing ladders: single stage ladders up to 5 metres or 6 metres in length.

3

Pole ladders: a variant of the above type, but with the stiles having been made from a long whitewood pole cut down the middle to give even strength and flexibility. Lengths can vary up to a maximum of 10 metres.

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The practice of shortening a pole ladder to fit a particular situation should be discouraged. The only time shortening a pole ladder is acceptable is when an end is damaged. Care must be taken to ensure that the fabric of the ladder remains stable if a tie wire is removed.

5

Extension ladders: these consist of two or three sections coupled together and extended by sliding over or inside each other.

6

Longer multi-stage ladders are extended by means of a rope and pulley. A three-section ladder, fully extended, may reach over 16 metres.

7

Stepladders: these are of various types, have flat rectangular treads and are usually free standing.

8

Roof ladders (for pitched roofs): a ladder with a hook on the top end of it for securing over the ridge of a roof.

9

Aluminium ladders: various types are available. Their main advantage is that they are light and weather resistant. They can be prone to slipping at the base if the rubber or wooden feet are not properly maintained.

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1.3.2.10 Classes of ladder (British Standards 1129: 1990, 2037: 1994 and BS EN 131) 10

Portable ladders, steps, trestles and lightweight staging are covered by BS 1129: 1990, BS2037: 1994 and BS EN 131.

11

A duty rating indicates their suitability of use.

12

Class 1: Industrial. Heavy duty - can be used frequently and in the tough conditions that can be found on site. These are the only ladders that are recommended for use on site.

13

Class 2: Light trades. Medium duty - can be used only in good conditions. Suitable for light trade purposes. (This class of ladder is now covered by BS EN 131.)

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14

Class 3: Domestic. Light duty - suitable only for domestic and household use.

15

Class 2 and 3 ladders are not recommended for general use on site.

16

All ladders should be marked with a unique identification number and the class or duty rating.

1.3.2.11 Inspection of ladders Every ladder should be inspected on a regular basis and should carry an identification mark, as detailed above. A written record should be kept of all inspections, defects and repairs.

2

Ladders should not be used if defective in any way and, if damaged beyond repair, they should be destroyed.

3

During the inspection of ladders, attention should be paid to the following points.

4

There should be no:

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damaged or worn stiles, particularly at the head or foot of the ladder

(b)

broken, missing, loose or worn rungs

(c)

mud or grease on the rungs

(d)

rungs supported solely by nails, screws or spikes

(e)

movement in the rungs or stiles

(f)

decayed timber, or the corrosion of fittings

(g)

insecure tie wires

(h)

warping, sagging or distortion; check that the ladder stands firmly.

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The condition of any ropes and cords, along with pulleys, hinges and any other fittings, should be checked for fraying to ensure that they are all secure with no sign of damage.

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1.3.2.12 Carrying a ladder 1

A short ladder may be carried comfortably by having it vertical against the shoulder and holding one of the lower rungs, using the other hand to hold the stile. Longer ladders should be carried horizontally by two people. Care should be taken in negotiating comers and obstacles.

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2

Ladders must not be taken into the vicinity of overhead power lines unless a permit to work has been issued. Even then, extreme care should be taken with the head of the ladder so that it is not allowed to get close to the overhead power lines.

3

Timber ladders generally do not conduct electricity (unless wet) but aluminium ladders are extremely conductive, and are dangerous to use in close proximity to overhead lines.

1.3.2.13 Erecting and lowering ladders The procedure for erecting a ladder, when the ladder is flat on the ground, is as follows.

2

One person stands on the bottom rung while the other takes position at the head of the ladder and takes hold of the top rung, raising the ladder off the ground.

3

Then, rung by rung, that person moves towards the foot of the ladder, lifting as they go. The person at the foot grasps the lower rungs as soon as possible and draws the ladder towards them, steadying it at the same time.

4

The sequence is reversed when lowering.

5

Short ladders may be raised by one person placing the foot of the ladder against a wall or fixture and pushing the ladder upwards starting at the top, walking, under-running and raising the ladder as they go.

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1.3.2.14 Extension ladders 1

Extension ladders are raised one section at a time and slotted into position. The minimum recommended overlap on extension ladders is as follows:

QCS 2014

Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document) Closed length

Approx. no. of rungs

Under 5 metres

2 3

Overlap of rungs

under 18

2

18-23

3

5-6 metres

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over 6 metres over 23 Latching hooks must be properly engaged.

4

Ordinary ladders must never be lashed, tied or spliced together in an attempt to make an extension ladder.

1.3.2.15 Roof ladders Roof ladders (shown below) should be erected as follows.

2

First, a standing ladder is erected for access to the eaves of the roof. It should extend at least 1 metre or five rungs above the eaves of the roof and be properly secured, but not to the guttering, downpipes or any other plastic or fragile material.

3

The roof ladder should then be brought up and pushed up the roof on its wheels, with the anchor hook or ridge hook uppermost.

4

Once over the ridge, the ladder is turned over and the hook engaged. It may be necessary to secure the ladder with a rope if ridge tiles are unsound.

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1.3.2.16 Storage of ladders 1

Ladders, especially if made of wood, deteriorate when exposed to the weather for prolonged periods. Where indoor storage is not available, they should be covered or stored in a protected, well ventilated position. They should not be exposed to steam pipes, boilers or other sources of radiant heat.

2

Ladders should be stored on racks, supported on the stiles only, with sufficient supports to prevent them from sagging. They must not be hung from the rungs or stiles.

3

Aluminum ladders should be kept away from wet lime or cement, which may corrode them.

4

Pulleys and hinges should be lubricated and the condition of ropes and cords checked.

5

Any damage or deterioration should be noted and made good before further use.

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1.3.2.17 Stepladders and alternatives Stepladders Many of the general rules for the safe use of ladders also apply to Stepladders. In addition, the following points should be considered. (a)

Stepladders are not to be used if a fall from one would cause the user to be injured (based upon a risk assessment).

(b)

The treads (or steps), hinges, bolts, screws and fixings must all be sound and secure.

(c)

Retaining cords or hinges should be of equal length and in good condition.

(d)

The stepladder must be stable when open and standing on a level base.

(e)

The legs of Stepladders should be positioned as far apart as the retaining cord or hinges allow, with all four legs firmly and squarely on the ground.

(f)

Wherever possible, the stepladder should be positioned so that the person climbing it is facing the work to avoid twisting and possible instability.

(g)

Unless the design permits, the knees of the person using the stepladder should be kept below the top step.

(h)

The user should not work from the top third of a stepladder unless it has been designed for this purpose.

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If it is not practicable to maintain a handhold when a load is being carried, a risk assessment must demonstrate that the use of the stepladder is justified because of: the low risk, and

(b)

the short time the stepladder is to be in use.

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Podium steps/mini mobile towers

The use of this type of equipment is preferred to Stepladders in most circumstances as it provides a small but stable working platform, complete with guard-rails. This type of access equipment has the advantage over a stepladder in that it allows the user to work in a safer manner facing any side of the working platform without it becoming unstable.

2

Podium steps and mini towers are lightweight in construction and some types will fold flat for transportation and are designed to be wheeled through a standard-sized door. Some types of this access equipment can be fitted with outriggers to increase stability.

3

Whilst providing a high degree of safety in most situations, there are a number of specific hazards with the use of this type of equipment and the Contractor should ensure the following precautions are considered in selecting and using podium steps.

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(a)

There are many differing types of podium steps with different arrangements of use. Some are just wheeled platforms and others have specific installation requirements. The instructions for each individual podium must be available and understood by the

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user. (b)

The height of the working platform should be assessed: too low and the user will not reach; too high and the user may be inclined to work from the steps rather than the platform.

(c)

Where adjustable height platforms are in use, ensure that the user is trained in how to adjust the platform and handrails to ensure protection.

(d)

Brakes must be used whilst the platform is in use and users must not be permitted to pull themselves along from the top of the podium.

(e)

Podium steps, like any other access equipment, must have an individual identifying mark and be subject to frequent inspection.

1.3.2.18 Lightweight staging and trestle scaffolds

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Split head trestles and trestle frames

These older type of trestle either consisted of two or more support-trestles supporting scaffold boards to form a working platform, or were made up using four split head trestles with the forks of the split head trestle taking a bearing timber (or two scaffold boards on edge) with boards or staging laid on top.

2

Both split head trestles and telescopic frames need a sound, level base.

3

Where a trestle system is used in which the positioning of trestle supports is variable, they should comply with the following criteria:

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(a)

(b)

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trestle supports must be spaced at the following distances apart: (i)

1 metre when using 32 mm thick boards

(ii)

1.5 metres when using 38 mm thick boards

(iii)

2.6 metres when using 50 mm thick boards.

The amount that the end of any board may overhang any trestle should not exceed four times (4 x) the thickness of the board used for the working platform, unless it is effectively secured to prevent it from tipping.

This type of trestle is now unacceptable in most circumstances because of the inability to fix guard-rails or toe-boards to the 'working platform' and the tripping hazard caused by boards that overlap. There may be rare circumstances where they can still be used safely, for example: (a)

where a fall is not possible because the working platform is completely and tightly

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enclosed by the walls of a room or other solid structure (b)

the working height and the surrounding floor surface are such that a fall could not result in a personal injury.

Modern trestle systems More modern trestles are similar in many ways to system scaffolding, including the fact that guard-rails and toe-boards are an integral part of the working platform. The spacing of the supports is fixed by the system design which enables platform boards to fit snugly without overhang or overlapping.

6

All lightweight staging should be marked with the maximum permitted distributed loading. This can be done by either specifying the maximum number of persons, allowing for their tools and equipment, or by specifying the maximum safe weight.

7

Guidelines are as follows:

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trestles must be set on a firm, level base

(b)

only one working platform is installed

(c)

guard-rails, barriers and toe-boards are required where a fall would cause a personal injury, as indicated by a risk assessment

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where fitted, guard-rails should conform to the standard outlined and dimensions specified in these Regulations

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(a)

(e)

if a guard-rail is removed, for example to allow materials to be stacked on the working platform, the guard-rail must be replaced as soon as practicable

(f)

scaffold boards used on trestles to form a working platform must be of a consistent length and of equal thickness

(g)

the trestle assembly must be completely stable when in use

(h)

a safe means of access to the working platform must be provided, for example a ladder that is of sufficient length, properly positioned and securely lashed

(i)

where locating pins are used, they should be of the correct size and type and not rebar off-cuts or other makeshift items.

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Construction Site Safety 1.3.2 Appendix Safety checklist Ladders Is a ladder the right piece of access equipment to be using?

8

Are ladders only used for very light work of short duration, or access?

9

Are all ladders properly stored and inspected regularly?

10

Are the ladders that are being used suited to the purpose or use to which they are being put?

11

Are there any damaged, loose or missing parts?

12

Are the rungs of ladders clean and free of mud or grease?

13

Are sufficient persons available to handle and place ladders properly and safely?

14

Are ladders set on firm and level ground?

15

Are ladders properly erected and secured?

16

If there is not an alternative suitable hand-hold, does the ladder project sufficiently above the landing place?

17

Is there the correct overlap on extension ladders?

18

Are the methods for raising tools or materials safe?

19

Are ladders placed so that the work does not involve overreaching?

20

Is suitable footwear that will give a satisfactory grip and prevent slipping being worn?

21

Are ladders set at the correct angle of 75°?

22

Are ladders clear of excavations or other potential hazards?

23

Are ladders being leant against or secured to any fragile material?

24

Are all lashings used of sound material, and made properly secure?

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Stepladders 25

Is the stepladder level and stable?

26

Is it open to the full extent of the retaining cords or hinges?

27

Are steps set at right angles to the workface wherever possible?

28

Are the user's knees below the top step?

29

Could the person using the stepladder fall a distance that would cause an injury?

30

Is the person using the ladder not using the top third?

Trestles Are trestles, and any boards that are being used with the trestles, safe, undamaged and of adequate strength?

32

Are the trestles set on a firm and level base?

33

Is the working platform of a sufficient width for the job in hand?

34

Are guard-rails and toe-boards fitted to trestle platforms if indicated as being necessary by a risk assessment?

35

Where indicated as necessary by a risk assessment, is the trestle tied to the adjacent structure?

36

Is a safe ladder access provided?

37

Is the maximum permitted distributed load indicated and complied with?

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Are the podium steps of sufficient size and the correct type for the task?

39

Have the operators been supplied with and fully understood the supplier's instructions for use?

40

Are all of the components available and in good condition?

41

Is the floor surface sound and of a level construction?

42

Are brakes provided, in working order and used?

43

Do all podium steps carry unique identifying marks and are they subjected to frequent inspection?

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Management responsibilities Management should: 44

Understand these Regulations and guidance on work at height that is appropriate to ladders, stepladders, podium steps, trestles and other access equipment

45

consider whether any safer system of work or access can be provided

46

know how and where access equipment is being used by employees

47

install permanently fixed ladders wherever possible

48

provide any necessary safety equipment

49

provide adequate storage for ladders and access equipment

50

institute a system of proper inspection and the keeping of records for all ladders and access equipment

51

ensure that all ladders, stepladders, podium steps, trestles and boards are of sound design and manufacture, and kept in good condition

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52

ensure that all users have been properly instructed and trained, and are competent to use the equipment safely and without risk to themselves or others

53

provide proper supervision of all employees who are using any form of access equipment.

Construction Site Safety 1.3.3

Working Over or Near to Water including Liquid Bodies

1.3.3.1 Key points Working over water will often, although not always, involve working at height. The potential risks arising from both hazards will have to be managed.

2

Ideally, work will be carried out from a stable working platform that may prevent an unplanned fall into the water.

3

Where there is a risk of someone accidentally entering the water, appropriate rescue equipment and people who are competent to use it must be available.

4

Working over water may result in a greater emphasis on the wearing of PPE than other types of work at height.

5

Suddenly falling fully clothed into water may induce shock and an increased risk of drowning if appropriate PPE is not worn.

6

Rescue drills should be planned and practiced.

7

If the use of a rescue boat is not appropriate, an established hierarchy of rescue methods should be followed; if a (powered) rescue boat is appropriate, it must only be operated by someone trained in rescue procedures.

8

Working near to deep water, for example adjacent to Mariner Quays can be as dangerous as working over water if appropriate control measures are not put in place.

9

Working over or near water can pose risks to health as well as safety.

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1.3.3.2 Introduction

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If employees have to work over or in the vicinity of water, a safe system of work must be developed, usually formalised in a method statement, and all those involved must be made aware of the risks and informed of the protective measures that have been put in place.

2

Equally important is the provision of proper rescue equipment and suitable emergency procedures, together with the information and training necessary to use the equipment and respond effectively in an emergency. While every possible effort must be made to prevent people falling into the water, it is essential to make sure that anyone who does fall in can swim or at least is sufficiently confident in water to float (assisted by a buoyancy aid) without panicking. Recovery of the person from the water must take place as quickly as possible.

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1.3.3.3 Health and Safety at Work (Construction Sites) 1

Contractors must do everything that is reasonably practicable to provide information, instruction, training and supervision; must provide a safe place and safe systems of work with safe access and egress; and must ensure provision is made for safe use and handling of materials, etc.

1.3.3.4 The Management of Health and Safety at Work 1

Every Contractor must make a suitable and sufficient assessment of risks to the health and safety of employees (and others) arising out of work activities and introduce risk control measures as are appropriate to reduce the risks to health and/or safety to an acceptable

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level. In the context of working over or near water, the risk control measures should include: (a)

ideally, ensuring that it is not possible for anyone to fall into water, by preventing falls

(b)

where that is not reasonably practicable, arresting any falls that do occur, providing there is sufficient clearance height for fall arrest measures to be effective or, where that is not reasonably practicable

(c)

ensuring that anyone who does enter the water is rescued in the shortest possible time

(d)

issuing appropriate PPE such as immersion suits and life jackets

(e)

making sure that appropriate rescue equipment and trained staff are available

(f)

providing information, instruction and training to those persons who have to work over or near water.

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The following summary of these Regulations is limited to their requirements as far as they apply to working over or near to water.

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prevent falls and to minimise the chance of drowning should a fall occur

(b)

ensure that rescue equipment is provided, maintained and used when necessary, to enable a prompt rescue

(c)

ensure the safe transportation of anyone to and from the place of work, when they are transported by water

(d)

ensure that vessel used to convey people to and from a place of work is not overcrowded or overloaded.

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These Regulations require that when, during construction work, a person is liable to fall into liquid (with a risk of drowning) appropriate measures are taken to:

The Regulations also place duties on: (a)

all contractors to ensure the competence of anyone working under their control the client to provide adequate pre-construction information on site conditions that might adversely affect health and safety, including in the context of this section, any known hazards arising out of the presence of water

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All construction projects

(c)

designers, by way of their designs, to eliminate the hazards or reduce the risks arising out of construction activities, so far as is reasonably practicable, including in the context of this section, working adjacent to, or over water.

All Projects 4

Duty holders must: (a)

ensure that the Engineer promptly provides the Contractor and all other subcontractors with health and safety information relevant to the site

(b)

take the information supplied by the Engineer and incorporate it into the construction phase health and safety plan

(c)

must take reasonable steps to ensure that everyone engaged in construction work is provided with a suitable site induction and adequate other training that is relevant to what they are required to do.

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1.3.3.6 Work at Height 1

On many occasions, working over water will also involve working at height.

2

Contractors are required to: avoid the need for working at height, where reasonably practicable

(b)

when it cannot be avoided, select the most appropriate equipment to prevent falls

(c)

reduce the distance and consequences of any falls that do occur

(d)

ensure that all work at height is properly planned, based upon a risk assessment and carried out safely by competent persons

(e)

ensure that equipment used for working at height is appropriately selected and inspected as specified

(f)

ensure that measures are taken to prevent anyone being injured by falling objects.

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1.3.3.7 Personal Protective Equipment

In the context of these Regulations, common-use personal protective equipment (PPE) will include such items as life jackets, safety harnesses, lanyards and immersion suits.

2

Where risks to health and safety cannot be adequately controlled by other means, Contractors must:

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identify appropriate and suitable PPE that will control the risks to an acceptable level

(b)

provide the PPE free of charge to those who are at risk

(c)

provide the users of the PPE with adequate instruction and training with regard to:

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the risks that the PPE will protect against

(ii)

the purpose for which it has been issued and the manner in which it is to be used

(iii)

maintaining the PPE in good working order.

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The Contractor must take all reasonable steps to ensure that employees use the PPE provided as directed.

4

Employees for their part must:

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(a)

use any PPE that has been issued as instructed and in accordance with any training received

(b)

return the PPE to any storage area that has been assigned to it, after use

(c)

report any loss or defect in the PPE to the Contractor.

Risk areas 5

Hazardous areas include docks, locks, canals, wharves, lakes, ponds (natural and artificial), reservoirs, water-filled pits, sewage ponds, slurry ponds, rivers, streams, swimming pools, water-holding tanks (if of sufficient size) and the sea. Working alongside or near the water's edge can be as hazardous as working over the water. Extra care is needed in the vicinity of culverts, outfalls and other discharge points, and at coastal sites, where drag or undertow due to tidal conditions may be encountered.

Leptospirosis (Weil's disease) 6

When working over water, consideration must be given to the health implications arising from

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the accidental entry into contaminated water. 7

The possibility of contracting leptospirosis whilst working over or near to rivers or streams must be considered.

Accidental entry into water Every effort must be made to eliminate the risk of accidental entry into water. This will involve protecting employees against: falls from heights (including a failure to use the fall prevention or arrest measures provided)

(b)

trips and slips from low level

(c)

persons being knocked over by moving objects, e.g. crane loads

(d)

loss of balance, e.g. caused by high winds, particularly when handling sheet materials

(e)

failure or absence of barriers

(f)

failure of ropes or lines

(g)

rising swell or swell from passing waterborne traffic

(h)

horseplay

(i)

being under the influence of prescribed drugs.

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The most immediate danger is of drowning. Causes or contributory factors include: shock of sudden immersion in cold water

(b)

weight of waterlogged clothing

(c)

incapacity following injury after striking an object during the fall or in the water

(d)

fatigue or hypothermia where rescue is not immediate.

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1.3.3.8 Prevention of falls Scaffolds and platforms

Where reasonably practicable, a stable working platform such as a scaffold is the best method of ensuring safe working over water. It should be designed for the task so that it is stable and of sufficient size for the proposed work.

2

Guard-rails and toe-boards should be fitted to prevent falls of persons or materials and it

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may be advisable to fit double height toe-boards, double guard-rails and brick guards or nets. Boards should be lashed to prevent high winds causing displacement. If a ladder is used for access to the scaffold or platform, it should be of sufficient length, extend at least five rungs above the stepping off point, be properly secured (preferably at the top) and set at the correct angle. If it is necessary for a long access ladder to be used, landing places should be provided every 9 metres. There should be a proper system for the inspection of ladders.

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Safety nets

If safety nets are to be used, they should be erected as close as possible below the working level and, if cantilevered nets are erected on the outside of the structure, the outermost edge should be higher than at the inner edge.

5

Nets are intended to save lives and prevent injury; they are not a substitute for the effective prevention of falls.

6

The manufacturer or supplier of a safety net must supply an instruction manual in accordance with BS EN 1263-1:2002. This guidance should contain:

maximum falling height

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(b)

the required anchorage forces

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(a)

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(c)

minimum catching width

(d)

safety net linkage

(e)

minimum distance below the safety net

(f)

storage requirements

(g)

inspection and replacement requirements.

7

These instructions may need to be supplemented by special installation instructions, depending on the specific application of the net. Reference should be made to BS EN 12632:2002.

8

There are two main types of safety net: (a)

Personnel nets: 100 mm mesh. Intended to catch a person falling from above.

(b)

Material or debris protection nets: smaller mesh 12 mm-19 mm. Intended to protect those below from falling objects.

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The size and siting of the nets are of critical importance; the further a person may fall, the larger the net needs to be.

10

The maximum recommended distance a person should fall before contact with the net is 6 metres.

11

For a fall of 1 metre, an out rigged net must have a horizontal projection beyond the outermost working point of 2.6 metres, while for a fall of 6 metres a projection of 4.4 metres is necessary.

12

Erection of safety nets should be carried out by competent and qualified persons who should ensure that any supporting framework can withstand impact or shock loadings and that the framework itself does not present a hazard to personnel who may fall into the net.

13

Nets should be securely attached to support framework with tie cords, hooks, rings or thimbles spaced at a maximum of 750 mm. The actual tie should be at least double the strength of the net and, if hooks are used, they must have positive locking of some description. See diagram below.

14

Nets can be out rigged on scaffolding provided that the scaffolding is securely tied into the structure and has been designed to take shock loading.

15

The risk assessment must take into account the rescue of anyone who has fallen into a safety net, including what to do if they are injured or unconscious. Where the safety net has been rigged immediately below the place of work, someone who is uninjured should be able to simply climb out of it.

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Safety nets are provided with short lengths of test cord attached, normally eight. They must not be used as tie cords. At intervals not exceeding three months, one cord should be removed and tested (see BS EN 1263) and a record kept. For nets which have been in continuous use for two years (i.e. eight times three months) or if there is any visible deterioration, advice should be sought from the manufacturers. Nets should be inspected weekly for damage, loose ties, etc., together with the framework and anchorage points. A net should also be inspected for damage and replaced, if necessary, subsequent to a person or other significant load falling into it. All such inspections should be recorded.

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Periodic testing

Care should be taken to reduce to a minimum unnecessary wear and mechanical damage likely to weaken the net. Materials must not be stacked on it and deliberate jumping onto, or dropping of objects into, nets must be prohibited. Sources of damage or wear such as accumulations of debris in the net should be avoided as far as possible.

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Care of nets

These Regulations permit the use of safety harnesses and lanyards where it is not possible to provide a standard working platform or safety net, provided that they are always worn and always secured to a safe anchorage.

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1.3.3.9 Safety belts, harnesses and lanyards

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Training

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Training should refer to the manufacturer's instructions and the importance of following them. It should cover fitting, adjustment and use of the belt or harness and the choice of suitable anchorage points. Personnel should not be permitted to use the equipment before instruction has been received.

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Selection and use of equipment

The selection of the correct type of harness for the work planned is essential. If any doubt exists concerning the suitability for a particular task or type of work, further information and advice should be sought from manufacturers or suppliers.

4

Whatever type is chosen it should give a high degree of safety, allied to mobility and wearer comfort.

5

Contractors should consider:

(b)

the selection, attachment and inspection of lanyards the selection of alternative fall-arrest devices

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(d)

the implications of suspension trauma

(e)

the selection of alternative types of access equipment.

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1.3.3.10 Rescue equipment and procedures 1

2

Although every effort should be made to prevent people falling into the water, the risk of this happening remains. In the event of there being a casualty, two things are of paramount importance: (a)

the person must be kept afloat

(b)

location and rescue must be achieved as quickly as possible.

Both of these aims should be kept in view when selecting rescue equipment and establishing rescue procedures. In addition, the effective use of the equipment and the speed and effectiveness of emergency procedures and rescue operations will depend on the training, instruction and information given.

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Life jackets and buoyancy aids All employees working over or near water, and at risk of falling in, should wear some form of life jacket or buoyancy aid. Both life jackets and buoyancy aids are designed to keep the wearer afloat. There are, however, important differences. It is recommended that life jackets are used in preference to buoyancy aids.

4

Life jackets to the relevant British Standards are designed to support an unconscious person in the water and turn them face upwards, by inflation when in the water. Inflation is by means of a CO2 cartridge, activated manually or automatically.

5

Selection of suitable life jackets must be made by the Contractor, having taken advice from the manufacturer or supplier, if necessary.

6

Refer to Appendix 2 for advice on the selection of life jackets and buoyancy aids.

7

Buoyancy aids are intended to provide a conscious person with enough extra buoyancy to stay afloat and achieve a reasonable flotation position. A basic buoyancy aid may not turn an unconscious person over from face-down. Buoyancy is usually incorporated in the form of closed cell foam.

8

Buoyancy aids are bulky and, in some people's view, hinder movement and may slow the progress of work, whereas life jackets are less bulky. Manually inflated life jackets, which are inflated by mouth after entry into the water, should not be used. Automatically inflated life jackets offer a high degree of freedom of movement and do not depend upon the wearer being conscious for them to inflate.

9

Decisions on the type of equipment needed for specific types of work should be based on an assessment of the factors involved. These may include, for example, whether a person is a competent swimmer, the length of time a casualty may be in the water, the risks of injury, water temperature, current and the proximity of assistance.

10

Specialist advice can be obtained from manufacturers on the suitability of equipment for a particular purpose, e.g. type of water, type of environment.

11

Where safety harnesses are to be worn in addition to flotation equipment, it is important to ensure each of these items functions effectively and will not interfere with the other.

12

Safety harness and buoyancy aid combinations are available from

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some manufacturers, though it is necessary to make sure that the harness is not merely a restraint for use in small boats, or a rescue harness, neither of which may be satisfactory for use in construction and similar work. 13

The provision of whistles and lights as aids to the location of people in the water may be advisable in some circumstances.

14

Wearers should be fully trained in the use of safety harnesses, life jackets and buoyancy aids. The functions of the equipment and, where appropriate, its limitations should be clearly understood by users.

Management A clear policy needs to be in place on the use, inspection and storage of automatically inflated life jackets. This policy also needs to address the training needs of the life jacket users.

16

Life jackets, if used regularly, should be allocated to individual users. Each individual, having been adequately trained, can then be responsible for carrying out pre-wear checks and inspections, and report defects according to company procedures. This will help ensure correct inflation of the life jackets is not jeopardised by the carelessness of others.

17

Management needs to enforce its policy on life jackets. This can be achieved by spot checks of both the condition of the life jackets in use and the records of inspection and servicing.

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All workers who use automatically inflated life jackets need to be trained and competent in their care and use, including pre-wear checks and inspection procedures. Training should cover: an explanation of the risks present and the need for life jackets

(b)

operation, performance and limitations of the equipment provided

(c)

instruction and practice on the selection, pre-wear checks, inspection, use and storage of the life jackets, including the use of the manual override lever and oral inflation tube

(d)

factors which can affect the correct operation of the life jackets, such as the working conditions, inadequate fitting, defects, damage and wear (recognising defects in life jackets and arrangements for reporting loss or damage).

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Training

Extra or refresher training may need to be given, for example, if a new type of life jacket or automatic inflation mechanism is introduced.

Pre-wear checks 20

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A pre-wear check needs to be carried out each day the life jacket is used. This should be carried out in accordance with the manufacturer's instructions and will normally include visual checks to ensure: (a)

the firing mechanism has not been activated. This is usually made obvious by the fact that the life jacket is found inflated

(b)

the automatic firing capsule and gas cylinder are correctly screwed in place

(c)

there are no signs of corrosion, cracks or dents in the gas cylinder or automatic firing capsule

(d)

unwanted movement within the firing mechanism (creepage) has not occurred.

Some automatic inflation mechanisms have colour-coded indicators to show when

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compression in the spring has been lost. Those that do not have such indicators will require careful inspection to judge whether the spring has lost any compression. Examination of the piston or other visible component may also show whether creepage has happened. Make sure: (a)

the whistle and light (when fitted) is in position

(b)

the oral inflation tube is capped

(c)

the straps and main body of the jacket are not worn or damaged

(d)

the jacket is correctly packed in accordance with the manufacturer's instructions (ensuring that any Velcro is correctly fastened and the manual inflation lanyard is accessible).

Inspection and maintenance As well as pre-wear checks, a more thorough inspection and testing programme needs to be carried out in accordance with the manufacturer's instructions. Where life jackets are used heavily, for example, off-shore, the periods between inspections may need to be shorter than the quarterly inspection recommended by some manufacturers.

23

As a general guide, where life jackets are used daily, inspections on at least a monthly basis may be necessary.

24

Inspection and testing need to be carried out by those competent in recognising defects and the remedial action to be taken. Records need to be kept of all inspections and repairs made.

25

Testing the air-tightness of the life jacket will involve orally inflating the life jacket and leaving it overnight (or submerging it in water) to check for leaks. The automatic inflation mechanism will need to be dismantled to make a detailed examination of its condition. Make sure:

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all screw threads are examined for signs of rust. Rust can lead to problems in locating the cocking cap or the gas cylinder in the correct position

(b)

the gas cylinder is examined for corrosion, cracks, dents and other defects. Particular attention will need to be paid to the cylinder cap as any indentations found could mean that the automatic firing mechanism has fired but failed to pierce the cylinder. If this is the case, the reason for activation and the cause of failure needs to be identified the cylinder fitting and groove of the firing pin are checked so that they are free from dirt

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(d)

the automatic inflation mechanism is operated manually (with the gas cylinder removed) to ensure that it operates smoothly, and that there is no obstruction to the movement of the pin which prevents it piercing the cylinder. The pin also needs to be checked to ensure that it is sharp

(e)

the 'salt' or 'paper ring' is inspected for any cracking, dissolving or tearing which has taken place since the last inspection

(f)

where fitted, the rubber '0' ring is inspected for damage and that it is correctly seated

(g)

the mechanism is checked for signs of 'creepage'.

26

Once the inspection is complete, the life jacket should be reassembled according to the manufacturer's instructions.

27

Manufacturers generally recommend life jackets to be serviced every two years by their appointed agents. However, where life jackets are used very regularly, an annual or more frequent service may be needed.

28

If any defects are found with either the gas cylinder or the automatic inflation mechanism,

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these parts must be replaced. If the life jacket is in need of repair, return it to the manufacturer. Repairs should only be carried out by people approved by the manufacturer. Storage Exposure to damp, humid conditions can lead to deterioration in the automatic inflation mechanism, known as 'creepage'. This has the potential to lead to failure of the pin to pierce the carbon dioxide gas cylinder. Life jackets need to be stored in suitable dry conditions. The following advice should be observed when storing life jackets: do not hang life jackets with wet oilskins or other damp clothing

(b)

if the life jacket is wet, unpack it and leave it to dry out on a hanger

(c)

do not store life jackets close to or directly above heat sources, such as convection heaters

(d)

to prevent water getting into the automatic inflation mechanism, do not store wet life jackets upside down or lying flat

(e)

make sure there is enough space around the life jacket, when it is stored, to allow the air to circulate.

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Lifebuoys

Lifebuoys should be available wherever people are working on, over or near water. Standard 760 mm diameter lifebuoys with rope or cord lifelines (usually 30 metres) attached should be placed in conspicuous positions near the water's edge.

31

A lifebuoy can be thrown only a short distance, perhaps 6-8 metres and then with little accuracy.

32

Handling 30 metres of rope may also present problems to the inexperienced person, although lifebuoys are available with the rope packed into plastic containers, from which it reels out when the lifebuoy is thrown.

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Lifebuoys should be suspended from a suitable hook or bracket, with the lifeline coiled ready for use.

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Rescue lines

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Various types of rescue line are available. One type employs 25 metres of line in a canvas bag with a small flotation chamber. The free end of the line is held, while the bag is thrown underarm towards the casualty. The line can be delivered accurately up to its full length, but underarm throwing may be hindered by guardrails and other forms of edge protection.

35

Another method of delivering the line is the capsule emergency lifeline. A light but strong line, 40 metres in length, is packed into a small plastic capsule. The free end of the line is secured to a cord grip which is held while the capsule is thrown, the line paying out as it goes.

36

The capsule may be thrown or flicked to the full distance of 40 metres using an extension rod which fits into the handle. Both line and capsule will float, allowing the casualty to grab the line and be hauled to safety. If the first throw misses, it can be very quickly used again. The ability to deliver the line up to 40 metres may avoid the

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need to launch a boat or for somebody to enter the water. 37

The capsules are small enough to be carried in a belt or, alternatively, can be mounted in cabinets (with the extension rod) at convenient locations.

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The majority of drownings occur close to the bank or water's edge; safety provision should take account of this, where it is the dominant risk. Lightweight throwing lines or similar equipment should be provided to supplement lifebuoys, especially if workers are moving from place to place, adjacent to the water. The mere provision of a standard lifebuoy may not be regarded as doing all that is reasonably practicable to secure the safety of employees.

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Rescue packs

This method requires the rescuer to swim out on a lifeline with a buoyancy aid for the casualty or, alternatively, wearing a deflated rescue life jacket which is inflated when the casualty is reached. Both are then pulled in on the lifeline.

39

The 100 or 200 metre floating line supplied in the pack ensures the rescuer is secured to the shore or edge at all times. In rough or tidal waters, this is an important consideration. If using this method, account must be taken of the fact that the person who has fallen may be panicking and, therefore, the rescuer must be trained in rescue techniques.

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Rescue boats

A rescue boat should be provided whenever work is being undertaken over or adjacent to deep, tidal or fast flowing water; it may also be advisable to provide a boat in some areas of still water, dependent upon the findings of a risk assessment.

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The craft may be rigid (wooden or fibreglass) or inflatable. It must have a reliable engine and carry oars and possibly a first aid kit. The operator should be experienced and competent at handling small craft on flowing water, particularly in rescue situations that involve special boat-handling and skills.

42

Note Where there is a possibility that a rescue might have to be carried out using a powered rescue boat, it is strongly recommended that the operator is trained to a minimum standard. Rescuing a person from the water in a power boat with a rotating propeller demands skill and experience, particularly if there is a current flowing. Ideally, there will be two people in the boat, the driver and a 'rescuer'.

43

Whether the rescue boat is to be permanently manned and constantly afloat, or not, will depend on the circumstances, as will its size and the equipment to be carried. If any work is to be done during the hours of darkness, the rescue boat will require high efficiency lighting.

44

Two-way radio communication between boat and shore may be necessary on large areas of water. Grab lines should be provided for persons in the water and a boat hook should be carried. Practice rescue drills should be held, so that the best method of rescuing, securing and landing a potential casualty is known in advance.

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Stop nets or lines 45

Given the right circumstances, including still or gently flowing water and no waterborne traffic, nets may be suspended just into the water or lines trailed across or in the water to

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allow a conscious person to hold on while awaiting rescue, or to pull themselves to the bank. These cannot be totally relied upon, because a casualty may be unconscious or otherwise unable to help themselves. 46

If there is a weir or sluice, nets should not be relied upon unless they can be positioned well upstream of it.

Rescue techniques Methods of rescuing a casualty, other than by using a rescue boat, may be summarised as follows: involve the emergency services

(b)

reach out from the bank or edge

(c)

throw out a means of flotation or recovery

(d)

wade out

(e)

go out.

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Emergency services. In many cases, the Civil Defence (Fire Department) or Qatar Coastguard service in appropriate circumstances will have the expertise and equipment to carry out rescue procedures. A judgement will have to be made as to whether it is advisable or practical to await their arrival. This must be balanced against the risks involved in attempting the following means of rescue.

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Reach out. If the casualty is near enough to the bank or edge, it may be possible to grab their hand, or use a sturdy stick, boat-hook, oar, broom handle, or anything they can seize to pull them in to safety. The rescuer should ensure that they have a secure foothold and sufficient grip and balance to counteract the weight of the casualty in the water.

50

Throw out. When the casualty is some way out in the water, a lifebuoy and rescue line or any buoyancy aid with line attached should be thrown to them. This technique is preferable to entering the water to reach the casualty, especially if the depth of water and state of currents is not known.

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Wade out. A shelving bed or shore may enable a rescuer to reach the person in the water while keeping their feet on the bottom. Care is needed, since currents, underwater obstacles and sudden changes in the depth of water may put the rescuer at risk.

52

Go out. Assistance should be summoned first when possible. Individuals should only act alone if they really have to. A boat should preferably be used to reach the casualty. If not, the rescuer should swim out with a lifeline secured to the shore or edge and a buoyancy aid.

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Avoid becoming a casualty. People who cannot swim should not enter the water, but must raise the alarm and wait for assistance.

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1.3.3.11 Onshore facilities and procedures 1

First aid. Almost irrespective of the size of the operation, first aid facilities should be provided, and trained and qualified first-aiders should be present at the site of all work adjacent to water.

2

Facilities should include provision for transferring casualties from boat to shore and ambulance access.

3

Alarms. Some effective means of raising an alarm must exist. Gongs, bells, whistles, pressurised canister fog horns, klaxons or similar items of equipment should be provided. All people on site should be instructed in the correct use of the alarm and the actions to be

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taken when the alarm sounds. Lighting. Water surfaces should be illuminated at night so that victims of falls can be seen and constantly watched while awaiting rescue.

5

Communications. The telephone number for the ambulance, coastguard and lifeboat services should be stressed to operatives and adequate provision should be made for effective on-site communications.

6

Rescue equipment. Rescue equipment is for use in an emergency. It must be properly maintained, not misused and never relied upon as a primary safeguard against accidents.

7

Clothing. High visibility vests or jackets should be worn. These will assist in keeping the casualty in view while the rescue operation is being mounted. High visibility immersion suits will be appropriate in some circumstances.

8

Checking personnel. Periodic checks should be made to ensure nobody is missing. Personnel should work in pairs or in sight of each other to enable one person to raise the alarm in the event of an emergency.

9

Weather and tides. Details of weather and, where appropriate, tides should be obtained before each shift.

10

Recovery of equipment from the water. In the event of tools, equipment or small plant falling into the water, no attempt should be made to recover them using amateur divers or improvised techniques.

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Training

A clearly defined and documented rescue procedure should be devised. All personnel should be familiar with the procedure and understand the actions they must take in an emergency.

12

The location of emergency equipment should be known and any special training in its use given to the personnel involved. Responsibility for co-ordinating and supervising rescue operations must be allocated to identify individuals, trained and competent to discharge it. Practices in rescue procedures should be held where appropriate.

13

Locally employed site-based staff and the employees of subcontractors should receive instruction in emergency procedures and the use of life-preserving equipment, and must be given such information as is necessary to enable them to act effectively in an emergency.

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Construction Site Safety 1.3.3 Appendix 1 Safety checklist: working over or near to water Management and planning Risk assessment carried out.

2

Safe system of work, usually specified in a method statement.

3

Permit to work system implemented where necessary.

4

Frequent accounting for all staff.

5

Lone working prohibited.

6

Regular auditing that safety rules are being adhered to.

7

Competence of all staff confirmed.

8

Site induction and relevant toolbox talks for all.

9

Other training provided where necessary.

10

Serviceability and suitability of all rescue equipment periodically checked.

11

Lighting available, if necessary.

12

Weather forecast monitored where the state of the weather could be an issue.

13

Tide-tables checked where the state of the tide is an issue.

14

Preparedness to suspend work, where appropriate.

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Keeping out of the water

Scaffolds: guard-rails, toe-boards fitted; inspections made.

2

Safety nets: secure mountings, correct size of net, at the right place.

3

Safety harness: right type, properly worn, good anchorage, attached constantly.

4

Effective rescue procedures developed, for example, from a safety net.

Keeping afloat

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Life jackets: right size and type, always worn.

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Buoyancy aids: suitable for purpose.

3

Prompt response by rescue craft.

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Rescue procedures 1

Lifebelt: correctly positioned, ready for action.

2

Rescue lines: available, personnel trained in use.

3

Rescue pack: requires a good swimmer.

4

Rescue boat: properly equipped, experienced crew.

5

Stop nets or lines, just in or on water.

6

Rescue hierarchy: (a)

emergency services

(b)

reach out

(c)

throw out

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wade out

(e)

go out.

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Avoid becoming a casualty.

Onshore emergency procedure Audible alarm.

9

Good communications: telephone, radio.

10

Emergency services: phone numbers displayed, clear directions to accident location.

11

Site access for emergency vehicles.

12

Trained first aiders/rescue team.

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Construction Site Safety 1.3.3 Appendix 2 Classes of life jacket Life jackets are divided into different buoyancy classes. The criterion of each class is the support (buoyancy) provided by each class, which is expressed in Newtons (N).

2

The EU standards which cover life jackets also require a level of protection for the unconscious person in the water. This means that life jackets must distribute the weight of the wearer in such a manner that the person is turned face-up. The standards require that automatic life jackets must self-inflate within 10 seconds of contact with water.

3

The buoyancy level in the standards relate to a person weighing 70 Kg, thus the amount of actual buoyancy provided by any life jacket will depend upon the weight of the wearer.

4

Consider the following situations:

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wearing a life jacket with too little buoyancy poses obvious problems as there may be too little support for a heavy person to keep their face out of the water or possibly even turn them face-up if unconscious

(b)

conversely, wearing a life jacket with too much buoyancy could also pose problems; wearers who are not particularly heavy will be more buoyant and, for example, could find it difficult to escape from an air pocket if they have to fully immerse themselves and their life jacket to 'duck under' an obstruction.

The selection of the most appropriate life jacket is therefore essential and the following text provides a guide.

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(a)

For use by good swimmers in safe water only as long as assistance is at hand. Not safe for unconscious persons.

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Suitable for adults who are swimmers and for use in inland waters and safe areas, providing limited protection for unconscious persons depending upon the clothing worn.

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100 N life jacket

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50 N buoyancy aid

150 N life jacket 8

Suitable for swimmers and non-swimmers in all waters. Only limited protection for unconscious persons wearing heavy waterproof clothing or in heavy seas.

275 N life jacket 9

For offshore use and extreme conditions. Immediate protection for unconscious persons, with turnover guaranteed in 5 seconds. Adequate buoyancy even in heavy clothing.

10

Buoyancy aids incorporate closed-cell foam inserts sewn into the material of the device.

11

Life jackets incorporate a gas cartridge which inflates a bladder within the life jacket. Actuation can be either manual (usually by pulling a toggle on an actuating chord), or automatic (when an inbuilt 'trigger' device comes into contact with water). If operated, either in an emergency or by accident, the bladder can be deflated and repacked and the life jacket can be fitted with a rearming kit so that it can be reused if undamaged.

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Construction Site Safety 1.3.4

System Scaffolds and Mobile Towers

1.3.4.1 Key points Scaffold of any type must only be erected, altered or dismantled by operatives who have been trained, or are under the direct supervision of someone who is competent to do so.

2

The modular construction of system and tower scaffolds could increase the temptation for unqualified persons to tamper with them. Site managers must be aware of this and monitor the situation.

3

Scaffolds must be subjected to statutory inspections with reports raised where appropriate.

4

All scaffolds must be properly erected, stable, tied to the structure as appropriate, suitable for their purpose and equipped with toe-boards and guard-rails on all working platforms.

5

BS EN 12811 series of standards highlights requirement for additional ties and bracing.

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1.3.4.2 System Scaffolds

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1.3.4.3 Introduction

System scaffolds and the components of mobile scaffold towers are generally of a modular layout. They comprise standards with welded node connectors to which ledgers and transoms are fastened, usually with proprietary wedges or rings (rather than loose coupler connections) or frames with both standards and transoms welded into one unit.

2

The safety requirements of system scaffolds are broadly similar to traditional scaffolds, but there are some significant differences.

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Work at Height

The height at which guard-rails and toe-boards must be fitted is determined solely by the findings of a risk assessment. The requirement now is that a Contractor must:

4

'take suitable and sufficient measures to prevent, so far as it is reasonably practicable, any person falling a distance liable to cause personal injury.'

5

Experience has shown that falls from less than 2 metres can cause serious and fatal injuries.

6

Contractors must consider:

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(a)

the organisation and planning of work at height

(b)

avoidance of risks from working at height

(c)

the competence of those who work at height and are involved with work equipment used for working at height

(d)

the general principles for the selection of work equipment for working at height

(e)

the requirements for particular work equipment

(f)

work on or near fragile surfaces

(g)

danger areas

(h)

the inspection of work equipment used for working at height

(i)

the inspection of places of work at height

(j)

the duties of persons at work in relation to work at height.

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Of relevance to this section, these Regulations refer to applicable Schedules in section C1, these include: (a)

the requirements for working platforms, guard-rails and toe-boards

(b)

additional requirements for scaffolding

(c)

additional requirements for fall-arrest systems

(d)

additional requirements for work restraint systems

(e)

the requirements for ladders

(f)

the particulars to be included in a report of inspection.

1.3.4.4 The Provision and Use of Work Equipment System scaffolds, including individual components and associated equipment, are classified as 'work equipment'. As such, all equipment must be suitable for its intended purpose, well maintained and inspected as necessary.

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Manual handling will be an activity linked to the erection, alteration and dismantling of scaffolds. It is also likely that those who work from scaffolds will be involved in manual handling activities during the course of their work.

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1.3.4.5 Manual Handling Operations

Before undertaking the erection of a system scaffold, the following points must be clearly defined:

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1.3.4.6 Basic system scaffolding considerations

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The management of risk

A risk assessment should be carried out.

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The scaffold, so far as it is reasonably practicable, should be the safest and most suitable 'work equipment' for the task it is intended to carry out.

4

The purpose of the scaffold is usually to provide a safe place of work, primarily at height and the configuration of a system scaffold may vary depending on its intended use. For example, scaffolds for bricklaying, masonry, refurbishment, glazing or painting may differ in their design and construction.

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Who will erect the scaffold? 5

Scaffolds must only be erected, altered or dismantled by, or under the direct supervision of, a competent person.

Where will it be erected? 6

Care will be required in the initial setting out of the system scaffold as far as leg or jack adjustment and the positioning of fixed length ledgers are concerned.

7

Measuring the length of the building and then positioning the first frames or standards and ledgers in relation to door openings will be important.

Are the ground conditions suitable? 8

Bay lengths may often differ from those associated with tube and fitting scaffolding, which

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can cause loads to be concentrated in particular spots. Initial ground inspection and levelling is essential to reduce the amount of jack levelling and adjustment required during scaffold erection. As with tube and fittings scaffolds, care should be taken with regards to manholes, slopes and the general load-bearing capabilities of the area on which the system scaffold is to be placed. What materials are to be used? 9

The availability of space for the standards and the width of the working area are prime considerations in deciding which type of scaffold should be used. An allowance must be made for the fact that heavy or bulky materials may be deposited on the scaffold.

Stability of the scaffold structure The scaffold structure must be of sufficient strength and rigidity when erected and, if appropriate, secured or 'tied-in' to the structure against which it is built to ensure stability.

11

If the scaffold is later adapted or altered, this must be done in such a way as to ensure that the scaffold structure remains stable.

12

A requirement of BS EN 12811 -1:2003 is that all but 'standard scaffolds' must be properly designed.

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Can safe access to the working place be provided?

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System scaffolds provide a variety of options for safe access to the working place, such as pole ladders, internal ladder systems or staircase towers. A decision must be made at an early stage in order that provision may be made for the particular type of access required.

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Platforms may have to be installed at every level, whether or not they are working places. This is a feature of some types of system scaffold. However, it is often the case that only one or two may be used as working places, and in such cases the manufacturer's recommendations must be followed as to whether or not platforms can be omitted.

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How many working platforms will there be?

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How and where will the scaffold be tied in? The principle of tying a system scaffold to the supporting structure is the same as for a tube and fitting scaffold. The pattern of ties and the frequency of their use will vary between manufacturers, and the different types of system scaffold will often incorporate their own proprietary ties instead of the conventional through ties or Hilti rings that are used on tube and fitting scaffolds.

16

It may be necessary to tie-in the scaffold at different places compared to the tying-in of tube and fitting scaffolds, and so consideration should be given to the exact locations available.

17

Note that BS EN 12811-1:2003 recommends the installation of additional ties in some circumstances, when compared to the requirement previously required under BS 5973.

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15

What bracing will be required? 18

Ledger bracing is not generally required in system scaffolds. This has the benefit of providing a clear walk-through at platform level. However, the frequency of facade bracing will vary from product to product, and plan bracing may be required if tie or anchor positions are not readily achievable or, if deemed necessary, under BS EN 12811-1:2003.

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Unauthorised alteration 19

Due to their design features, most types of system scaffold are generally easier to alter than is a tube and fitting scaffold. This makes unauthorised alteration, for example the removal of a guard-rail or the repositioning of a working platform, that much easier.

20

Unauthorised alteration can make a scaffold an unsafe place of work for the unwary and possibly breach the scaffold design criteria from a stability point of view.

21

It is for site management to make clear to anyone who has to work on a system scaffold that unauthorised alteration must not be carried out and that appropriate actions will be taken against individuals who do so.

1.3.4.7 System scaffold specifications

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Materials

Components should be free from any weld defects, bends, distortion or corrosion that may affect the safe functioning of the items. Many scaffold systems are galvanised, so the risks from corrosion are reduced.

2

Fittings employed for tying and adaptations to the scaffold should be free from worn threads and damaged bolts.

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The requirement for any supplementary support or load-spreading capability will depend upon: the nature of the surface on which a system scaffold is to be erected

(b)

the weight of the scaffold itself

(c)

loading that will be imposed upon the completed scaffold by materials, people and equipment.

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Foundations and levelling

In most cases, the installation of either base plates alone, or base plates plus sole boards, will be sufficient.

5

On system scaffolds, the ledgers and transoms connect to the standards at fixed points so there is not the degree of vertical adjustment that there is with tube and fitting scaffolds.

6

Because of the difficulty of levelling a system scaffold as erection progresses, all such scaffolds should be properly levelled and located at the first level. If this is done correctly, components should be vertically self-aligning, but great care must be taken to check the initial vertical alignment at the base.

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Platform decking 7

As the scaffold frames and components have been designed by the manufacturer to meet the requirements then, if used in accordance with the manufacturer's assembly instructions, platform span and thickness requirements will be met.

Types of platform 8

There are several different types of platform available for use with system scaffolds: (a)

conventional scaffold boards (225 mm x 38 mm x 3.9 m) (plus steel and aluminium versions of similar dimensions)

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(b)

timber battens (typically 225 mm x 60 mm x 2.5 m)

(c)

decking platforms of plywood and aluminium (650 mm x 50 mm x 2.5 m or 3.0 m or 3.5 m)

(d)

steel decking platforms (330 mm x 50 mm x 2.5 m or 3.0 m)

Only scaffold boards, whether timber, steel or aluminium, require supporting at 1.2 m or 1.5 m centres. Other decking products have been generally designed to span distances of up to 3.0 m or 3.5 m. The manufacturers of the various types of decking will provide specific guidance.

Requirements for scaffold boards Any scaffold boards used should comply with BS 2482:2009 Scaffold boards should not be warped, twisted, split or badly worn. They should be banded or nail plated.

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All scaffold boards or decking platforms should be secured against the possibility of wind uplift. There are several types of fitting and straps available to achieve this. Design features such as locking devices to prevent wind uplift are increasingly built into proprietary platforms.

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Reaction to windspeed

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Platform widths

There is a requirement for a minimum width of a working platform, 600 mm, as specified in BS EN 12811-1 is 'standard' minimum.

13

The actual width chosen will depend largely upon the nature of the application, for example, bricklaying will not be suitable on a 750 mm-wide scaffold, but painting and cladding may be well suited to this width.

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12

Additional ledger bracing is not generally required within system scaffolds due to the inherent stiffness of the joints. However, if the system scaffold is to exceed the design boundaries of a 'standard scaffold', the layout should be specified by a competent scaffold designer.

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Ledger bracing

Longitudinal or facade bracing The requirement for longitudinal or facade bracing will be specified by the manufacturer or scaffold designer, and will vary from product to product.

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Ties 16

The need for ties on a system scaffold is the same, in principle, as on a traditional scaffold.

17

However, a system scaffold has different characteristics (for example, its components are shorter and lighter) so the tie pattern will need to be specified by the manufacturer, or a competent scaffold designer. Requirements for ties may vary from product to product.

18

Increasingly, new methods of tying are being used to replace conventional through ties or Hilti rings. Eyebolt and plastic plug type ties are now used on some systems.

Sheeting of scaffolds 19

Caution must always be exercised before a decision is taken to sheet any scaffold. The sheeting of any scaffold increases the wind-loading on it. The requirement for additional ties

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will be determined by the manufacturer or a competent scaffold designer.

1.3.4.8 Access Requirements for ladders Any ladder (including those used in conjunction with a system scaffold) must be in good condition, and of sufficient strength.

2

It must be prevented from slipping during use either by securing it at the top or bottom or by an effective anti-slip device or other equally effective means. However, industry best practice is that all ladders, irrespective of length, should be properly secured at all times.

3

The top of the ladder should extend to a sufficient height above the platform level unless alternative means are used to provide a safe handhold. (It is suggested that 1 metre or five rungs is a suitable height.)

4

If a ladder, or a series of ladders, rises a vertical distance of 9 metres or more, rest platforms or safe landing areas must be provided.

5

Pole ladders and steel ladders are still used for access to system scaffolds even though they have been a contributory factor in many falls from height.

6

Staircase towers or built in ladder sections for access onto the working platform are now widely available and used as an alternative to conventional ladders.

7

Staircase towers may be more appropriate for the movement of higher numbers of people and particularly for heights in excess of 10 metres.

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1.3.4.9 Concentrated loads 1

Where concentrated loads, e.g. pallets of bricks or tiles, are to be placed on the scaffold, loading towers may be required. These specially designed and braced scaffolds provide support for concentrated loads, the weight of which would be excessive on standard scaffold working platforms.

1.3.4.10 Incomplete scaffolds 1

Where a loading tower constructed in a system scaffold is erected adjacent to the working scaffold, the two structures should be securely tied both to each other and to the building.

1.3.4.11 Safe places of work, and stability of working platforms Any working platform on a scaffold must:

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1

have safe access to it and egress from it

(b)

be of suitable and sufficient strength and rigidity for the purpose for which it is to be used

(c)

be so erected and used so that none of the components can come loose or be displaced and endanger anyone

(d)

be stable when being erected, used and dismantled

(e)

be of sufficient dimensions to permit safe passage of persons and materials, and provide a safe working area for the work that is to be done there

(f)

have a suitable (non-slip) surface so as to prevent slipping or tripping

(g)

not have any gaps through which a person or materials could fall

(h)

be used and maintained so that persons cannot be caught between the working platform and any adjacent structure

(i)

be dismantled in such a way as to prevent accident displacement.

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Each item of plant and equipment used in conjunction with any scaffold must be of sound construction and materials, and must be sufficiently strong and suitable for the job it has been designed to do. It must be maintained in such a condition.

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1.3.4.12 Plant and equipment

1.3.4.13 Requirements for guard-rails and toe-boards 1

Where the proper erection of a scaffold has not been completed, it should not be left unattended without the display of a notice stating: Scaffolding incomplete - do not use

2

It is also a good idea to remove and secure access ladders.

3

For Mobile Towers, please see the next page.

1.3.4.14 Mobile Towers 1

The use of lightweight aluminium mobile towers on construction sites is a popular alternative to the use of traditional tube and fitting towers. However, these systems have some limitations and should only be used when they can satisfy both legislative and general site requirements.

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Five different items make up a basic mobile aluminium tower: frames

(b)

braces

(c)

platforms

(d)

legs

(e)

wheels or castors.

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General conditions and provisions

The UK Prefabricated Access Suppliers' and Manufacturers' Association (PASMA) has developed two methods of installing guard-rails that do not require the erector to stand on a working platform until the guard-rail frames have been installed:

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advanced guard-rail system

(b)

through-the-trap (3T method)

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(a)

These methods should be adopted by Contractors as best industry practice in Qatar.

5

The advanced guard-rail system involves the use of specially manufactured, hinged guardrail frames that can be raised and slotted into position from below.

6

The 3T method involves the erector only passing through the platform trap-door far enough to be able to locate the guard-rail frames in place. In many cases, safe erection of the guardrail sections can be achieved with the erector sitting on the platform with their legs through the trap and their feet supported on the ladder section below.

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Materials 7

Mobile towers may be constructed from steel, but are principally of aluminium.

8

All components must be free from any welding defects, dents, bends or distortion, or any corrosion that could prevent their safe use. Platform boards must be free from holes, cracks, splits or any delamination would affect their safe use.

Competence 9

Any person erecting a mobile tower must be competent to do so, having received adequate

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training or, if not fully competent, be under the supervision of an experienced and competent person. 10

The tower must start off and remain vertical as it is built and used.

Maintenance 11

All aluminium mobile towers are work equipment.

12

As such, mobile towers (including individual components) must be suitable for the job in hand and properly maintained.

Preparation and planning A risk assessment should be carried out to determine whether or not a mobile aluminium tower scaffold is a suitable item of work equipment for the type of work that is to be carried out and the environment in which it is intended to be used.

14

Factors that should be considered when deciding whether or not it is safe to use a mobile tower are:

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The ground surface (1) - is the surface sufficiently level to use a mobile tower if there is no adjustment on the legs for levelling the tower? A tower scaffold should not be erected if it cannot be levelled and therefore made stable.

(b)

The ground surface (2) - mobile towers only have a small area of each wheel in contact with the ground and therefore each wheel imposes a high loading at each point of contact. Is the surface strong enough to take the loading? It may be possible to use sole boards on soft ground to effectively spread the load and allow a mobile tower to be used, providing that there is no chance of the tower sinking, tilting or otherwise becoming unstable.

(c)

The ground surface (3) - are there any features such as drain covers or underground pipes that may not be able to take the direct or indirect loading imposed by one or more wheels?

(d)

The weather (outdoor use) - aluminium tower scaffolds are lightweight structures which can become unstable in moderately high winds. Has a check of the weather been made for the period that the tower will be erected? Is it possible to tie-in the tower to the structure against which it is to be erected? If any doubt exists on the limitations of the tower in high winds, has the manufacturer or supplier been consulted?

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(a)

(e)

Overhead power lines - are there any lines that are close enough to render the use of a metal scaffold unsafe? Remember, it is not necessary to touch a high voltage cable to get a shock. Many overhead power lines are not insulated and the electricity can 'arc' through the air to an adjacent metal object.

Pre-assembly inspection 15

The competent person who is to erect a mobile tower should check that all the components are present and undamaged and ensure that they are all from the same manufacturer/supplier, and are for the same type of tower.

16

A check should be made that the castors and wheels rotate and swivel freely and that they have a functioning locking device (brake).

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Safety during use Stability Due to their lightweight nature, stability can be a problem with aluminium tower scaffolds, the more so the higher they are built.

18

Individual manufacturers carry out tests on their products to enable them to provide specific guidance on height-to-base ratios, including circumstances where the installation of outriggers will be necessary. Such guidance should be available to the competent person erecting the tower.

19

As general guidance, it should be assumed that stabilisers will be required if an aluminium tower is to have a working platform higher than 3 metres above ground level.

20

In addition to the dimensions of the erected tower scaffold, there are several other factors that can affect its stability:

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Sheeting (out of doors) - will increase the wind-loading on a tower scaffold. In many instances it will not be acceptable to sheet a tower scaffold unless it can be tied-in to the structure.

(b)

Overreaching - if this is so severe that the centre of gravity is moved to a point outside the base area of the scaffold, it will overturn. It is far safer to move the tower scaffold.

(c)

Work activity - any work that involves applying a sideways pressure to the adjacent structure, for example water-jetting, at a point that is high on the tower, will create an equal and opposite pressure that may overturn the tower. In many cases, tying-in the tower to the adjacent structure may overcome this problem.

(d)

Hoisting materials - if heavy items are hoisted up the outside of the tower, it could become unstable and overturn. Again, tying-in the tower to the adjacent structure may overcome this problem.

(e)

Climbing the tower - access to the working platform should be gained by using the built-in stair or ladder sections. If a vertical ladder is built into an end frame of the tower, the person climbing the ladder must do so on the inside of the tower. Climbing the outside could overturn the tower. Never gain access to the working platform by leaning a ladder against the tower.

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(a)

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Tying-in a tower scaffold

Care should be taken to avoid couplers causing damage to the aluminium tubing and, accordingly, only special couplers should be used. Advice on the horizontal and vertical frequency of ties will be supplied by the manufacturer or supplier or, in the case of substantial or 'linked' towers, the scaffold designer.

The working platform 22

The access hatch to the working platform must be closed as soon as everyone working from the tower is on the working platform.

23

The working platform must be fully boarded unless a design feature of the scaffold enables safe access and egress and effective guard-rails and toe-boards to be installed around a partially boarded platform.

24

These state that a working platform must be of sufficient dimensions for the safe passage of people, plant and materials with due regard to the type of work being carried out. However, BS EN 12811-1 recommends that platforms on all types of scaffold should not be less than 600 mm wide.

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Gaining extra height 25

Placing stepladders and ladders on the working platform of a mobile tower to gain additional height is particularly dangerous and must be prohibited. Adjustable legs are only to be used for levelling, and not to gain additional height. If additional height is needed then a further lift should be added, providing this is within the manufacturer's height limitations.

The brakes 26

The wheel brakes must be locked in the 'ON' position at all times when the tower is not being moved. The lightweight nature of aluminium tower scaffolds presents the potential for unattended towers to be moved by the wind if the brakes are not applied, particularly where they are used on exposed floor slabs at height.

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Moving a tower scaffold The tower must not be moved whilst anyone is on the working platform. Any item that could fall or cause the tower to be unstable whilst being moved, taking into account the condition of the floor surface, must also be removed. A tower scaffold must only be moved by pushing or pulling at the base.

28

The tower must never be moved by:

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towing it with a vehicle

(b)

a person who is on the platform pulling the tower along using an adjacent structure.

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(a)

Avoiding collisions

Suitable barriers should be erected to prevent people or vehicles from accidentally colliding with a tower scaffold, particularly where it is erected in a public place.

30

It may be necessary to create a safety zone around a tower simply because of the nature of the work being carried out above.

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The capacity of each platform and tower structure is often shown on labels attached to the frame of the mobile tower, or will be in the manufacturer's assembly guide. Never exceed the recommended loading levels as this may cause the tower to become unstable.

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Loading capacity

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Incomplete towers 32

Where the proper erection of a mobile tower has not been completed, it should not be left unattended without the display of a notice stating:

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Inspection and reporting 33

34

Where the tower constitutes a working platform, it must be inspected: (a)

before being used for the first time

(b)

after any substantial addition, dismantling or other alteration

(c)

after any event which is likely to have affected its strength or stability

(d)

at regular intervals not exceeding seven days since the last inspection.

An inspection report is not necessary, however, for any mobile tower, unless it has remained erected in the same place for a period of seven days or more.

Wind strength Aluminium structures are very vulnerable to the strength of the wind. It is recommended by many manufacturers that if the wind reaches a speed of 17 miles per hour then all work should cease on the tower.

36

If the wind speed is likely to reach 40.23 km/h, the tower should be tied-in to a rigid structure. If there is a possibility of the wind reaching speeds approaching or in excess of 64.37 km/h, the tower should be dismantled.

37

Operators should be aware of the possibility of sudden high winds in exposed or gusty conditions.

38

It must be remembered that winds at high levels are often higher than at ground level. The wind speed can also increase as it funnels between buildings or other solid structures.

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Construction Site Safety 1.3.4 Appendix Wind strengths and effects (Beaufort Scale)

0-1

Light air

Direction of wind shown by smoke drift, but 1.1-5.5 not by wind or weather vanes.

1-2

Light breeze

Wind felt on face. Leaves rustle. Wind or weather vanes move.

5.6-11

2-3

Leaves and small twigs in constant motion. Wind extends light flags.

12-19

3-5

Gentle breeze

Wind raises dust and loose paper. Small branches move.

20-28

5-8

Moderate breeze

29-38

8-11

39-49

11-14

50-61

14-17

62-74

17-21

Chimney pots, slates and tiles may be blown 75-88 off. Other slight structural damage may be caused.

21-24

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Fresh breeze

6

Strong breeze

7

Near gale

8

Gale

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Small trees in leaf begin to sway. Little crested wavelets form on inland waters.

Large branches in motion. Umbrellas used with some difficulty.

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Strong gale

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Calm, smoke rises vertically

3

9

≤1

Speed m/sec

Calm

1

2

Speed Km/h

Wind effect locally

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Description of wind

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Windforce number

Whole trees in motion. Becoming difficult to walk against the wind.

Twigs break off trees. Progress is generally impeded.

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Construction Site Safety 1.3.5

Tube and Fitting Scaffolds

1.3.5.1 Key points Scaffolds must only be erected, altered or dismantled by operatives who have been trained to do so and are competent, or are under the direct supervision of someone who is.

2

Scaffolds are subject to statutory inspections, with reports of inspections raised where appropriate.

3

All scaffolds must be properly erected, stable, tied to the structure as appropriate, suitable for their purpose and equipped with toe-boards and guard-rails on all working platforms.

4

The BS EN 12811 series is supported by the UK National Access and Scaffolding Confederation's technical guidance note TG20 'Guide to good practice for scaffolding with tube and fittings'.

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1.3.5.2 Introduction

The purpose these Regulations is to give readers an understanding of the safety issues that relate to the use of scaffolds, particularly where site managers or other readers have to manage scaffolding operations and assess the suitability of scaffolds which have been erected by others.

2

The majority of guidelines for good practice in scaffolding can be found in UK NASC safety and technical guidance notes.

3

The main British and European Standard for scaffolding is BS EN 12811 (Part 1) Scaffolds Performance requirements and general design.

4

This latter standard, which focuses more on scaffold design, does not cover the same range of good practice as the old Code of Practice BS 5973 (now withdrawn) and readers are directed to the range of UK National Access and Scaffolding Confederation (UK NASC) particularly 'Guide to Good Practice for Scaffolding with Tubes and Fittings TG20.

5

They must also be used in accordance with the manufacturers' instructions or the scaffold should be designed by a competent engineer.

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1.3.5.3 UK NASC Technical Guidance TG20:08 Wherever TG20' appears in the text, it refers to UK National Access and Scaffolding Confederation publication Guide to Good Practice for Scaffolding with Tubes and Fittings (TG20:08).

1.3.5.4 Competent persons 1

For the purposes of scaffold inspection, a competent person may be defined as:

2

A person who has practical and theoretical knowledge, scaffold inspection training and actual experience of what they are to examine, in respect of a scaffold, so as to enable them to detect errors, defects, faults or weaknesses that it is the purpose of the examination or inspection to discover; and to assess the importance of any such discovery.

3

As regards the competence of individuals in relation to the erection of scaffolds, 'competence' may be taken to mean:

4

A person who has practical and theoretical knowledge, together with actual experience of

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scaffolding, and has acquired, or who is being supervised while being trained to acquire, a recognised qualification in scaffolding.

1.3.5.5 Work at Height These Regulations are covered in detail in Section C1. The key provisions of these Regulations that can apply to scaffolding are: to ensure that the work is risk assessment based and that it is carried out safely

(b)

the definition of 'work at height'

(c)

fall prevention and protection

(d)

falling object prevention and protection

(e)

danger zones where people would be at risk of falling or being struck by falling objects

(f)

fragile surfaces

(g)

competence for planning, organising and working at height

(h)

weather conditions

(i)

emergencies and rescue

(j)

requirements for guard-rails, toe-boards and similar barriers

(k)

requirements for working platforms

(l)

requirements for access and egress and the use of ladders.

(m)

statutory scaffold inspections

(n)

scaffolding design

(o)

a scaffolding plan

(p)

duties on employees to report hazards and work at height safely.

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1.3.5.6 The Management of Health and Safety at Work In general terms, these Regulations place a requirement on the Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazards to employees that might be encountered during their work, or to any other persons who might be affected by what employees are doing. This includes the work of those who erect, alter and dismantle scaffolds and also those who use scaffolds as a place of work.

2

When hazards are identified, it is the Contractor's duty to either eliminate the hazard or to put into effect control measures to reduce the risks to health and safety arising from the hazard, so far as it is reasonably practicable to do so.

3

The Contractor must provide employees with information on the risks which exist and the measures that are put in place to control them.

4

The employees then have a duty to comply with any instructions they have been given, and to tell the Contractor about any work situation, or any aspect of the work, which presents a risk to them or anyone else. These Regulations, therefore, cover the duty of the Contractor to carry out 'work at height' risk assessments.

5

These Regulations include a specific requirement to produce a scaffolding plan (or method statement) covering the assembly, use, alterations and dismantling, which is a form of risk assessment.

6

Contractors must consider the physical capabilities of employees who are required to erect, alter or dismantle scaffolding, due to the physical nature of the occupation.

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1.3.5.7 Provision and Use of Work Equipment 1

Scaffolding, including individual components and associated equipment, are classified as 'work equipment'. As such, all equipment must be suitable for its intended purpose, well maintained and individual components inspected as necessary.

1.3.5.8 Manual Handling Operations Manual handling will be an activity linked to the erection, alteration and dismantling of scaffolds. It is also likely that those who work from scaffolds will be involved in manual handling activities during the course of their work.

2

Contractors carrying out scaffolding activities must assess the risks arising out of manual handling. This is usually undertaken as part of the general risk assessment and method statement/scaffold plan.

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Architects and designers have duties under these Regulations to consider the design of temporary works such as access scaffolding, falsework and formwork structures. Where these temporary structures would be required for construction or future maintenance, designers have a duty to carry out a 'design risk assessment' to design out risk and communicate any residual hazards that remain.

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When selecting a scaffolding contractor you must check that they are competent and consider: the competence of management and operatives for the type of work

(b)

a proven track record for the type of work

(c)

the past health and safety performance

(d)

the allocation of sufficient physical and human resources to service the contract (e.g. scaffolding equipment, transport, qualified scaffolders and supervision)

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Before engaging a specialist scaffolding contractor, it is a good idea to prepare information on the intended use of the scaffolds for the scaffolding contractor to take into account. For further information reference should be made to TG20 (Volume 1 clause 37.2.2) 'Client's brief.

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1.3.5.10 Planning for a scaffolding contract

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1.3.5.9 Construction (Design and Management) CDM

1.3.5.11 Basic scaffolding considerations 1

Before the erection of any scaffold, the following points must be clearly defined. (a)

What is the scaffold for?

(b)

Is it to be a 'standard scaffold' as defined in UK NASC guide TG20 Volume 1?

(c)

Exactly where is it to be erected?

(d)

What materials are to be used?

(e)

Can safe access be provided for the erection and use of the scaffold?

(f)

How many working platforms will there be?

(g)

Is the ground condition where the scaffold is to be erected suitable?

(h)

How and where can the scaffold be tied-in?

(i)

What bracing will be required?

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(j)

What loadings will be imposed upon those working platforms, and on the scaffold as a whole?

(k)

Will it be sheeted?

1.3.5.12 Scaffold design These Regulations require all scaffolds to be calculated unless constructed to a generally recognised standard configuration. This means for tube and fitting scaffolds they must be a 'standard scaffold' as defined in TG20 Volume 1 Section 2. Otherwise the scaffold MUST be designed and calculated by a competent engineer.

2

Further sections of Volume 1 and Volume 2 of TG20 provide information for engineers to design and calculate 'special scaffolds' in tube and fittings.

3

Scaffolding contractors should have suitable arrangements in place to manage and control the erection, alteration and commissioning of special scaffolds (such as issuing drawings; managing variations to the design; inspection and handing over designed scaffolds).

4

Note that for all standard scaffolds erected, a simple procedure must be followed to determine the maximum safe height as required by TG20 (Volume 1 Section 2 Clause 4.4.3). This basic calculation is intended to be carried out by those planning and organising scaffolding and not necessarily an engineer.

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1.3.5.13 Fall prevention and protection while scaffolding While a scaffold structure is actually being built, the scaffolders do not always have the protection afforded by guard-rails and toe-boards until such time as they themselves have installed them. They rely upon the use of personal fall protection equipment (harnesses) to arrest a fall during this time.

2

In order to assist Contractors, the UK National Access and Scaffolding Confederation (UK NASC) has produced UK NASC Guidance Note SG4:05, Preventing Falls in Scaffolding and Falsework. This is the accepted industry standard to which all scaffolding contractors should be working.

3

Under the heading of 'Step 1 - Planning for work at height', the guidance states:

4

'Scaffolding contractors should consider measures that prevent falls from height, such as providing adequate work platforms with suitable guard-rails or other collective measures, before resorting to fall arrest equipment (i.e. harnesses).'

5

Devices and systems of work that provide collective fall protection, such as Advanced Guardrail Systems and Step-ups, are now available for certain scaffolding operations. These collective measures enable scaffolders to provide guard-rail protection in advance of erection and to maintain fall protection for alterations and dismantling. Such systems do not completely eliminate the risk of a fall in all circumstances and UK NASC still recommends the use of personal fall protection equipment. Most of the current industry guidance is based on the content of BS EN 13374.

6

Scaffolding plans must also consider the rescue and recovery of a scaffolder suspended by their personal fall protection equipment. For further information on rescue planning see UK NASC safety guidance note SG19.

7

Personal fall protection equipment used for scaffolding should be inspected:

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(a)

before use by the user

(b)

thoroughly by a competent person every three months and recorded

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thoroughly at other intervals if the need is identified via a risk assessment.

8

For further information on the inspection of fall protection equipment see UK NASC safety guidance note SG16.

9

To ensure compliance with the above requirements: (a)

scaffolders and their supervision should be trained in the requirements of SG4:05 and the rescue plan

(b)

site managers and others who run construction sites should check that the scaffold contractors coming on to their sites have been adequately trained in the requirements of SG4:05.

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1.3.5.14 Scaffold features

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Foundations The foundations for all scaffolds must be of adequate strength to support and disperse the load. On hard surfaces, such as steel and concrete of sufficient strength and thickness, standards may be placed directly on the surface, although it is generally preferable to use a base plate which is 150 mm x 150 mm in size. Sheeting or proprietary plastic treaders can also be used to protect sensitive floors from damage or marking.

2

On other surfaces, the load should be spread by using base plates and sole boards (see above). The soil or ground beneath the sole board should be level and properly compacted.

3

When a sole board is used on hard ground, the area beneath any one standard should be at 2 least 1,000 cm . If a timber sole board is used, it must be not less than 35 mm thick.

4

On soft or disturbed ground, the sole board area should not be less than 1,700 cm . Each sole board should support two standards.

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Sole board minimum dimensions 5

These should be: on hard ground 450 mm x 225 mm x 35 mm on soft ground 760 mm x 225 mm x 35 mm

6

Bricks, blocks and scraps of odd timber must not be used as sole boards.

7

On sloping ground, steps should be cut into the ground to accept base plates or sole boards (see below). If the slope exceeds 1:10, an engineer should check that the ground has sufficient stability.

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Scaffolds founded on roofs or other suspended surfaces will need special consideration for the loads imposed. An assessment and calculations may need to be made by an engineer to ensure the loads can be supported, or whether temporary supports (shoring) will be required. Alternative scaffolding materials, such as aluminium, can also be used to reduce the loads imposed by the scaffolding.

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Materials

Scaffold tubes and fittings must comply with BS EN 39:2001 (older tube to BS 1139). Ends should be cut square and clean, free from any bends or distortion, corrosion, lamination splits or surface flaws.

10

Fittings must comply with BS EN 74:3 2007 and BS 1139 Part 2.1. Fittings should not have worn threads or damaged bolts and excess surface oil which may reduce friction grip.

11

All scaffold boards should comply with BS 2482:2009 and should not be warped, twisted, split or badly worn, painted or otherwise treated so as to conceal any defects.

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Standards

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Standards should be: (a)

placed vertically spaced closely enough to provide an adequate support (see TG20 Table 1 Load classes)

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(c)

on a base plate and sole boards to prevent displacement

(d)

near to ledgers

(e)

positioned so that joints are staggered ensuring there are no more than three joints in any one bay.

Ledgers 13

Ledgers should be: (a)

horizontal and fixed securely to the inside of standards with right-angled, load-bearing couplers

(b)

fitted so that joints are staggered, and not situated in the same bay

(c)

positioned so that joints in ledgers are in the end thirds of the bay, adjacent to the standards.

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Putlogs and transoms The length of putlog tubes and transoms will vary to suit the width class of the scaffold in accordance with TG20 Table 7.

15

In order to avoid injury to site workers (and in some circumstances, the public), the outermost ends of the putlogs or transoms should not project an unnecessary distance beyond the face of the scaffold and/or be shielded by the use of purpose-made protective plastic cups or other suitable protection.

16

Where appropriate, transoms should be long enough to butt up against the supporting structure and enable the attachment of facade bracing tubes.

17

Putlogs should be:

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securely fixed to ledgers or standards with right-angled or putlog couplers

(b)

supported with the blade placed in the mortar bed joint of the brickwork, and pushed right into the wall to provide a sufficient support (see above). The blade should be horizontal and bedded approximately 75 mm into the brickwork.

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When putlogs are used on existing buildings for tasks such as refurbishment or repointing, each putlog blade can be installed either with the flattened end located in a vertical joint (pert) or the horizontal bed in the brickwork.

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1.3.5.15 Boarded lifts

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Width

The recommended minimum width in accordance with BS EN 12811-1 is 600 mm.

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Lift height

BS EN12811-1 requires a minimum headroom height of 1.75 m on working lifts.

3

Under TG20, the maximum lift height is 2.0 m for standard putlog and independent tied scaffolds.

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Where pedestrian access is required under the first lift, a 2.7 m base lift is permissible, provided that the scaffold is tied at the first level to alternate standards.

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Transom (or putlog) spacing 5

The spacing of transoms or putlogs for boarded lifts will be determined by the standard or grade of scaffold board used and the load class of scaffold required.

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The spacing between transoms or putlogs must not result in an unsupported length of board greater than that specified in Table 8 of TG20.

Loading 7

It is essential that scaffolds are not loaded beyond their maximum design load. Materials should be distributed as evenly as possible with heavy items, such as piles of bricks, positioned adjacent to standards. See Table 1 of TG20.

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1.3.5.16 Non-boarded lifts 1

For scaffolds up to 15 metres high, transoms and putlogs used for non-boarded lifts should be fixed at every pair of standards, including the pair at each end of the scaffold, to either the standards with right-angled couplers, or to the ledgers with putlog couplers, and should be within 300 mm of the ledger and standard connection. For scaffolds higher than 15 metres, specialist guidance should be sought.

2

Note that SG4 requires all platform boards to be correctly supported as part of the safe system of work. Transoms provided as temporary board supports on non-boarded lifts must be left in place for alterations and dismantling.

1.3.5.17 Ledger bracing Ledger bracing on 'standard scaffolds' should usually be fixed to alternate pairs of standards to all lifts.

2

BS EN 12811-1 requires unimpeded access along the working lift. For this to be achieved in tube and fittings, reference needs to be made to TG20 Volume 2 and the structure classed as a 'special scaffold'.

3

Ledger bracing should be fitted on alternate pairs of standards, except where the width of the bays is 1.5 m or less. Then they may be fitted on every third pair.

4

Ledger bracing should be fitted:

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to ledgers or standards using load-bearing fittings, which will have a minimum slip resistance of 5 Kn

(b)

to the full height of the scaffold

(c)

to start at base plate level (unless a pavement lift is required).

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1.3.5.18 Facade bracing

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(a)

Facade bracing runs parallel to the face of the building or structure and is also known as longitudinal, face or sway bracing. It is fixed to the outside standards for independent tied scaffolds.

2

Facade braces can be attached to transoms with right angle couplers at every lift, or to every standard using swivel couplers.

3

Facade bracing must be fixed to every sixth bay and set at an angle between 35-55 degrees. All joints should be made with sleeve couplers. However, when joint pins are used, a splicing tube should overlap by a minimum of 300 mm and be fixed with two swivel couplers on either side of the joint.

4

There are three standard facade bracing patterns.

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(a)

Zigzag across two bays (ledger braced).

(b)

Continuous for wider facades.

(c)

Zigzag across one bay only*.

*Note that plan bracing is required for this form of facade bracing (see Plan bracing below).

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1.3.5.19 Plan bracing 1

Plan bracing is required horizontally across the scaffold on all standard scaffolds taller than 8 m where the facade bracing is fixed across one bay only (see Facade bracing above).

2

Plan braces are fixed to the standards with right angle couplers, except where headroom is critical, when it may be fixed with swivels to the ledgers.

3

Plan bracing should be fitted every 8 m (four lifts) vertically and every 12th bay to correspond with the facade bracing.

4

Greater detail on the fitting of plan bracing can be found in UK NASC guide TG20.

1.3.5.20 Scaffold ties A tie secures the scaffold to the supporting structure and is provided to resist the inward and outward movement of the scaffold and also to give some additional longitudinal stability.

2

Ties are generally designated as 'moveable' or 'non-moveable', the terminology being selfexplanatory. Where possible, ties should be left undisturbed until the scaffold is dismantled. Where it is necessary for ties to be removed, even for a short period, the scaffold will be less stable and the fitting of additional temporary ties will be necessary unless the initial tiepattern was designed to allow for the temporary removal of some ties.

3

Ties must not be removed by anyone other than a competent scaffolder or someone who is under the direct supervision of one. The removal of scaffold ties must be carried out in compliance with a method statement.

4

Scaffolds fitted with debris netting, sheeting and tarpaulins will be subjected to extra loading due to wind pressure and will require the scaffold designer to increase the number and frequency of ties, or the tie capacity.

5

Ties often pass through openings into the building, although alternative methods of tying can be employed.

6

Generally, each tie must have a minimum tensile or compressive capacity of 6.1 kN, although designers can consider heavy duty ties at 12.2 kN and light duty ties at 3.5 kN.

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1.3.5.21 Layout and frequency of ties 1

Ties should be evenly distributed over the scaffold, both horizontally and vertically with a vertical spacing of no more than 4 m.

2

TG20 offers alternative tie patterns. If these minimum tie patterns cannot be achieved, the pattern will need to be calculated by an engineer. At least 50% of ties must be fixed to ledger braced standards.

3

The density of ties will be decided by the scaffold designer based on all the factors that have the potential to affect the loading on the scaffold.

4

Full details of tying scaffolds are included in UK NASC guide TG20.

1.3.5.22 Rakers 1

For lower level and domestic scaffolds, where it is not possible to install normal ties, the stability of a scaffold can be achieved by the use of rakers. A single, unjointed raking tube not more than 6.4 m in length may be coupled at the top to the ledger at the second lift,

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extending at an angle not greater than 75° to the horizontal (4:1). The foot of the raking tube must be well founded and must always be tied back to the main scaffold. This arrangement can be used in place of a single tie.

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1.3.5.23 Freestanding access scaffolds 1

Freestanding access scaffolds for modern methods of construction, such as timber frame structures, require calculations to be made for stability. These scaffolds would therefore be classed as special scaffolds.

2

Engineers can utilise alternative methods of achieving stability, such as buttressing, kentledge (ballast or counterweights), guys and ground anchors. Returns around corners, access towers and loading bays can also be taken into account by engineers when calculating stability.

3

For further information see UK NASC safety guidance SG28 Safe systems of work for scaffolding associated with timber frame construction.

1.3.5.24 Types of tie The following methods may be employed.

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Through tie: This type of tie relies on a tube, usually placed vertically inside an opening or window in a building. The tie tube should preferably rest on the sill, as close to one edge of the opening as possible.

2

Through ties should be placed as close as possible to the window reveal and secured with right-angled couplers.

3

Reveal tie: In cases where it is not possible to open or leave windows open or where it is impractical to fit other types of tie, a reveal tube may be wedged or jacked tight between the opposing faces of the window opening. Timber packing should be thin (10 mm) to reduce the possibility of timber shrinkage and approximately 75 mm x 75 mm. It should be checked frequently for tightness.

4

A bridle tube should then be attached to the reveal tube with a right-angle coupler, within 150 mm of end opposite to the reveal pin (whether this is horizontal or vertical). The bridle tube is usually fixed to the scaffold in two places with right-angle couplers although other satisfactory arrangement may be used.

5

It should be noted that reveal ties generally depend entirely upon friction for their integrity and therefore:

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they should be checked frequently for tightness

(b)

their use is limited to a maximum of 50%. Refer to UK NASC guidance TG20.

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(a)

Box tie: This forms an assembly of tubes and couplers around columns or other parts of a building. It should preferably be at the level of the scaffold lift and joined to both inside and outside ledgers or uprights.

7

Lip ties: An alternative form of tie, where box ties cannot be used; these take the form of an 'L' shaped arrangement of tubes and couplers which hook the scaffold behind elements of the building, such as parapets. Lip ties do not resist inward or sway movement of the scaffold; adjacent butting and sway transoms should be used to prevent this.

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1.3.5.25 Cast-in or drilled-in anchorages 1

A selection of screwed plates, eyes, sockets and nuts are available for setting into concrete during pouring. These may be used as anchorages.

2

There is a wide range of drilled-in anchorages available, also known as masonry anchors.

3

The accepted industry standard for the selection, use and testing of masonry anchors is UK NASC technical guidance TG4:04 'Anchorage Systems for Scaffolding'.

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4

Masonry anchors must be used in accordance with the manufacturer's instructions. Scaffolders who install these anchors should be trained in accordance with those instructions.

5

TG4 requires two levels of testing. (a)

Preliminary testing, wherever there is doubt about the base materials to help select the correct type of anchor.

(b)

Proof testing, to check the installation and that the required tensile loads can be achieved. A minimum of three ties must be tested and 5% (1 in 20) thereafter. Ties must be tested to 1.5 times the required tensile load e.g. 6.1 kN tie requires a 9.2 kN tensile test load.

If any anchor fails the test the cause must be investigated and the test frequency increased to 10%. A test report should be provided with the test results as part of the handover process.

7

Ring bolts are produced in two sizes.

A smaller ring for use with wire or steel banding ties, which should be turned around a node point of the scaffold or otherwise prevented from slipping.

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(b)

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A ring of 50-55 mm internal diameter, through which a scaffold tube could be passed.

The strength and pull-out capabilities of all cast or drilled anchorages must be confirmed before use.

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1.3.5.26 Wire or steel banding ties

Scaffolding may be secured to the building using the small ring bolt described previously, with 6 mm wire rope threaded through the ring and around a scaffolding member with a minimum of three turns. Steel banding of the equivalent strength may be used for the same purpose.

2

This method does not prevent movement inwards; butting or sway transoms should be used to prevent this.

3

Some architectural features of a structure may be of sufficient strength for attaching wire or banding ties although they must not be used until their suitability has been verified, by testing if necessary. If there is any doubt, they must not be used and an alternative method of tying must be found. Rainwater guttering and soil pipes must never be used for the attachment of ties.

4

When viewed in plan, tie tubes or banding ties should be set at right-angles to the building.

5

Information regarding design loads for ties can be obtained from UK NASC guidance TG4:04.

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1.3.5.27 Scaffold boards 1

The minimum amount by which any scaffold board should overhang any putlog or transom must be no less than 50

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mm. 2

The maximum overhang varies with the thickness of the scaffold board used. For further information, see Table 8 of TG20.

3

All scaffold boards which comply with BS 2482:2009 should: be free from splits, shakes, excessive knots, paint, oil or concrete

(b)

be usually 225 mm wide and not less than 220 mm

(c)

not be painted or otherwise treated to conceal defects

(d)

be banded or nail-plated at ends

(e)

be supported by putlogs or transoms at the appropriate spacings

(f)

overhang at least 50 mm but not more than four times the thickness of the board, unless secured from tipping

(g)

be guarded against the wind causing the boards to lift

(h)

be secured to prevent movement if short boards less than 2.13 m are used.

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1.3.5.28 Working platforms and decking

All working platforms and decking should be closely boarded to their full width and free from tripping hazards. Where reasonably practicable, overlapping boards should be avoided. Where an overlap is unavoidable, the lapped board should be secured to prevent movement and, if necessary, bevelled pieces should be installed.

2

The platform should be of an adequate width for the work to be carried out and safe passage of people. The suggested widths as shown in Table 7 of TG20 may be taken as current industry guidance.

3

When material is deposited on a platform, a clear passage must be maintained for access.

4

The space between the inner edge of a working platform and the adjacent structure should be kept as small as possible to prevent falls. However, there can be circumstances in which this gap has to be left wider. This is usually due to the nature of the work being carried out, for example to enable the craning-in of sections of curtain wall between the scaffold and the building under construction or where there is only primary steelwork inside the scaffold.

5

In such circumstances, suitable compensatory measures must be taken if there is a risk of people falling, or people being struck by falling objects. For example:

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(a)

use of inner guard-rails and toe-boards

(b)

segregation of the areas below the scaffold and post warning signs

(c)

areas of the scaffold designated as 'danger areas', where access is restricted by guard-rails and warning signs

(d)

use of personal fall protection equipment (harnesses).

6

The space between scaffolding boards should be kept as small as possible and in any case should not exceed 25 mm.

7

Boards should be securely fixed and present no risk to any person below.

1.3.5.29 Gangways and runs 1

All gangways and runs should be:

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(a)

600 mm wide (3 boards) if used for harrowing and the passage of materials

(b)

preferably horizontal, but where this is not possible they may slope up to a maximum gradient of 20% (1 unit vertical to 5 units horizontal) without the requirement for stepping laths.

If the gradient is unavoidably over 20%, or if the conditions are slippery, stepping laths must be provided. Whilst there is no recommended distance between stepping laths, a 300 mm separation is suggested. Stepping laths may incorporate a maximum central gap of 100 mm for barrow wheels.

1.3.5.30 Guard-rails Guard-rails are just one of the options a Contractor may consider as a 'suitable and sufficient measure' or means of protection when a person could fall any distance liable to cause them personal injury. As guard-rails are generally a collective measure, by offering protection to everyone, they are to be preferred to other measures that only protect individuals, such as safety harnesses.

2

A guard-rail must be 950 mm above the edge (or above a working platform) from which any person is liable to fall.

3

A second guard-rail (or mid guard-rail) may be placed approximately halfway between the top edge of the toe-board and the top guard-rail, so that there is no gap larger than 470 mm between the guard-rails or between the mid guard-rail and the toe-board.

4

All guard-rails must be fixed inside the standards with right-angle couplers to each standard.

5

Brick guards should always be installed where there is a possibility of materials toppling from working platforms. If using the common type of brick guard, mid guard-rails should also be fitted.

6

There will be occasions when it is possible to fall from the working platform into the structure under construction. In these cases, it will be necessary to consider installing guard-rails to the inner edge of working platforms or using other fall prevention/arrest measures.

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1.3.5.31 Temporary removal of guard-rails 1

Where it is necessary to load out scaffolds with bulk materials and so on, ideally there will be a purpose-built loading bay with a lifting safety gate or similar. Where this is not the case, it

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is permissible to temporarily remove guard-rails and toe-boards, provided that;

2

(a)

unless other work is stopped, other equally effective fall prevention/arrest measures are put in place (such as safety harnesses) whilst there is an exposed edge

(b)

once the loading has been completed, the guard-rails and toe-boards are replaced immediately.

The removal and refitting of guard-rails and toe-boards must only be carried out by a competent scaffolder or a trainee who is under the direct supervision of a competent scaffolder.

1.3.5.32 Toe-boards

fitted in conjunction with all guard-rails

(b)

a minimum height of 150 mm in accordance with TG20

(c)

fixed inside the standard, at a minimum of two positions.

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Toe-boards must be:

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1.3.5.33 Access to scaffolds

Contractors are required to specify the use of existing structures as a means of access to height, for example lifts or a permanent staircase, in preference to temporary measures such as ladders.

2

Whilst ladders have been the commonly used means of access to scaffolds, the use of other, safer means of access, such as stair towers, should now be considered in preference.

3

BS EN 12811 recommends that where extensive work is carried out, stairways should be provided for access, and for taller scaffolds consideration should be given to the use of a passenger hoist.

4

Note: Where passenger hoists are used, then additional non-mechanical access must also be provided in case of breakdown or emergencies.

5

The UK NASC recommends the following hierarchy of access from TG20.

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(c)

Ladder access bays with multiple lift ladders.

(d)

Internal ladder access with protected ladder traps.

(e)

External ladder using a safety gate.

Stairways.

Ladder access bays with single lift ladders (to reduce the potential fall distance).

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Where a ladder protrudes through a working platform (known as a ladder trap), the remaining width of the platform must be at least 450 mm (2 boards wide).

1.3.5.34 Ladder access 1

Straight ladders used for access to a scaffold must: (a)

be manufactured to BS EN 131/BS 1129

(b)

not be defective in any way

(c)

not be painted or treated in any way that might hide defects

(d)

be placed on a firm footing, with each stile equally supported

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(e)

be so positioned that there is sufficient space at each rung to give an adequate foothold

(f)

be positioned approximately at an angle of 75°, that is: 1 measure horizontal to 4 measures vertical

(g)

be secured at the top using square lashings or a proprietary ladder clamp. For longer ladders, additional ladder supports (stays) can be used to prevent the ladder deflecting when used. The stay must not obstruct the rung of the ladder

(h)

extend approximately 1 m above the working platform, unless there is another adequate handhold

(i)

be provided with suitable rest platforms if rising more than 9 m

(j)

be the 'right way up' (tie wires or bars positioned under the rungs).

Where scaffolds are designed with internal ladders, working platforms must be provided with access holes for each ladder. Such access holes should be at least 450 mm wide (across the platform) and not less than 600 mm in the other direction. The access hole should be protected with a ladder trapdoor as good practice.

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Note: Shorter/Ladders, which provide access to only one lift, are recommended.

be fitted with guard-rails and toe-boards, as previously detailed

(b)

not be used for the storage of materials

(c)

be installed at a maximum vertical height of 9 metres and multiples thereof

(d)

be equipped with access holes of similar dimensions to working platforms as detailed above.

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Lateral gaps in guard-rails and toe-boards for access and egress must be kept to a minimum and protected with a ladder safety gate as good practice.

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Landing platforms should:

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1.3.5.35 Landing platforms

1.3.5.36 Incomplete scaffolds 1

Where the erection of a scaffold has not been completed, physical measures must be taken to restrict access to the scaffold, e.g. remove or board over the access ladder(s) and warn people of the fact

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that the scaffold is not safe to use. The method of warning will usually be 'scaffold incomplete' signs at each point of access. 2

On larger scaffolds that are substantially complete, it may only be necessary to deny access to the part of the scaffold that remains incomplete, providing: (a)

the part of the scaffold that is complete is safe to occupy

(b)

all access points from the completed part of the scaffold, beyond which the scaffold is incomplete, are clearly defined by warning signs and access to the incomplete part of the scaffold is effectively prevented with guard-rails or other barriers.

1.3.5.37 Loading of scaffolds Any working platform on a scaffold should not be so loaded that it gives rise to a danger of collapse or to any deformation which could affect its safe use.

2

Any scaffold, or part of, that is to be loaded by mechanical means (e.g. crane or fork lift truck), must be specially designed and calculated as a loading bay or tower.

3

The scaffold should be checked periodically to ensure that the loads are within the permissible limits. Refer to Table 7 of TG20.

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1.3.5.38 Loads on scaffold fittings

BS EN 74 Part 1 contains specifications for scaffolding couplers, including the 'slip-load' of scaffold fittings. Load-bearing fittings such as right-angle and swivel couplers have much higher slip values than non-load-bearing items such as putlog clips.

2

Other considerations are:

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scaffold fittings must not be oily or greasy. This will cause reduced frictional resistance between the tube and the fitting

(b)

the correct spanner or podger must be used, and used in the correct manner, otherwise the screw threads may be overstressed

(c)

scaffold fittings and tubes must be free from corrosion or other obvious defects.

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1.3.5.39 Hoisting of materials When working at heights, various items of lifting equipment or ancillary lifting equipment will usually be required. These may include block and tackle, motorised winches, wire ropes, chains or slings.

2

Goods and passenger hoists should not be tied to the scaffold unless specially designed and calculated for the purpose.

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1.3.5.40 Inspection of scaffolds 1

All scaffolds and working platforms (together with all other protective measures) are 'work equipment' and so the inspection requirements of these Regulations apply:

2

'Every Contractor shall ensure that where the safety of work equipment depends on how it is installed or assembled, it is not used after installation or assembly in any position unless it has been inspected in that position.'

3

This clearly applies to all scaffolds including mobile and static tower scaffolds.

4

The inspection must be carried out by a competent person. A Contractor may wish to have a

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commercial arrangement with a scaffolding contractor in order to carry this out. 5

There is a further requirement in that every Contractor must ensure that work equipment exposed to conditions that may cause any deterioration liable to result in dangerous situations is inspected at suitable intervals, and also when any exceptional circumstances that are liable to jeopardise the safety of the work equipment have occurred.

6

In addition, Contractors must ensure that working platforms used for construction and from which a person could fall more than 2 metres are not used in any position unless they have been inspected in that position within the previous seven days.

1.3.5.41 Inspection of places of work at height An additional requirement as regards inspection (or checking) is that every Contractor must ensure, so far as it is reasonably practicable, that every surface, parapet, permanent rail or other such fall protection measure of every place of work at height is checked before each use.

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1.3.5.42 Reports

Where an inspection has been carried out, a written report of the findings of the inspection must be made before the end of the working period.

2

The person who prepares the written report must provide a copy within 24 hours to the person on whose behalf the inspection was carried out. The report, or a copy of it, must be kept on the site where the inspection was carried out until the construction work is completed, and then kept at the company offices for three months.

3

Contractors are free to design their own inspection report forms or purchase pads of them from commercial suppliers.

4

In either case the following details must be included:

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The name and address of the person for whom the inspection was carried out.

(b)

The location of the work equipment inspected.

(c)

A description of the work equipment inspected. The date and time of the inspection. Details of any matter identified that could give rise to a risk to the health or safety of any person.

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(a)

(f)

Details of any action taken as a result of any matter identified in 5.

(g)

Details of any further actions considered necessary.

(h)

The name and position of the person making the report.

5

Where someone has carried out an inspection of a scaffold and believes that it is not safe to use, they must inform the person for whom the inspection has been carried out that the scaffold is unsafe. The scaffold must not then be used until it has been made safe.

6

An example of an inspection report form is included in Appendix 7 of this module.

1.3.5.43 Use of scaffolds by other employees 1

Scaffolds erected for one Contractor may (provided that permission has been sought and given) be used by employees of another company, providing that the second Contractor is satisfied that the scaffold is safe for its intended use and conforms to these Regulations.

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1.3.5.44 Protection of the public 1

Protection of the public and other persons against falling materials should be provided by the use of nets, brick guards, toe-boards and protective fans, etc.

1.3.5.45 Scaffold in a public place These can cause particular problems to people with physical and visual disabilities, unless adequate steps are taken to reduce 'contact' hazards with such items as tube ends and threads on fittings.

2

This can usually be achieved by cladding the run of standards or binding the scaffold poles and fittings with suitable padding and/or brightly coloured bunting and tape.

3

All joints should be wrapped to protect the public and other persons from sharp edges, and plastic protective cups should be placed in or over the ends of tubes.

4

In most cases the scaffold will need to be designed to allow for ledger braces to be omitted at ground level so that members of the public can pass under the scaffold.

5

The bottom or 'pavement' lift of the scaffold should be at a height no greater than 2.7 m. The lift above pavement gantries must be fully close boarded, with a double layer of scaffold boards and a layer of impervious sheeting.

6

It is not sufficient to warn the public of the hazard just by placing safety signs on the, scaffold. Contractors must have acted to reduce the hazard as far as reasonably practicable.

7

To ensure the scaffold is not struck by vehicles, no part of it should be allowed to project into the roadway, unless appropriate measures are taken, such as traffic control or a road closure. The provision of lighting at night may also be necessary.

8

Supplementary lights should be installed on the scaffold where it has been erected in a place to which the public has access (whether pedestrians or vehicles), unless the level of 'background' lighting after dark is thought to be sufficient.

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1.3.5.46 Handover certificates 1

Contractors may, in their own interests, require that scaffold handover certificates are issued by the scaffolding contractor.

2

Such certificates usually specify: (a)

that the scaffold is complete and complies with the requirements of relevant standards or guidance

(b)

the maximum distributed loads which are permitted on the working lifts

(c)

the guarding of working platforms

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(d)

that the bracing and ties are complete

(e)

that inspection is required every seven days or following exposure to adverse weather conditions

(f)

that the findings of the inspection should be recorded

(g)

that the Contractor is responsible for their employees working on the scaffold

(h)

that sheeting or netting is not to be fixed to the scaffold structure unless the scaffold has been specifically designed for it

(i)

that unauthorised modifications or alterations are not to be made to the scaffold.

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A specimen handover certificate is shown in Appendix 9.

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Construction Site Safety 1.3.5 Appendix 1 Widths of access scaffold platforms Table 7 from TG20:08 (1)

Minimum number of 225 mm nominal width boards mm

Effective width of boarded platform for (2) loading calculations mm

Working platforms for men without materials or only for the passage of materials

500

3 boards

705

For men and materials provided there is 430 mm left clear for the passage of men or 600 mm if barrows are used

800

4 boards 4+1 boards 4+2 boards

1,050

For use in dressing or roughly shaping (3) stone

1,300

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1,155 1,435 1,655

6 boards 7 boards

1,350 1605

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5 boards 5+1 boards 5+2 boards

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For carrying trestles or other similar higher platforms

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Minimum clear width (4) mm

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Notes:

Where internal ladders are incorporated the minimum width may be 430 mm, i.e. two boards

2

Effective width as defined in BS EN 12811-1 includes a 30 mm allowance for toe-board

3

These scaffolds should be specially designed

4

For hop-up platforms, a minimum width of 450 mm is required

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Construction Site Safety 1.3.5 Appendix 2 Maximum and target span of scaffold boards Table 8 from TG20:08

Board specificatio n

Thickness

Transom spacing (span of board) Target span

Maximum span

Span

Tolerance

Minimum

Maximum

mm

mm

mm

mm

mm

mm

38

±2

1,200

+100

ns

50

150

38

±2

1,500

+100

ns

50

150

50

±3

ns

ns

2,600

50

200

63

±3

ns

3,250

50

250

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mm

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BS 2482-1 38-1.2 m

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Nominal Tolerance

Board overhang

(1)

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Notes:

Board properties verified by machine stress grading

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1.3.5 Appendix 3 Load classes for access and working scaffolds made from tube and fittings Table 1 from TG20:08 (Extract)

Load class

Likely use of platform

Duty

Max. bay length

Max. spacing Max. number board of boards transoms

m mm Inspection and very light duty

Inspection, painting, stone cleaning, light cleaning and access

2.7

2

Light duty

Plastering, painting, stone cleaning, glazing and pointing

2.4

3

General purpose

General building work including brickwork, window and mullion fixing, rendering and plastering

1,200

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2.1

1,200

4

1,200

5 4+1

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Masonry work, concrete block work, and very heavy cladding

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Heavy duty

4+2 5+1 5+2 1.8

900

54+1 4+2 5+1 5+2

The above table is an extract of Table 1 from UK NASC Guidance Notes TG20:08. It is reproduced only for the purpose of highlighting to readers the different load classes to which scaffolds may be erected and examples of work activities for which each class might be used.

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Construction Site Safety 1.3.5 Appendix 4

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Putlog scaffold

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Safety checklist Check from the ground:

Check from inside building or on the scaffold: 9. Spade end of putlog laid horizontally where possible, fully home (75 mm) in brickwork (bed joint)

2. Line of standards and ledgers. Standards vertical

10. Ties, particularly on lift below working platform or, in early stages, rakers on alternate standards. Special attention to 'through' ties on large flank ends without windows. Load-bearing couplers to be used

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1. Base soundness; adequate spread of load; particularly as there is only one line of standards, avoidance of pavement lights, manhole covers, etc.; no nearby excavation

3. Spacing of putlogs

11. Platform loading (not overloaded)

4. Working platform. Check line and even support of boards; overhang; lapped boards and fillets

12. Security and correct use of all fittings (couplers), particularly on transoms and bracing

5. Guard-rails and toe-boards

13. Condition of tubes and fittings

6. Security of boards, toe-boards and guard-rails

14. Damage from falling material

7. Longitudinal bracing

15. Security of stacked materials

8. Means of access

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Construction Site Safety 1.3.5 Appendix 5

Safety checklist Check from the ground:

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Independent tied scaffold

Check from the scaffold:

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1. Base soundness; adequate spread of load; 9. Ties, particularly on lift below working platform or, in early stages, avoidance of pavement lights, manhole covers, etc.; no rakers on alternate standards. Special attention to 'through' ties on nearby excavation large flank ends without windows. Load-bearing couplers to be used

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2. Line of standards and ledgers; standards vertical

10. Special loadings by protective fans, wind sails, etc.; anchorage and spread of load

3. Staggering of joints (vertical and horizontal)

11. Security of boards, toe-boards and guard-rails

4. Spacing of transoms

12. Security and correct use of all fittings (couplers), particularly on transoms and bracing

5. Working platform. Check line and even support of boards; overhang; lapped boards and fillets

13. Condition of tubes and fittings

6. Security of guard-rails and toe-boards

14. Damage by loads swinging from cranes or by falling material

7. Longitudinal, ledger and plan bracing

15. Overloading

8. Means of access

16. Security of stacked materials

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Construction Site Safety 1.3.5 Appendix 6

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Safety checklist 1. 2. 3. 4. 5. 6. 7. 8. 9.

Base Line of standards and ledgers Line and spacing of transoms Diagonal bracing (in both directions) Plan bracing Security of boards, toe-boards and guardrails. Maximum gap at wall Security and correct use of couplers and fittings Condition of tube and fittings Even spread of load on platform

10

Means of access

11. Overloading 12. Security of stacked materials

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With birdcage scaffolds, the floor of the building has to carry the full weight of the scaffold and its load. Sole plates are therefore necessary to help distribute the load as widely as possible - and they should always be set at right angles to the underlying floor beams or joists.

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Construction Site Safety 1.3.5 Appendix 7 Report of inspection on *scaffolding, *work equipment or working platform (*delete as appropriate) Inspection carried out on behalf of: ........................................................................................................... Inspection carried out by (name and position): .........................................................................................

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Details of any further action required

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Details of any action taken as a result of any matter identified

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Description of Details of any place of work, matter identified or part giving rise to the inspected health and safety of any person

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Date and time of inspection

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Address of site (or location of work equipment): .......................................................................................

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Construction Site Safety 1.3.5 Appendix 8 Short checklist Check at each inspection that your scaffold does not have these faults:

Footings

Bracing (facade 1 2 3 4 and ledger)

Ties 1

2 3 4

1 2 3 4

Some missing

Some missing

No base plates

Loose

Loose

No sole boards

Wrong fittings

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Soft and uneven

2 3 4

Boarding

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1 2 3 4 Putlogs and transoms

Not plumb

Loose,

Jointed at same height

Wrongly spaced

Wrong spacing

Wrongly supported

Incomplete boarding

Damaged

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Undermined

Insufficient supports

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2 3 4

Guard-rails and toeboards 1 2 3 4

Wrong fitting

Loose

No check couplers

Wrong height

Joint in same bays

Loose

Some missing

Damaged

Damaged

Not level

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1 2 3 4

Bad boards Trap boards

Couplings

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Ledgers

Bridles

1

2 3 4

Ladders

Weak support

Not tied

Wrong spacing

Damaged

Wrong couplings

Insufficient length

Key: 1 = good, 2 = average, 3 = poor, 4 = N/A

1 2 3 4

1 2 3 4

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Construction Site Safety 1.3.5 Appendix 9 Specimen handover certificate (This is a type of handing over certificate which could be used.) SCAFFOLDING - HANDING OVER CERTIFICATE To (Contractor): .............................................................................. Date: ................................................ Site: ................................................................................................ Time: ...............................................

.

Description of scaffold or section of scaffold handed over: .....................................................................

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Drawing No: .............................................................................................................................................. (where applicable)

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Scaffolding as described above has now been completed and complies with current standards. It is structurally sound and should only be used and loaded in accordance with our Quotation No:

Use only for:.......................................................................................................................................

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b) Loading to be: ..................................................................................... working lifts with distributed

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Load of: ......................................................................................................... .....(kN/m2 (lb/ft2) per lift)

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The detailed requirements of the Regulations with regard to guard-rails - working platforms - toeboards - bracing and ties have been complied with.

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In order to comply with the Regulations, this scaffold must be inspected before being taken into use for the first time, at regular intervals not exceeding 7 days since the last inspection, after any event likely to have jeopardised the safety of the scaffold and after any substantial addition, dismantling or other alteration. Particulars of each inspection must be recorded in a Report of Inspection. This scaffold has / has not (delete as appropriate) been designed to take tarpaulin sheets (or other windsails). Scaffold Contractor: .................................................................................................................................. Depot: ....................................................................................................................................................... Certificate received on behalf of the Contractor: ......................................................................................

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Construction Site Safety 1.3.6

Safe Working on Roofs and at Heights

1.3.6.1 Key points Gravity is the only rule that works every time! Those who work on roofs are, by the nature of their work, at risk of falling if appropriate measures are not taken.

2

Those who plan, supervise or carry out roof work must be competent to do so.

3

A risk assessment and, where considered necessary, a method statement, must be compiled for all such work.

4

Integral features of roofs such as a steep pitch, valleys, fragile cladding or roof lights can increase the risk of falling.

5

Falls through fragile roofing materials continue to be the cause of many deaths and injuries.

6

Bad weather can have a significant impact on the risk control measures that have to be taken.

7

Ideally work will be carried out from a stable working platform, fitted with guard-rails and toeboards.

8

Where such fall prevention measures cannot be used, effective fall arrest measures must be put in place, ideally 'collective' measures such as safety nets or other soft landing systems.

9

Those who work on roofs must also take into consideration the safety of anyone passing below to protect them from falling materials or tools.

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1.3.6.2 Introduction

Roof work, including work on fragile roofing materials, gives rise to a substantial number of fatal and serious accidents.

2

It needs to be emphasised, however, that there is not just the actual roof working to be considered, but the whole process - including planning the job, creating a safe access, the safe storage of equipment and materials etc.

3

There is no such thing as a 'safe height'; anyone who is off the ground is at risk of falling. The hazard exists on working platforms, scaffolds, ladders, flat and pitched roofs, open steelwork and any area in which work is being done in proximity to fragile materials, openings, holes and roof edges.

4

Most accidents could be avoided, given the provision of appropriate equipment and the adequate information, instruction, training and supervision of those who use it.

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1.3.6.3 The Management of Health and Safety at Work 1

These Regulations require that a 'suitable and sufficient' risk assessment of all work activities is carried out and that significant risks are recorded. By its very nature, work carried out on roofs will entail a significant risk of falls from height unless appropriate control measures are put in place.

2

The risk assessment must:

3

(a)

identify the hazards arising from working on roofs which will include working at height

(b)

specify the control measures that will be put in place to reduce the risk of falls to an acceptable level.

These Regulations then require that the control measures identified are put in place.

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1.3.6.4 Work at Height

Contractors to ensure that work at height is planned, supervised and carried out in a safe manner by competent persons

(b)

work at height to be carried out using appropriate work equipment, particularly that which provides collective fall protection

(c)

suitable and sufficient steps to be taken to prevent falling objects which are likely to cause injury to any person

(d)

give consideration to the weather conditions

(e)

where appropriate, the need to plan how the rescue of someone who has fallen but is suspended might be achieved

(f)

where there is a risk of a person falling or being struck by a falling object, steps to be taken to prevent unauthorised access into that area.

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The relevant requirements of these Regulations with regard to roof work are considered to be:

The key areas are planning and competence to ensure that the control measures will be put in place and followed.

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1.3.6.5 Provision and Use of Work Equipment

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1

All equipment used in connection with work carried out at heights is classified as 'work equipment' for the purposes of these Regulations. This will include not only items such as scaffold components and ladders, but also the tools used such as slate rippers, screw guns and the like.

2

These Regulations require that whoever supplies work equipment must ensure that it is suitable for the job in hand, maintained in good working order and subjected to inspection as necessary.

3

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to competent and specified workers.

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In the context of roof work, these Regulations apply to those items of work equipment that are used for mechanically lifting or lowering any load to or from a place of work at height, such as:

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1.3.6.6 Lifting Operations and Lifting Equipment

2

(a)

mobile cranes

(b)

mobile elevating work platforms

(c)

passenger lifts

(d)

inclined hoists

(e)

tele-handlers

(f)

powered hoists

(g)

gin-wheels.

Also covered by these Regulations are the accessories that are used in conjunction with lifting equipment, such as: (a)

ropes

(b)

hooks

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chains

(d)

eye-bolts

(e)

slings.

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1.3.6.7 Personal Protective Equipment Where a risk to health and safety has been identified by a risk assessment and cannot be adequately controlled by other means that are equally or more effective, the Contractor must provide suitable personal protective equipment (PPE) and ensure that it is used by employees. PPE should only be used as a last resort after other methods of controlling the risk have been considered and deemed not to be reasonably practicable.

2

In the context of roof work, the definition of PPE includes items of fall-arrest equipment such as safety harnesses and lanyards.

3

In deciding which type to issue, the Contractor must take into account the risk that the PPE is being used for, and also ensure that the PPE will fit the wearer and allow them to work comfortably.

4

The Contractor must ensure that employees have been given adequate and appropriate information, instruction and training to enable them to understand the risks being protected against, the purpose of the PPE and the manner in which it is to be used.

5

Whilst the Contractor must take reasonable steps to ensure that any personal protective equipment supplied is used, the employee in turn must ensure that they use the equipment provided in accordance with instruction and training given and know the procedures for reporting loss or defect to their Contractor.

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These Regulations place legal duties on several categories of duty-holder, each of which has the potential to reduce the risks to health and safety during and after the construction phase.

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1.3.6.8 Construction (Design and Management) CDM

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Designers

The definition of designer under CDM is extremely wide and many contractors will also be designers. A common scenario would be where the client simply asks the contractor to sort out a leaking roof and the contractor designs the solution.

3

Whoever devises the specification for the work is likely to be considered a designer. This is very important as the designer has a legal duty to consider health and safety issues in relation to not only carrying out the work, but also the maintenance, cleaning and eventual removal (demolition) of the roof.

4

In common with all aspects of design, the person carrying out the design should be sufficiently knowledgeable of the construction process to specify how the work can be carried out safely.

5

Roofers working on industrial type buildings are commonly faced with the problem of fragility. This may be because the roof itself is made of a fragile material such as asbestos cement sheets or simply because the rooflights are not load bearing. As the standard specification for rooflights is 10% by area, this represents a significant amount of fragile roof surface.

6

When designing roofs, designers should also consider such things as ongoing maintenance activities, for example how rooflights and gutters can be cleaned safely and whether the safe access for this type of work can be designed-in at the design stage.

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Clients Under these Regulations the client must provide relevant pre-construction information to other parties such as the Contractor and Engineer to enable the job to be planned so that it can be carried out safely. The client, along with other duty-holders, must take reasonable steps to ensure that all parties involved are competent to do what is required of them.

8

The main type of information that would be relevant for roof work would be the presence of asbestos, areas of damage, loading limitations of the roofing material, the existence of fallrestraint systems, the location of safe access routes where known, as built drawings where available and so on.

9

It should be noted that the client may not be aware of such factors as damaged areas of the roof or the existence (or lack) of safe access routes. The client may well assume that the job will be carried out by a method that is neither practical nor safe. They commonly expect roofing contractors to be able to access places and do tasks that they would simply not allow their employees to do.

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(b)

Selection of contractors/staff

(c)

Planning

(d)

Carrying out the work

(e)

Post-completion information (at the end).

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Where a Contractor is using its own employees to carry out roof work, it is essential that several factors are taken into consideration. Both training and operational work on roofs can be hazardous, strenuous work, often involving: work at considerable heights for long periods of time

(b)

work outdoors usually in hot, cold or wet weather and possibly high winds repetitive materials handling

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The stages of a roofing project

(d)

reaching, stretching, and maintaining balance in awkward postures whilst carrying loads on varying roof terrains.

12

This means that fitness to work is particularly important and needs to be considered by the Contractors.

13

It is vital that people working on roofs do not suffer from: (a)

any neurological condition likely to cause seizures

(b)

weakness of limbs, loss of balance including vertigo (dizziness from being at height)

(c)

any heart or lung condition likely to be aggravated by strenuous work

(d)

any disability/impairment of limb function

(e)

any other disease, disability, medication, alcohol, drugs or effects of toxic substances (lead etc.) likely to impair mental or physical activity, especially at a height

(f)

temporary ailments such as influenza or other conditions that may affect judgment

(g)

uncorrected sight problems

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a physique that would be unsuitable for the work.

It is very strongly suggested that Contractors should establish a policy on fitness for work.

Planning Planning the work should include consideration of the progression of the work with regard to: (a)

site-specific risks

(b)

weather conditions

(c)

emergencies (including rescue)

(d)

safe means of access and egress

(e)

materials handling and storage.

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working above public areas such as shopping malls or public streets

(b)

the difficulties in delivering materials and transferring them to roof level

(c)

the presence of site traffic or road traffic on a public road

(d)

awkward working environments, such as occupied houses or factories

(e)

emergency situations, such as rescuing someone who has fallen and is suspended at high level in a safety harness

(f)

vent pipes that may suddenly shower unsuspecting roof workers with anything ranging from high pressure steam to noxious chemicals

(g)

certain species of bird that will aggressively defend their territory

(h)

the presence of accumulated bird droppings.

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It goes without saying that the weather can have a significant impact upon the intention to carry out roof work and may ultimately be the reason for the start of a job being delayed, or it being suspended part-way through.

18

Heavy rain, high winds, frost or snow might make it unsafe for operatives to work at height.

19

The only note of caution is that the forecast wind speed is given for 'ground level'. The wind speed can be considerably higher at height, for example, if installing a glass atrium roof on top of a multi-storey tower block.

20

If a roofing job has started and the weather is forecast to be changeable, with perhaps extremes of conditions, it will be essential to monitor the forecast so that work can be halted before it becomes unsafe to continue.

21

The wind speed could have an impact upon whether or not it is safe to handle or store certain types of materials, such as roofing sheets, at height.

22

Work involving the handling of sheeting and cladding requires extra care in windy conditions, when a sheet may act like a 'sail' causing the person holding it to lose their balance.

23

Working in gusty wind conditions can be particularly dangerous. Industry Guidance suggests that the following activities should cease when the average wind speeds shown are

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exceeded: (a)

27.36 km/h - handling lightweight materials and any materials over 5 metres long or rolls of felt

(b)

37.01 km/h- general roofing activities.

Emergencies (including rescue) Several types of emergency, such as a fire, could occur either at ground level or at height, which requires that an emergency evacuation of the whole site or the roof be carried out. For this reason the planning stage must ensure that safe access and egress will be available at all times. Depending upon the nature of the job it may be necessary to have more than one access/egress route.

25

If the site layout necessitates that the asphalt/bitumen boiler has to be sited on the roof, the question will have to be asked as to whether it is still possible to get off the roof safely if a fire occurs.

26

It may be necessary to deal with medical emergencies where someone becomes incapacitated at height through illness or injury and is unable to make their way back to ground level. In such circumstances, the local fire and rescue service may have to be involved to effect a safe rescue. It is not unknown for someone who has been incapacitated at height to be recovered to ground level in an empty skip suspended from a tower crane whilst being attended to by a paramedic.

27

Carrying out roof work will often involve the use of fall-arrest equipment such as safety nets or safety harness and lanyard. Anyone who falls will have to be rescued promptly, particularly if they are suspended in a harness.

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Safe means of access and egress

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The means of gaining access to height and safely working there will depend upon many factors such as the nature of the roof structure, whether there is room to erect a scaffold or bring in a MEWP and even the length of time that the job is expected to take.

29

Some common means of gaining access to height or actually working at height are:

(b)

mobile access equipment fixed or mobile towers

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(d)

stair towers

(e)

independent scaffolds.

Materials handling and storage 30

Part of the planning process will involve taking decisions on: (a)

what roofing materials are required and quite possibly where they can be stored safely at ground level

(b)

a safe means of transferring roofing materials to height and in what quantities

(c)

avoiding the overloading of any part of the roof by stacking materials prior to installation

(d)

the safe storage of sheet materials if they are to be stored for any length of time, particularly during windy weather

(e)

the safe distribution of materials around the roof during installation

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the safe transfer of waste materials back to ground level.

1.3.6.9 Carrying out the work 1

To a large extent, the risks of doing the job, the risk-control measures that will be necessary and therefore the way in which the work is carried out will depend upon the type of roof.

Flat roofs On flat roofs, falls most frequently occur from: the edge of a completed roof

(b)

from the leading edge where work is being carried out

(c)

through openings or gaps

(d)

through fragile material.

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A roof with a pitch of less than 10° is classed as a flat roof. Safe access to the roof, and to any working place on that roof, must be provided and maintained.

4

If there is no parapet or similar barrier to stop anyone from falling, edge protection must be provided. This may take the form of standard guard-rails and toe-boards or, providing nobody will approach the edge, a barrier set back from the edge.

5

Where works are to be undertaken which could result in materials or equipment falling onto people passing below, protective measures must be taken. This can range from adding netting, close boarding or debris fans to scaffolds or establishing exclusion zones. These could range from permanently fenced off areas to simply having someone stopping people from accessing the 'drop zone' at critical times.

6

There will be times when operatives need to work at exposed leading edges, but it is not reasonably practical to install guard-rails or other fall prevention measures. In these circumstances, it will be necessary to install or provide fall-arrest systems. The most suitable type of fall-arrest system will be indicated by a risk assessment. Where safety nets, air bags or other soft landing systems are used, they will provide collective safety for anyone working above them who falls.

7

Alternatively, it may be decided that operatives should wear a safety harness with a lanyard clipped to a strong anchor point or a horizontal 'running line'. The effectiveness of this system depends upon the training of operatives in the use of the equipment and the operatives actually 'clipping on'.

8

When a safety harness and lanyard is used, consideration must be given to the position of the anchor point, which ideally will be above the head-height of the user. Where the anchor point is at ankle level, for example, there will be more slack in the lanyard and the fall will be further before it is arrested. It has been calculated that in some circumstances a person could fall up to 5.5 metres before the fall is arrested. In this situation, where the person is working less than 5.5 metres above ground level, impact with the ground would occur before the fall could be arrested.

9

Sometimes, guard-rails have to be moved or removed to enable work to be undertaken. If this is to happen:

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(a)

an equally effective safe system of work must be in place and maintained, which will prevent falls of persons or materials

(b)

the guard-rails must be replaced or re-erected as soon as practical.

Some flat roofing systems will involve the use of various chemicals or hot-works and the

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liberation of fumes or solvents may occur, Consideration to COSHH should be given as well as the significant possibility of fire, explosion or burns from hot bitumen. Traditional pitched roofs On traditional pitched roofs, most falls occur: from the eaves, by slipping down then falling from the roof

(b)

into the structure during truss erection

(c)

from gable ends during salvage prior to demolition

(d)

through fragile roofing materials, particularly fragile roof lights

(e)

when passing along valley gutters with fragile materials alongside the access way.

A sloping roof is defined as any roof having a pitch of more than 10°.

13

Work on pitched roofs should only be carried out:

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by persons who are physically capable and adequately trained

(b)

using roof ladders or a temporary work platform equipped with guard-rails and toe-boards as necessary and securely fixed to prevent it slipping

(c)

providing either a suitable catch barrier or a working platform with guard-rails is erected at the eaves of the building.

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(a)

This requirement applies to any work on a sloping roof, including access to and egress from other workplaces.

15

If the steepness of the roof is such that it prevents a secure foothold, a working platform must be erected. Roofs pitched at over 50° should be regarded as 'steep', as should shallower slopes if they are slippery.

When working on a curved roof such as a glass barrel-vault structure, providing:

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(a)

the roofing material is load-bearing, and

(b)

there is a secure anchorage at the apex of the roof

17

it is usually necessary to employ rope access techniques such as work-positioning or abseiling. It is essential that any such system incorporates a self-locking device to prevent the uncontrolled descent of anyone who loses their footing.

18

Additionally, proprietary 'rubber steps' are available that follow the exact contour of a curved roof, with sections being joined to extend the overall length. These steps must be regarded as a foothold only as they are not equipped with a hand-rail. They must therefore only be used in conjunction with another form of fall protection, such as a fall-arrest block.

19

Where there is a risk of falling through a curved roof, consideration should be given to installing safety nets inside the roof.

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Profiled roofs These range from a single asbestos cement sheet on an outside toilet to the latest continuously extruded system formed in situ to cover large portal frame buildings. The systems will differ in complexity and range from single skin through to composite factoryproduced units.

21

New build profiled installation will normally be carried out over a system of safety nets which provide fall protection.

22

There are other means of providing safe access for roofs. Traditionally for new build systems this was called leading edge protection and used working platforms in the form of lightweight staging. This system advances along the roof in line with, or previously, in advance of the installation of the roof sheets.

23

If a double skin roof system is being installed, the inner sheet or liner tray must be fixed by at least four fixings before it can be stood on.

24

Metal profile roof sheets are therefore still fragile until they have been fixed. Furthermore, many rooflight assemblies, which are often installed as part of a profiled roof system, are also fragile. This will necessitate proprietary work platforms such as 'Youngman' boards are used to enable safe access.

25

Any working platform must be a minimum of 600 mm wide with hand-rails on one or both sides, depending on whether a fall can occur. This does create practical difficulties in terms of moving them due to their bulk and weight. In a new build situation it can be possible to run the boards on a wheeled system referred to as purlin trolleys.

26

The only other option therefore is to physically step on the roof and lift the staging’s. A 5 metre platform with guardrails weighs about 50 kg. Given that the platforms should be joined together, then physically moving them does offer challenges. Also, how the stagings are put in place to start with can often be an issue. It is not a safe system of work to simply carry the staging up the steelwork. They may need to be craned up and positioned at the same time as the packs of sheets.

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Fragile roofs

Fragile roofing materials include asbestos, glass, plastic, cement sheets and similar brittle surfaces.

28

Non-fragile roof lights should be fixed with a red coloured fixing to allow people to differentiate between them.

29

As far as the strength of the materials is concerned, the appearance of fragile roofs is often misleading. Surface coatings, dirt or moss may conceal the fragile nature of the material, thereby giving a false appearance of soundness to glass, plastic, asbestos, etc. Even if the roof is clad in a load-bearing material, roof lights are often fragile.

30

Asbestos and various plastic materials are particularly brittle and will shatter without warning.

31

Many deaths and serious injuries have occurred as a result of roof workers falling through fragile surfaces. Most of the falls could have been easily prevented had a risk assessment been carried out and a safe system of work developed. Even if the falls did occur, the deaths and injuries could have been prevented by the use of safety nets or another soft landing system.

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Ideally, another way of carrying out the job would be found that does not require anyone to work on or near to fragile roofing materials. However, in many cases, this may not be practical.

33

If it is necessary to pass across a fragile roof, a roof-board complete with a guard-rail should be used to spread the weight and provide a good handhold. Depending upon the job, it may be necessary to use more than one roof-board: one to support the person whilst the other is moved to a new position.

34

The practice of trying to 'walk the line of the bolts' or 'the line of the purlins' is very dangerous and must not be attempted. Where walkways with a hand-rail are not an integral part of the roof structure, a safe system of work must be devised.

35

Walkways near fragile surfaces (in valleys, parapets, gutters or channels) must be provided with suitable guard-rails or, if not, the fragile surface should be over-laid with a load-bearing material to prevent the possibility of anyone falling through.

36

Warning signs must be fixed at all approaches to roofs constructed with fragile materials……….

37

Where such signs are not fixed in place, it is essential that the presence of fragile material is identified in advance and those doing the job are made aware of it by other means.

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1.3.6.10 Access arrangements Ladders 1

All ladders used for access to elevated work positions, including working platforms or roofs, must comply with the following requirements. (a)

A risk assessment must be carried out before a ladder is used either for access or as a place of work.

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The risk assessment must show that it is not reasonably practicable to use an alternative, safer means of access.

(c)

Ladders should only be used as a place of work for light work of short duration where the risk assessment shows the risk of falling to be low.

(d)

30 minutes is a guide to short duration. This is not 30 minutes in one place and then 30 minutes having moved the ladder 1 m along the wall.

(e)

Such work could be an inspection or light maintenance work involving the use of one hand only. Removing cast iron gutters would obviously not fall under this definition.

(f)

All ladders should be to the correct industrial specification and not domestic quality (Class 3).

(g)

The ladder must be securely fixed near to the top of the stiles or, if this is not physically possible, footed near to the bottom to prevent undue swaying or displacement.

(h)

9 metres is the maximum height suggested for footing a ladder.

(i)

The ladder must be set on a firm level footing (for example, not on loose bricks).

(j)

Both stiles must be properly supported.

(k)

The ladder must extend at least 1 metre (5 rungs) above the landing place, unless another suitable handhold is provided.

(l)

There must be sufficient clear space at each rung to allow a safe foothold.

(m)

The vertical run of the ladder should not exceed 9 metres, unless an intermediate landing has been provided, where practical.

(n)

The ladder must be set at the correct angle, approximately 75° - one measure out for every four measures up.

(o)

The ladder must not be lashed to any gutter or soil stack or similar item, which may be fragile or insecure.

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(b)

Where two-handed operations are necessary, a risk assessment must be carried out to determine a safer method of working, e.g. a static or mobile tower erected by a competent person, scissor lift or cherry picker.

3

Independent or putlog scaffolds, which provide safe access to and around the roof edge, storage space and possibly a loading bay, are another solution.

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Pitched Roof ladders 4

Ideally, where it is necessary to use a pitched roof ladder, access to the lower end of it will be from a working platform at the eaves.

5

Pitched roof ladders must be: (a)

only used by persons who are competent to use them

(b)

positioned to enable easy and safe transfer between:

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Section 11: Health and Safety Part 1.03: Working at Heights (Regulatory Document) (i)

any other ladder used to get to the eaves and the roof ladder

(ii)

the roof ladder and the place of work

Page 104

designed for the purpose

(d)

of good construction, strong enough to enable the planned work to be carried out and regularly inspected

(e)

adequately supported to take the user's weight without damaging the roof

(f)

securely fixed to the sloping part of the roof by means of a ridge hook placed over the ridge. Ridge hooks must not bear down on ridge tiles or capping tiles.

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1.3.6.11 Landing places

All landing places must be of adequate dimensions.

2

If a person is liable to fall from a height that would result in injury, landing places must be provided with: a guard-rail at a height of not less than 950 mm

(b)

an intermediate guard-rail

(c)

a toe-board

a gap not exceeding 470 mm between the toe-board and guard-rail, or between any two guard-rails

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(e)

an intermediate guard-rail if standard, light-gauge brick guards are used.

1.3.6.12 Openings, corners, breaks, edges and joisting in a floor 1

2

Where reasonably practicable, edge protection, in the form of guard-rails and toe-boards, must be provided if people have to work close to what would otherwise be an unprotected edge, where: (a)

a person who fell would be injured as a result of the fall

(b)

material, tools or equipment could fall

(c)

the work is over water, other liquid or dangerous materials.

All holes in floors, etc. must be similarly guarded or securely covered. The covering must be of a suitable material, securely fixed and clearly marked 'Hole below'.

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Open joists through which a person could fall must be boarded over to provide safe access to a working place.

4

Guard-rails, toe-boards and covers may be removed to allow access for people and materials, but must be replaced as soon as possible. This does not apply to demolition work unless it is left unattended.

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1.3.6.13 Mobile access platforms

Mobile access platforms are often used as an alternative to ladders, scaffolds and cradles.

2

The range of equipment includes mobile elevating work platforms (MEWPs), forklift trucks equipped with work platforms, and mast climbing work platforms (MCWPs). Each of these types of equipment can be suitable for carrying out particular types of roof work. For example, using a telescopic boom MEWP (cherry picker) might be a suitable and safe way of accessing a job that would otherwise require someone having to cross a fragile roof. This is particularly important for inspection work. Truck mounted cherry pickers now have sufficient reach to enable inspection of nearly all buildings to be made without having to directly access the roof.

3

Where people are working from these platforms, calculations of the real loads must be made. Typically an allowance for each person of 100 kg covers operative and tools. If materials are to be carried as well, then the weight must be estimated to ensure that the platform is not overloaded.

4

Finally, thought must be given to emergencies, and how aerial rescue could be carried out if necessary.

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Mobile elevating work platform (MEWP) 5

Easily moved from place to place, MEWPs are particularly suitable for short duration tasks requiring a work platform.

6

Work platforms may be towable units, lorry or trailer-mounted, or self-propelled.

7

Also, it must not be overlooked that MEWPs are classified as lifting equipment and as the task is so called 'man riding' the inspections must be at six-monthly intervals.

Working platforms on forklift trucks 8

Forklift trucks equipped with work platforms may be used for access to limited heights, usually for maintenance work. The platform or 'cage' must be designed for the purpose, fitted to the forklift truck in a manner that prevents it from becoming accidentally detached.

9

If the use of a forklift truck for this purpose becomes part of an established pattern of work, consideration should be given to

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introducing a purpose-built mobile platform. 10

The use of so-called 'non' integrated work platforms on forklift trucks is not seen as a particularly safe practice. They are very concerned on the use of rough terrain telescopic forklifts.

11

These are very commonly used on demolition sites when stripping roofs for salvage or removing asbestos cement sheets. To be able to use them, as a minimum the platform and forklift must have the following: tested under Lifting Operations Lifting Equipment (LOLER) every six months

(b)

the basket must have a plate displaying information about loading etc.

(c)

harness points identified

(d)

dipper ram controls isolated

(e)

signage on the forklift confirming that it is suitable for the use.

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Crane and 'man riding basket'

One way to overcome the access difficulties associated with fragility is simply not to land on the roof at all. It is possible to use man riding baskets from a mobile crane. The crane itself would normally be expected to be fitted with a 'dead man's' handle so that the driver cannot inadvertently lower the basket to the ground, and must be on 'power lower' as opposed to 'free fall'. This may rule out some older crawler cranes.

13

All physical parts of the system will require thorough examination under LOLER every six months. It would be expected for the operatives to be harnessed in and typically the harnesses are attached to the hook block of the crane, which offers a second level of safety so-called redundancy.

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(a) (b)

they should be erected only by skilled and competent persons they should be used only by trained operatives they should be inspected daily before use, by the user

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With this equipment, the platform or cradle rises up one or more static masts in a similar way to a hoist, providing a temporary work platform at height, usually on the side of a building. Some of the procedures to be observed in the erection and use include:

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Mast climbing work platforms (MCWPs)

(d)

they should be regularly inspected by a competent person and records maintained of the inspection

(e)

they should be thoroughly examined every six months

(f)

they should be clearly marked with the safe working load and permitted numbers of persons allowed on the platform at each configuration

(g)

they should not be used as a substitute for using stairs or a passenger lift for travelling to higher levels.

Access to chimneys 15

Various purpose-designed lightweight stagings are available for work on or around chimneys. Alternatively, tube and fitting scaffolding should be erected or a MEWP used. In no circumstances should work be carried out on a chimney without the use of a properly constructed and stable working platform.

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1.3.6.14 Other considerations Stacking materials on roofs

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Care must be taken at all times when stacking material on or at roof level. Attention should be given to the following: the size of the load involved

(b)

the types of material involved

(c)

the methods of raising the load, whether manually or mechanically

(d)

the means of communication (signals) and the competence of the slinger or signaller

(e)

the position authorised for stacking materials

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(a)

the distribution of the loads (loading plan)

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(g)

the maximum load or stack size

(h)

the loading limitations of the roof

(i)

adequate support or packing to the truss

(j)

protecting the existing roof surface and any weather-proofing

(k)

preventing the displacement of loads which should be: (i)

secured against the wind, especially split bundles and sheets

(ii)

secured against sliding down sloping roofs (sheet stop).

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Permission to load roofs

the owners or occupiers, or

(b)

the architect or a consultant engineer, or

(c)

the Contractor.

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1.3.6.15 Danger areas

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Contractors are to ensure:

the safety of those working at height (from falls)

(b)

the safety of others who may be working or passing below (from falling objects), by the creation of 'danger areas', either around the high-level workplace and/or below it.

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Permission to place a load on a roof structure must be obtained from:

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This is achieved by preventing unauthorised access into any danger area, so far as is reasonably practicable, by the use of equipment such as barriers and appropriate signs.

3

Contractors may find in particular situations that it is not practical to create a permanent 'exclusion zone' beneath the work being carried out above. In these circumstances a solution would be to deploy 'safety marshals' at the lower level to enforce exclusion from the danger area as and when it is necessary.

4

In such circumstances it is essential that an effective means of communication be established between those working at height and the workers controlling the danger area.

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Roof trusses 5

The placement and installation of roof trusses and their associated bracing has the potential to be a very hazardous activity and a safe system of access and protection must be planned and implemented. The risk assessment should have considered these and all other aspects of the work.

6

A safe working platform around the perimeter of the roof should be erected and, where access is required within the trusses, safe access provided. This can be achieved by boarding out the bottom chord of the trusses, so long as they are stable and capable of taking the imposed loads.

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Safety nets can be used, provided a safe clearance distance can be achieved below the net. However, it is difficult to arrange a strong fixing for a net on a new build house. The most common fall protection systems in use in building are 'bean bags', air bags or crash decks.

8

There are a number of proprietary soft-landing systems available in which the fall-arrest bags simply interlock to provide a cushioned landing if someone falls.

9

Crash decks could be as simple as a tower scaffold under the place of work.

10

Roof trusses can be boarded out if access is needed or timber sheets

11

Safe access within the trusses

12

They do require moving periodically so that they remain under the place of work and of course they are nowhere as comfortable to land on as a soft-landing system.

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Working over water

Where there is a risk of persons falling from a structure into water, a secure form of fencing, barrier or fall arrest equipment (preferably safety nets) must be provided. This can be briefly removed for access and the movement of materials, but must be replaced as soon as possible.

14

Other points to be considered include:

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ensuring that a risk assessment has been carried out

(b)

if possible, providing a suitable working platform

(c)

safety nets, if used, must be properly erected and periodically inspected

(d)

warning notices must be placed near to all edges

(e)

adequate lighting must be provided as necessary

(f)

special care must be taken in inclement weather such as fog, frost, snow and rain

(g)

special attention must be paid to the possibility of tides or storm surges changing water levels or flow rates

(h)

life jackets must be provided, and worn by all operatives involved in working over water

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preferably only operatives who can swim should be used

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(a)

(j)

suitable rescue equipment must be provided, maintained and operated by trained and competent staff

(k)

frequent checks must be carried out to ensure that the correct number of personnel can be accounted for

(l)

all persons must work in pairs, or in larger groups, as necessary (no lone working)

(m)

all persons must be trained in the procedures for raising alarms and in rescue drills.

The presence of birds 15

The accumulated droppings of birds, if disturbed into airborne dust and then inhaled, can cause severe respiratory problems. It is anticipated that this will mainly be a problem during refurbishment and repair work or demolition.

16

If during the early visits to site it is evident that pigeons have been, or are present, measures must be taken to clean up the droppings before work starts, using a safe system of work, and to discourage the return of the birds.

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Construction Site Safety 1.3.7

Fall-arrest and Suspension Equipment

1.3.7.1 Key points 1

In situations where the prevention of falls from height cannot be guaranteed, it is essential that measures are put in place to ensure that any fall that does occur is arrested, without injury to the person who has suffered the fall.

2

In many cases safety nets are the preferred method of arresting falls because: they provide what is termed 'collective' fall protection

(b)

if rigged immediately below the work area, they limit the height of the fall to the minimum and recovery of the 'faller' should not be a problem

(c)

they are a 'soft landing system' that should cause no injury to the person who has fallen.

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(a)

Safety nets can suffer wear and damage and must be inspected periodically.

4

Other forms of soft-landing systems, such as air-bags or bean-bags, also offer collective protection and are more appropriate for some types of work.

5

If fall-arrest is to be achieved using a safety harness and lanyard, the wearer must be trained in fitting and adjusting the harness and selecting the appropriate lanyard and a secure anchorage.

6

Harness and lanyard offer personal fall-arrest protection only.

7

Some items may need a regime of inspections and thorough examinations.

8

Personal suspension equipment, such as rope-access equipment and a boatswain's chair must only be used by people who have been trained and are competent.

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1.3.7.2 Introduction

Where a risk assessment has identified that the risk of falls from height cannot be eliminated by the installation of barriers, guard-rails or other similar measures, the use of fall-arrest equipment may then be the best option.

2

Safety nets or the use of other soft landing systems are preferred to the use of safety harnesses and lines, as they protect the whole area and all persons working above them. They do not rely on individual workers wearing a safety harness and lanyard connected to a secure anchorage point.

3

In situations where people and traffic pass below others working at height, a safety net used in conjunction with a fine mesh debris net will protect those below from falling tools and materials, as well as providing fall-arrest for the people working at height.

4

Where safety nets cannot be rigged for any reason, and it is not practical to use another form of soft-landing system, it may be necessary to resort to the use of a safety harness and lanyard, providing:

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(a)

operatives have been trained in the use and care of the equipment and wear it correctly

(b)

the work environment enables falls to be arrested without injury to the person who has fallen

(c)

a secure anchor point is available

(d)

the person working at height actually 'clips-on'.

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Whichever system is used for minimising injury from falling, whether it be safety nets, another soft-landing system or harness and lanyard, the system must be: (a)

designed to provide a safe system of work

(b)

installed by competent persons

(c)

maintained, inspected and supervised to ensure it is used correctly.

1.3.7.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify the hazards arising out of that work and the persons or groups who might be affected.

2

When hazards are identified, it is then the Contractor's duty to either remove the hazard or to put control measures in place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

4

Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other persons who may be affected.

5

These Regulations require that, additionally, the Contractor provides employees with adequate information, instruction, training and supervision to be able to carry out any work safely and without risks to their health.

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1.3.7.4 Provision and Use of Work Equipment Safety nets, equipment used in other soft landing systems, and harnesses/lanyards are all classified as work equipment and must therefore comply with these Regulations.

2

These Regulations require that Contractors only provide work equipment that is suitable for the job and ensure that it is maintained and kept in good working order.

3

Contractors must ensure that where the safety of work equipment depends upon the way it is installed, it is inspected as necessary.

4

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to competent and specified workers.

5

Employees must be provided with information, instruction and training in the use of work equipment, where necessary for their health and safety.

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1.3.7.5 Personal Protective Equipment 1

These Regulations require that where a risk has been identified by a risk assessment, and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment (PPE) is used by employees.

2

In essence, PPE may only be used as a last resort after all other means of eliminating or controlling the risk have been considered.

3

In deciding which type to issue, the Contractor must take into account the hazard that the

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PPE is being used to protect against, and that the PPE must fit the wearer and allow them to work comfortably. 4

The idea of comfort is important and needs to take account of other items of equipment and other PPE that will also be worn.

5

Whilst the Contractor must take 'reasonable steps' to ensure that any PPE supplied is worn, employees in turn must ensure that they wear the equipment provided and know the procedures for reporting any loss or defect to their Contractor.

1.3.7.6 Work at Height The fact that some form of fall-arrest equipment is to be used is indicative that work at height is to be carried out. These Regulations place duties on Contractors, the self-employed and employees to ensure that such work is carried out safely.

2

The key provisions of these Regulations are that Contractors should:

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where it is reasonably practicable, avoid the need to carry out work at height

(b)

where such work cannot be avoided, make sure to select the most appropriate work equipment for the work and to prevent falls

(c)

reduce the distance, and potential consequences, of any fall

(d)

ensure that the work is risk assessment based and that it is carried out safely by competent persons

(e)

ensure that equipment used for working at height is appropriately selected and inspected as specified

(f)

ensure that measures are taken to prevent anyone being injured by falling objects.

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1.3.7.7 Lifting Operations and Lifting Equipment The definition of 'load' within these Regulations includes a person. This means that if it is foreseeable that the equipment may be used for lifting a person, then these Regulations will apply. So inertia reels, harnesses, strops and other equipment are likely to be covered.

2

The main requirements of these Regulations are that: lifting equipment and accessories must be of adequate strength and the lifting equipment stable, for each lift undertaken

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(b)

lifting equipment used for lifting persons is constructed and used so as to protect the safety of the person(s) being carried

(c)

the load must be under full and proper control at all times

(d)

lifting equipment and accessories must be clearly marked with their safe working load and other markings if designed for lifting persons

(e)

every lift must be properly planned by a competent person, properly supervised and carried out safely

(f)

generally lifting equipment must be subjected to a programme of inspections and thorough examination as is appropriate.

1.3.7.8 Inspection and thorough examination 1

The frequency and type of inspections and thorough examinations should be determined by a competent person. This is quite simply because the risk of damage will depend on the work activity and environment. For example, a harness worn by a demolition burner will probably require more frequent checks than that of a utility engineer inspecting street lighting

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columns.

1.3.7.9 Safety nets Nets are an area where complying with best practice means testing, inspection record keeping and storage facilities are required to ensure that the net itself is fit for use. It is important that the end users appreciate that a safe net is not simply about whether the net erectors have a training records card, but also look deeper to check that the net itself has been checked and inspected.

2

There are a number of British Standards which relate to safety nets. They should be manufactured to the requirements of BS EN 1263-1 and erected in accordance with BS EN 1263-2. This latter standard gives information on the installation and use of safety nets.

3

A further standard, BS 8411, contains construction-specific information and more importantly a list of duties for the parties usually involved in construction projects.

4

This standard specifies that anyone who is planning the installation of a safety net system should take into account the:

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experience and competence of the net erectors

(b)

sequence and type of work being carried out during installation and removal

(c)

sequence of construction work to be carried out whilst the nets are in position

(d)

provision of effective anchorages

(e)

means of access for erecting and removal

(f)

access for inspection, debris removal and temporary repair

(g)

clearance distances below the net

(h)

protection of anyone below

(i)

recovery of anyone who has fallen into the net.

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(a)

Modern safety nets are efficient at saving lives and preventing injury. They are an energyabsorbing system designed to minimise the consequences to the person who has fallen. Safety nets should be erected as close as possible to the working level to minimise the height of any fall that may occur.

6

There are two types of net manufacture.

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(a)

Knotless. These provide energy absorption by permanent plastic deformation (stretching) of the net material.

(b)

Knotted. This, generally heavier and older type of net, provides energy absorption by tightening at the knots and permanently deforming.

7

Safety nets are manufactured in square or diamond mesh, with two mesh sizes: 60 mm and 100 mm. The 100 mm is the normal mesh size used in the UK.

8

All safety nets should carry an identification label. This includes the date of manufacture; the net type, class and size; and reference to the British Standard BS EN 1263-1. It should also carry a unique serial number for record purposes and traceability.

Fall heights 9

The positioning of a safety net system is critical to minimise the height of falls that may occur. Although safety nets are designed for a maximum fall height of 6 m, the maximum fall, if installed directly under the workplace, should be under 1 m.

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10

When nets are installed, the maximum amount of sag in the net should be no more than 10% of the bay width.

11

When a load or person falls into a correctly erected net, the net material will deform as it absorbs the energy from the fall.

12

It is therefore critical to provide adequate clearance below the net, to allow the deformation to occur without the load or person striking the ground or some other object.

13

If a person were to fall 2 m into a net between 5 m and 9 m wide, the total deformation, including the erection sag, may be between 2.6 m and 3.5 m, depending on the width of net. It is essential to check the manufacturer's specification to ensure that there is adequate clearance below the planned net position.

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Competence The way in which safety net systems are installed is critical. Not only must those installing the net system be trained and competent, so must the people who carry out the routine inspection of safety nets.

15

The issue of competence is important, as a handover certificate should be issued. Always receive a handover certificate from the riggers for each section of netting as it is completed.

16

There are industry agreed standards and qualifications for training in the rigging and inspection of safety nets. The training of inspectors is aimed at site management staff as well as professionals within the industry.

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Safety nets are provided with short lengths of test cord attached to the net. These cords carry the net's unique serial number and are so fitted that they receive the same environmental exposure as the net material. At yearly intervals, a test cord should be detached from the net and sent back to the manufacturer so that it may undergo a tensile failure test, to monitor the degradation of the net material through exposure to sunlight. Typically a net is made with three so called 'test diamonds'. The presence or absence of these gives the site manager a clear indication as to whether the basic testing regime is in place.

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Periodic testing

18

Where safety net systems are erected, they should be inspected on a weekly basis by a competent person to ensure that they are still in a safe condition, fixed correctly and will provide the fall-arrest capability if required.

19

Inspections should be carried out more frequently if circumstances indicate that the integrity of the net system is in doubt.

20

A net should also be inspected after a person or substantial load has fallen into it, to determine whether it should remain in service or be replaced. In some cases, it may be necessary to seek specialist advice.

21

Findings of all inspections need to be recorded.

Care of nets 22

Care should be taken to reduce to a minimum unnecessary wear and mechanical damage likely to weaken the net. Materials must not be stacked on it and the deliberate jumping into, or dropping of objects on to nets must be prohibited, as permanent deformation may occur.

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The following sources of damage or wear should be avoided as far as possible: (a)

dragging the net over rough surfaces

(b)

contact between the net and sharp edges

(c)

an accumulation of debris in the net

(d)

any sparks from hot work, welding, grinding, burning operations, hot gases from blowlamps, or hot ash from chimneys or furnaces

(e)

chemical attack

(f)

any form of radiation.

Special care should be exercised and precautions taken to prevent the net and any supporting framework from being struck by loads on moving vehicles or by the vehicles themselves.

25

Regular inspection is necessary to ensure that the nets remain serviceable. The net manufacturer should be consulted when there is any doubt about the suitability of nets for use in hazardous conditions, after any known contamination or when deformation has occurred.

26

When erecting nets in the vicinity of electricity lines or overhead power cables, the appropriate authority should be consulted before work starts.

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Maintenance

Nets must always be inspected after use and before storing to identify any damaged areas. Glass, metal, grit and other debris should be removed to prevent abrasion.

28

If contaminated by acids or alkalis, nets should be thoroughly washed, preferably by hosing, and allowed to dry naturally away from heat.

29

If areas of damage are found or chemical damage is suspected, contact the manufacturer to obtain a list of competent people able to repair or clean the nets.

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Storage

Nets should be stored away from heat, chemicals and solar radiation.

31

Nets should be stored in dry conditions.

32

Nets should be stored to minimise vermin attack.

33

Wet nets should be dried naturally.

34

Storage cupboards should be well ventilated.

35

Nets should be turned periodically to allow air circulation.

36

If stacked, nets should be packed up clear of the ground.

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Rescue from a net system 37

Where the net is erected as close as possible below the work area, many of the situations where persons enter a net will be minor 'step-ins', with the person able to climb out unaided.

38

On other occasions, a person may fall a considerable height into a net. They may fall onto materials lying in the net, or strike their head or body on, for example, structural steelwork

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during the fall. 39

When such accidents occur, extreme care must be taken during the rescue of the person lying injured in the net. Due to the 'stretching' nature of the net, it is possible that any rescuer entering it could inadvertently and unavoidably cause further injury to the victim.

40

It is therefore essential that Contractors using safety net systems have, as part of their risk assessment process, emergency procedures written for: (a)

treating first aid needs whilst the injured person is in the net

(b)

emergency recovery from a rigged net system.

1.3.7.10 Other soft landing systems Alternative soft landing systems are an effective alternative to safety nets in some circumstances.

2

Designed to be used in buildings with a storey height of up to 2.5 m, one type of system comprises large polypropylene bags (typically 2.5 m long x 0.55 m wide x 0.55 m deep) that are packed with polystyrene chippings or another energy-absorbing material. The depth of the bags both cushions a fall and reduces the distance of that fall (by the depth of the bag).

3

The bags are linked together with plastic snap-clips to completely fill the area over which protection is required. They can also be used on the first or subsequent floors while trusses are being installed or in the roof space when fixing bracings.

4

An alternative system that may be considered in appropriate circumstances is the use of airfilled bags. Similar to the above, bags of varying sizes may be clipped together to completely fill the area over which fall-arrest protection is required. Air bags require an air compressor running all the time that fall-arrest is required, to maintain the pressure in the air bag system. These devices work on the principle of a controlled rate of constant inflation and leakage so that the air bags will absorb the energy of someone falling on to them without bouncing.

5

Whilst soft landing systems do not prevent falls, they are very effective in eliminating injuries in falls of less than 2 m.

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1.3.7.11 Safety belts, harnesses and lanyards If fall prevention measures (for example, working platforms, barriers, guard-rails) or collective fall-arrest measures (safety nets or other soft landing systems) are not practical, an alternative safe system of work must be employed. This safe system may require the use of safety harnesses and lanyards, but it should be a last resort. Whereas safety nets and other soft landing systems are 'collective measures', i.e. they automatically provide protection for everyone working above them, safety harness systems only protect the user, and only then if the equipment is used correctly.

2

Care must be taken when planning to use a safety harness, lanyard and energy-absorbing system since, depending on where the lanyard is anchored, a falling person may fall around 4 m before the fall is arrested.

3

One of the limitations of using such fall-arrest equipment is that it only protects a person if they adjust and wear the harness properly and connect the lanyard to an appropriate and secure point. The use of any such system requires a high degree of training, competence and supervision.

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Training 4

Training should only be carried out by competent accredited third party trainers, following

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industry guidelines. Training should refer to the manufacturer's instructions and should emphasise the importance of following those instructions. It should cover the selection, fitting, adjustment, maintenance and use of the safety belt or harness, and explain the choice and use of suitable anchorage points. Employees should not be permitted to use the equipment before adequate instruction has been received, and they have been judged to be competent in its use.

6

Safety belts and harnesses are wrongly regarded by some workers as an encumbrance and a restriction on their freedom of movement. The fact that a safety belt or harness can prevent serious injury or even save a life is often ignored.

7

The problems arising from such attitudes can and must be solved by applying the principles of good health and safety management. These include educating employees in the need for the equipment, training them in its use, ensuring it is provided and, through adequate supervision, ensuring it is always used.

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Types of belt or harness

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While the British Standard which defined the various types of belt and harness has been replaced by a European Standard, the common construction industry terminology for these pieces of equipment is as shown on the next page. A - Pole belt

(b)

B - Chest harness

(c)

C - General purpose safety harness

(d)

D - Safety rescue harness.

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General purpose safety harness

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Selection of equipment

The correct selection of a safety harness or safety belt is important. If a person falls more than 600 mm when using a safety belt, serious injury can be sustained due to a heavy load being exerted on the spine and internal organs. Safety belts should only be used for pole access or other similar specialist access needs.

10

If any doubt exists concerning the suitability of a piece of equipment for a particular task or type of work, further information and advice should be sought from the manufacturer.

11

Whatever type is chosen, it should give a high degree of safety allied to mobility and wearer comfort.

12

The main characteristics of the types of appliance, together with an indication of their uses, are given below.

13

A - Pole belt. A simple waist belt for use by pole linesmen and for other similar tasks. They are not intended for situations where a drop may exceed 600 mm.

14

B - Chest harness. A safety belt with shoulder straps, for use where a lanyard and anchorage point limit the drop to a maximum of 600 mm. It must be worn quite tightly to prevent any slippage after a fall.

15

Both A and B above are for very specific and for restricted use only.

16

C - General purpose safety harness. A full harness with thigh and shoulder straps. In the event of a fall, a person is suspended in a reasonably upright position from the attachment

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point. If the harness is of the right size and properly adjusted, the wearer cannot fall out. 17

D - Safety rescue harness. Designed to be worn by anyone in a confined space or location where they may be overcome or incapacitated and need to be rescued. A safety rescue harness looks similar to Type C, but will support a person almost upright for rescue purposes. It is intended for a maximum drop of 600 mm.

18

A competent person should draw up a schedule for testing and examination, which is likely to also include a requirement for thorough examinations at six-monthly intervals and userchecks each time the equipment is used. The six-monthly examination is a detailed visual examination, typically following cleaning where the harness is checked for contamination by oils and other solvents as well as abrasion and damage. The user check is simply to make sure that 'all the bits' are still there and there are no obvious defects.

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1.3.7.12 Type of lanyard There are several types of lanyard, each intended for a particular purpose.

2

Fall-arrest lanyards incorporate an energy-absorbing feature to reduce the shock loading on the body of the person who has fallen when the fall is arrested.

3

Twin tailed lanyards are a type of fall-arrest lanyard that allows greater mobility at height by enabling the repositioning of one tail at a time so that the user is constantly 'clipped on'.

4

However, this type of lanyard can pose additional risks to safety if it is not used correctly. If only one tail is clipped to a secure anchorage and the second tail is not located correctly, then during a fall the second tail could loop over a fixed object and arrest the fall before the energy-absorber has deployed, which may cause severe personal injury.

5

The second tail must never be clipped back on to the user's harness unless it is fitted with purpose-fitted 'parking points' that will break away from the harness if the second tail comes under tension. Alternatively, the second tail can be either left to hang free or (on this type of lanyard only) be simultaneously clipped to the same secure anchorage. If there is any doubt about these lanyards' safe use, the supplier or manufacturer should be consulted.

6

Restraint lanyards are shorter and used as a means of limiting the range of movement of the wearer to stop them entering an area of danger, for example to prevent a cherry picker operator from being thrown out of the basket. These lanyards are not designed to arrest falls and have no energy-absorbing feature. Sometimes two of these may be worn at the same time, with each lanyard fixed to a clip on either side of the harness to make the harness what is termed a 'work positioning harness'.

7

Irrespective of the type of lanyard used, they are only effective if the free end is securely anchored to a suitable anchorage point.

8

Manufacturers and suppliers will advise on the appropriate type of lanyard for particular work situations.

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Selecting the anchorage point 9

In order to limit the drop, the anchorage points should always be as high as possible above the person and as near to vertical as possible in order to avoid 'the pendulum effect'.

10

Anchorage points must be capable of withstanding the anticipated shock loading.

11

Consideration should also be given to how persons would be rescued following an arrested fall, particularly when work is from high structures. Some harness manufacturers also produce rescue systems that enable a single rescuer to raise a suspended person back to

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the working platform or safely lower them to ground level. Markings on belts and harnesses Safety belts and harnesses must be clearly and indelibly marked or permanently labelled with the following information: (a)

the British Standard, or International Standard, to which it conforms

(b)

the name, trademark or other means of identification of the manufacturer

(c)

the year in which the harness or belt was manufactured

(d)

the type of belt or harness

(e)

the manufacturer's serial number

(f)

the company serial number, or other recognition system, for recording maintenance and inspections.

Under these Regulations the safe working load would also be required, and it would be common to see some form of marking that indicates that the harness has been tested.

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the British Standard, or International Standard, to which it conforms

(b)

the name, trademark or other means of identification of the manufacturer

(c)

the year of manufacture

(d)

the manufacturer's model number and the type of belt or harness with which the lanyard is designed to be used

(e)

the company serial number, or other recognition system, for recording maintenance and inspections.

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Ideally, lanyards will have a label with the words (or similar):

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Lanyards which are not permanently attached to belts or harnesses must be clearly and indelibly marked or permanently labelled with the following information:

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Markings on lanyards

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'For maximum safety attach the free end to a point as high as possible above you and avoid looping the lanyard around small joists and angles with narrow edges.'

Lanyards should preferably be permanently attached to belts so that 'longer' lanyards cannot be substituted.

Shock absorbers 17

If a person wearing a harness and lanyard falls, there is a considerable shock loading to the body. The further the fall, the greater the shock. Generally speaking, the maximum distance a person should fall before a fall is arrested is 2m.

18

Shock absorbers in the form of tear-away stitching, stretch springs or a deforming metal strip are built into fall-arrest lanyards as a means of reducing the shock loading. Once a lanyard has been used to arrest a fall and the energy-absorber has been deployed, it must be discarded.

Arrester devices 19

These devices are similar in operation to the 'inertia reel' safety seat-belts fitted in cars.

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The safety harness is attached to a self-reeling cable which is securely anchored. The wearer is free to move normally but, in the event of a sudden movement (i.e. a fall), the locking device is brought into operation.

21

Most 'inertia reel' type arresters are only designed to safely arrest someone who has fallen from a position directly below, or very close to, the anchorage point (which should be above the head-height of the user). They are not designed to compensate for the 'pendulum effect', which will occur when the faller is a significant horizontal distance from the suspension point.

22

A typical misuse would be to see a line rigged along the ridge of an industrial roof with inertia reels fixed to it by carabiners. The work being carried out is not actually on the roof but on a lower level, resulting in the safety lines being stretched, and possibly abraded, across the lower edge (eaves) of the pitched roof.

23

The issue is that most examples of this type of device are not tested for 'over the edge' type falls in which the retractable lanyard is pulled tight across the edge of a surface, for example a roof sheet or floor slab, by the weight of the fallen person. In these circumstances it has been reported that the lanyard could snap or fail to limit the height of the fall to a safe distance.

24

If this is the proposed work method, then advice needs to be taken from the manufacturer that their equipment will work satisfactorily in this manner.

25

Various other types of fall-arrester are often incorporated as a permanent fixture into the structure being built, such as a traveller on a pre-tensioned vertical cable. There are also proprietary systems where the lanyard is attached to a traveller which moves along a prepositioned and tensioned horizontal or vertical steel cable. This permits movement around corners and past obstacles without the need to unclip.

26

Where the client provides this equipment as is common in many cases, care still needs to be taken that it has been inspected and checked as required and that the users understand how it works.

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Storage 27

While not being worn, appliances should be stored in a cool dry place and not subjected to direct sunlight. The use of purpose-designed cabinets which allow ventilation is recommended. If the appliances get wet, they should not be dried by direct heat.

28

The equipment should not be subjected to unnecessary strain or pressure and must be kept free from contact with sharp implements, corrosives and other possible causes of damage.

29

Recommended cleaning instructions should be followed.

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Inspection The wearer must make a visual inspection of safety equipment before use. The equipment should be examined by a 'competent person' at least once every six months and a record kept of this inspection.

31

Safety belts, harnesses and lanyards should be examined by a 'competent person' after a fall or other circumstances in which the equipment has been deployed, before it is reissued for use.

32

Safety belts, harnesses and lanyards should be taken out of use if found to be damaged or defective.

33

Under most circumstances, knots in lanyards would be considered to be a significant problem. Typically, a knot is presumed to reduce the strength of the rope or strop by 50%.

34

Particular attention should be directed to the points below.

35

Webbing and leather. Examine for cuts, cracks, tears or abrasions, stretching and distortion, damage due to deterioration, contact with heat, acids or other corrosives and rot.

36

Snap hooks. Examine for damaged or distorted hooks, faulty springs and strained jaws.

37

Buckles. Carefully examine the shoulders of buckles; inspect for open or distorted rollers, and undue wear.

38

Sewing. Examine for broken, cut or worn threads, open seams and failed stitching.

39

Lanyards, ropes and chains. Examine for damage or signs of wear and, in the case of ropes, inter-strand wear, unravelling extension and fusion.

40

For webbing lanyards, specific attention should be given to:

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surface abrasions to surface or edges

(c)

damaged stitching

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a knot in the lanyard other than the manufacturer's results of chemical attack.

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30

Unauthorised modifications. Examine equipment for 'home-made' attachments or adaptations. It should be impressed upon the wearers that their lives could depend upon the continued efficiency and durability of their safety equipment and that, by frequent personal inspections, the possibility of equipment failure will be reduced to a minimum.

Records 42

A card or history sheet should be kept for each harness and lanyard, and particulars of all examinations and other details of interest recorded. Each harness and lanyard should be marked with an individual serial number for identification purposes.

Dead weight anchor devices 43

The use of dead weight anchors in accordance with International and British Standards BS EN 795 and BS 7883 (Class E) has become an acceptable means of providing a safe fallarrest anchor device on flat roof surfaces, particularly where it is not possible to penetrate the roof surface.

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44

However, the increased usage and range of devices developed over recent years has revealed a number of factors not previously considered.

45

To ensure the safety of users, Contractors should consider the following points: (a)

Have the BS EN 795 and BS 7883 tests been carried out in accordance with the latest version of BS 7883?

While many dead weight anchor devices have been tested for use on single-ply membrane roofs, it has recently been found that the performance of some (and, possibly all) is far less satisfactory on embossed membranes rather than on plain, smooth membranes. This is thought to result from the reduced contact surface area between the anchor device and the roof surface. This effectively reduces the amount of friction,

47

Anyone who wishes to use a dead weight anchor device on an embossed membrane surface or a surface that is not smooth should seek advice from the anchor device manufacturer before proceeding.

48

The attention of users is drawn to the fact that no standard, at present, specifies tests for fallarrest systems in the following circumstances.

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When a full body harness is connected via a retractable fall-arrestor to a dead weight anchor device using a connector.

(b)

When a full body harness is connected via an energy-absorbing lanyard to a dead weight anchor device using connectors.

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Users who wish to connect such a system to a dead weight anchor device are advised to seek confirmation from the manufacturer of the retractable fall-arrestor or energy-absorbing lanyard that their products are safe to use in this way.

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Suspension trauma

One of the effects of being suspended in a harness is a tightening of the leg straps that bear the body weight of the suspended person. This can affect the blood circulation in the legs and cause the suspended person considerable discomfort, possible kidney failure and eventually unconsciousness and death. This is known as suspension trauma. It is essential that someone suspended in a harness is recovered in the shortest possible time.

51

Fall victims may be able to slow the onset of suspension trauma by relieving the pressure on their legs by pushing down vigorously with the legs, by positioning their body in a horizontal or slight leg-high position, or if there is something nearby upon which the feet can be rested, by standing up. However, the design of the harness and injuries sustained during the fall may prevent these actions being taken.

52

Some harnesses are fitted with stirrups that are secured out of the way by Velcro during normal use but can be lowered after a fall to enable the person to effectively 'stand up' in the harness.

53

The person must be placed in a horizontal position, preferably the standard 'recovery' position. It is essential that the emergency services are summoned immediately if it becomes apparent that there could be a medical emergency situation.

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1.3.7.13 Rope access (abseiling) 1

rd

This technique is only to be carried out by 3 party accredited fully trained and competent persons. It is generally suitable for inspection and other similar activities but not for general construction work except in exceptional circumstances. An example might be the rigging of safety nets where it is not reasonably practicable to do it by using other means of access such as a MEWP or another form of working platform.

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2

Generally anyone carrying out roped access uses a system that incorporates two separately anchored lines: the 'working line', which is the means of access, and a 'safety line', which prevents a fall if the working line fails.

3

This requirement may be ignored in exceptional circumstances where: (a)

the risk assessment shows that the use of a second line would increase the risk to the person

(b)

effective alternative safety measures are taken.

The person must be connected to both lines by automatic locking devices that prevent an uncontrolled descent should the person lose control of their actions.

5

The ropes, harnesses and other equipment are covered by the six-monthly thorough examination and inspection requirements.

6

Protection must be installed if there is a danger of materials or equipment falling onto persons below.

7

It is essential that only persons trained and competent in the use of rope access equipment, to current industry standards, are allowed to carry out such activities.

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1.3.7.14 Boatswain's chairs

Boatswain's (or bosun's) chairs should only be used where the work is of a relatively short duration and where no other means of access or working, such as a suspended scaffold, is practicable.

2

Note: Independently anchored safety line and safety harness not shown

3

A person in a boatswain's chair is extremely vulnerable. They are suspended high above the ground and, if anything goes wrong, the chances are that they are beyond rapid or immediate help. The risk assessment should cover rescue procedures should an emergency occur.

4

The installation and use of a boatswain's chair must be supervised by an experienced and competent person. Only properly trained and competent operatives should be permitted to use them. These Regulations must be strictly observed.

5

The traditional non-British Standard boatswain's chair is still used by specialist trades such as steeplejacks and lightning conductor engineers. Operatives need to be fully trained and competent before being permitted to use and work from it.

6

Where possible, consideration should be given to the provision of a second safety line connected to a harness being worn by the operative. In this way, should there be a problem with the Boatswain's chair, this safe system of working will prevent a fall. It may not always be possible and if this is the case, then the reason for this should be recorded as part of the work at height risk assessment.

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Rigging 7

A boatswain's chair should always be rigged with a pair of single sheave pulley blocks, having a safe working load of at least 225 kg. Outriggers and other supports must be strong enough, and be securely fastened down. Where weights are used, a safety factor of four is required.

8

A boatswain's chair is classified as a 'roped access system', therefore, the system should be rigged with a separately anchored safety line complete with an automatic locking device attached to the user of the seat that prevents or limits a fall should the primary suspension system fail.

Chair

.

A boatswain's chair should meet the following requirements: compliance with BS 2830. A certificate of compliance should be available from the manufacturer

(b)

be of a recommended size:

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(a)

between 450 mm and 610 mm wide

(ii)

not less than 225 mm deep

(iii)

have a back not less than 250 mm high

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(i)

if the chair has a single central leg or suspension member, this should be without sharp bends and be securely fixed to the seat as far back as practicable, so that the user sits with one leg at either side

(d)

be provided with a safety harness to prevent the occupant falling out

(e)

the back and the suspension member should be placed so that no one can fall out

(f)

the suspension point must be at least 500 mm above the seat, with provisions for suspension. No part should be able to become detached

(g)

be made for a safe working load of 115 kg. A proof test of 150 kg is recommended.

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When the risk assessment identifies that work from a boatswain's chair will take place above areas where people may be present, adequate protection must be installed to prevent them being injured from falling equipment or materials.

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Protection of the public

Safety factor 11

The counterweight (W) x tail length (T) should be at least four times the projection length (0) x weight of the person, the chair and any tools or equipment being carried (C).

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Note: Independently anchored safety line and safety harness not shown

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Lifting equipment

All ropes and chains used should be thoroughly examined before their first use for any sign of chafing or wear, and then every six months. They must be securely attached to the chair and to the anchor. Swivel connections should be used to prevent spinning.

14

Fall ropes should not be less than 18 mm in diameter. They should be tied off correctly in the working position. The rope must not be removed from the cleat while the chair is in use; a controlled descent is achieved by removing the locking-hitch from the rope in the 'tied-off' position and easing it around the cleat.

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Hooks should be 'moused', 'C' shaped, or fitted with a spring-loaded device to prevent the displacement of the load.

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Cradles

Cradles, which come within the category of suspended access equipment, may be used for window cleaning, painting, exterior maintenance and inspection.

17

They may be permanently rigged and attached to the roof, or be a temporary installation which can be dismantled. Safe access to the cradle must be provided, either at ground or roof level. Cradles, as 'man riding' equipment must be inspected at appropriate intervals and subjected to six-monthly thorough examinations.

18

Two main types of cradle in use within the construction industry are:

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(a)

those 3.2 m or less in length, suspended on pulley blocks with natural or synthetic fibre ropes

(b)

those more than 3.2 m in length, suspended on wire ropes controlled by handoperated or power winches which are mounted on the cradle.

Both types can be installed as: (a)

Fixed cradle - Rise and fall only

(b)

Travelling - Capable of moving horizontally across the workface as well as rising and falling.

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Rigging 20

The erection of a cradle must be carried out and supervised by an experienced, competent person who is familiar with the type of equipment being erected.

Outrigger 21

Timber poles, roller steel section or specially stiffened scaffold tube may be used. The framework must be secured at intersections to prevent displacement and the counterweight must be sufficient to give a resisting moment at least three times the overturning moment, i.e. W = 3 x O x C T W = Counterweight 0 = Overhang

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C = Total weight of fully loaded cradle

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Where:

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T = Tail length

Where a traversing track is required, this should be an alloy or steel section, properly joined or shackled to the outriggers. If the track is joined to provide a continuous run, this must be with both the load-bearing connectors and the join supported by an outrigger. End stops must be in place at either end of the track, to prevent the trolley from running off.

23

When installing temporary cradles, a check must be made that nothing on the face of the structure, for example, satellite dishes, will obstruct its range of travel.

24

Care must be taken not to damage the roof or structure, and adequate packing should be used on copings.

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Markings

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To identify compliance with BS 2830, markings should clearly show the safe working load and maximum number of persons held.

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Working platform 26

Should be not less than 600 mm wide.

27

Should be closely boarded (except for drainage).

28

There must be no gaps in platforms through which materials may fall and injure people below.

29

Timber boards should overhang the stirrups by at least 100 mm but not by more than 200 mm.

30

Should be supplied with a non-slip surface, if possible.

Toe-boards 31

Ideally will not be less than 150 mm high.

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Guard-rails 32

Should be at least 950 mm above the working platform.

33

There should be an intermediate guard-rail or other substantial barrier.

34

The space between guard-rails and toe-board should be not more than 470 mm.

Suspension points 35

Should be positioned centrally in the width of the platform.

36

Heights should be not less than 1.67 times the clear width of the platform.

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Safe working distributed load 225 kg when there is a 2 m clear working length.

38

295 kg when there is 2-3.2 m of clear working length.

39

The maximum number of persons allowed on a platform should be displayed. (This does not take into account the weight of any materials.)

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1.3.7.15 Stirrups

Stirrups should pass under the platform and be secured.

2

If hinged for operational purposes:

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the pivot point should be non-detachable

(b)

the stirrup should be able to be locked in the vertical position.

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(a)

The stirrup should be hinged to a metal strip of the same strength as the stirrup which is fixed under the platform.

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Demountable stirrup

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Should be designed so that it cannot become accidentally detached.

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Guard-rails required for hinged and demountable stirrups should be secured with captive devices.

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Suspension 6

Ropes should be not less than 18 mm in diameter and should be either natural fibre or synthetic fibre, conforming to BS EN standards, as appropriate.

7

Wire ropes used to suspend cradles should have a safety factor of at least eight.

8

The proper inspection of wires and ropes is essential to safety, with renewal as soon as necessary.

9

Suitable devices should be fitted or other steps taken, where practicable, to prevent the carrier falling if the main support fails.

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Pulley blocks 10

Must be suitable for the ropes which are to reeve through them.

11

The safe working loads for cradles are: (a)

250 kg for cradles with 2 m clear working lengths

(b)

380 kg for cradles with 2 - 3.2 m clear working lengths.

Winches or similar The safe working loads for winches are: (a)

225 kg for cradles up to 2 m in length

(b)

295 kg for cradles up to 3.2 m in length.

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Hooks As for boatswain's chairs

When working above areas where people may be present, adequate protection must be installed to prevent people being injured from falling equipment or materials.

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Protection of the public

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Fall-arrest devices

These are provided to avoid the consequences of a suspension rope failure. They must be installed in accordance with the manufacturer's instructions.

16

If such a device is not used, operatives must wear a safety harness attached via a selflocking device to an independently anchored safety line.

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General

Care must be exercised when planning works at elevated positions, where the 'safe distance' from electric cables may be reduced. The risk assessment should specify appropriate distances and precautions.

18

Only competent and properly trained personnel should be employed in the erection and use of cradles.

19

All equipment must be thoroughly examined at six-monthly intervals and tested in compliance with the relevant legislation and standards, and proper records must be kept,

20

The public should be warned of operations.

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Typical suspended cradle

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Construction Site Safety 1.3.7 Appendix 1 Safety nets Safety checklist Before use Has a risk assessment been carried out?

2

Are the safety nets rigged to minimise the height of any fall such that an uninjured person can simply climb out?

3

If not, have emergency rescue procedures been established?

4

Have checks been made to ensure that free fall distances are not more than specified?

5

Have the safety nets been rigged by trained and competent persons?

6

Is the use of safety nets to be supervised by competent persons?

7

Have safety nets been inspected prior to current use?

8

Are complete and proper records kept of all inspections and examinations?

9

Has the safety net system been inspected within the previous week?

10

Are all anchors and supports secure?

11

Is the safety net clear of all debris?

12

Have checks been made to ensure that nothing is positioned under the net to reduce the minimum clearance distance required?

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During use

Is the net being kept clear of debris?

2

Are the safety nets inspected: after a fall

(b)

for the effects of contamination

(c)

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every seven days during use

to ensure that the safety net is not damaged and that the anchorage points and ties are sound.

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After use 1

Are safety nets inspected for any damage following use and before being stowed away?

2

Are any defects reported promptly and correctly?

3

Are repairs only carried out by a competent person?

4

Are adequate records maintained as to the use and condition of safety nets?

5

Are safety nets dried and stored correctly?

6

Are the annual condition tests being undertaken?

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Construction Site Safety 1.3.7 Appendix 2 Safety belts, harnesses and lanyards Safety checklist Before use Has a risk assessment been carried out?

2

Have emergency rescue procedures been established?

3

Has the most suitable harness or belt been selected for the type of operation and hazard?

4

Are the operatives who are to use the equipment adequately trained in its inspection and use?

5

Is it all in good order and fit for purpose?

6

Is a secure and appropriately positioned anchorage point available?

7

Have checks been made to ensure that the weather conditions are such that an operative can work safely in the prevailing conditions?

8

Is there a schedule of detailed examination of the equipment?

9

Are records of the examinations kept?

10

Have steps been taken to see that adequate warning notices are displayed?

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During use

Have safety lines been set by a competent person?

2

Are only authorised, trained and competent personnel allowed to use the equipment?

3

Is all equipment inspected before the start of work each day, following an established routine, particularly for damage to webbing lanyards?

4

Have set procedures been established and implemented?

5

Is horseplay strictly prohibited?

After use

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Is the equipment inspected for damage?

2

Are defects reported promptly and correctly?

3

Is defective equipment quarantined (if it can be repaired) or discarded?

4

Is the equipment cleaned and stored correctly?

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Construction Site Safety 1.3.7 Appendix 3 Boatswain's chair Safety checklist Before use Has a risk assessment been carried out?

2

Have emergency rescue procedures been established?

3

Has a separately anchored safety line been installed?

4

Is the installation and use of a boatswain's chair supervised by trained, experienced and competent personnel?

5

Are the chair and associated equipment carefully examined for defects prior to use?

6

Is confirmation at hand that test and examination certificates are valid?

7

Has the safe working load been established?

8

Have checks been carried out to ensure that the user is both trained and competent in the use of the chair?

9

Are warning notices displayed and has notification of intention to carry out work been given?

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During use

Is the chair free of materials or articles which could interfere with the user's control of the chair?

2

Has the fall rope been properly tied off whilst the chair is in use and always under or around a cleat to act as a brake?

3

Has a safe area been created below the work area or protection installed?

4

Is the safety line being properly used?

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After use

Is the chair inspected for defects following its use?

2

Are chairs and ropes left in a safe condition, i.e. is the chair raised to the first floor level if possible, and the top rope secured?

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(b)

have the chair and rope been secured to prevent swing?

(c)

have the ropes (and chair, if timber) been dried before storage?

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Construction Site Safety 1.3.7 Appendix 4 Cradles Safety checklist Before use Has a risk assessment been carried out?

2

Have emergency rescue procedures been established?

3

Are cradles installed and supervised by a competent person?

4

Are cradles inspected and appropriate reports made?

5

Are current test certificates available for winches, wire ropes, blocks and so on?

6

Have users been properly trained?

7

Has adequate protection been installed and proper warning given to members of the public and other people who might be affected?

8

Have occupiers of the building been warned not to open windows?

9

Have steps been taken to erect the correct warning signs?

10

Have secondary safety ropes and harnesses been provided as necessary?

11

Is the safe working load of the cradle marked?

12

Has a check been carried out for obstructions on the face of the structure?

13

Have effective fall-arrest measures been installed?

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During use

Is a competent person in charge of all operations when cradles are being used?

15

Are operations being carried out with authorised operatives only?

16

Are inspections carried out weekly?

17

Have checks been made to ensure that there are no knots or kinks in the ropes?

18

Are ropes correctly reeved on the drum with at least two turns left when the cradle has reached its maximum operating distance? (Power-operated cradles only.)

19

Have both power supplies and cables been checked before operating?

20

Have checks been carried out to the controls for correct function and to ensure that pendant controls are secured to the cradle?

21

Have all ropes been securely anchored?

22

Are the stops and over-runs operational?

23

Are secondary safety devices properly secured and anchored?

24

Has the cradle been tied-off to the building to prevent sway?

25

Have checks been made to ensure that the safe working load is not being exceeded?

26

Is the cradle kept clean and clear of rubbish?

27

Have all necessary precautions been taken to ensure that the platform is not slippery?

28

Are all tools carried in the cradle secured?

29

Is there adequate protection from above to stop any falling materials?

30

Are all necessary steps being taken to ensure that the proper access is being used?

31

Is the practice of climbing down ropes strictly prohibited?

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32

Are all personnel aware that there must be no transferring between adjacent cradles?

33

Have all possible steps been taken to ensure that personnel do not allow ropes and cradles or connections to lie in gutters?

34

Are all operatives aware that use in high winds or adverse weather conditions is not safe and is prohibited?

After use Are the cradle and all ropes, in a secure position to prevent unauthorised access or usage?

36

Are checks carried out to ensure that power supplies are isolated and control equipment is removed and secured?

37

Are defects and breakdowns reported promptly and correctly?

38

Are all warning signs removed after the completion of work?

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Construction Site Safety 1.3.8

Safety with Steelwork

1.3.8.1 Key points The majority of jobs that involve erecting steelwork will also involve working at height, and exposure to the associated potential hazards.

2

A schedule of erection should be in place to ensure the safe erection and stability of the structure until it is complete.

3

All steel erection must be the subject of a risk assessment and carried out in accordance with a method statement.

4

Ideally, the erection of steelwork will be carried out in such a way that those doing the job are on a stable working platform at all times, be that a scaffold or a mobile elevating work platform (MEWP). Operatives having to go onto the steelwork should be a last resort.

5

Ground conditions must be suitable to take the weight of MEWPs and their loads.

6

Designers have the potential to ensure that the erection of steelwork can be carried out safely, for example, designing-in lifting eye attachment points, or specifying ground-level fabrication.

7

The erection of steelwork will usually involve extended crane operations, the use of MEWPs in and around the new structure, lorry movements, steel laydown areas and possibly a lorrypark, all of which must be planned for when the site is first set up.

8

All lifting operations, including the use of cranes and MEWPs, must be carried out by, and under the control of, competent persons.

9

The presence of overhead power cables and the possible need to manually align steelwork components for connection are other potential hazards associated with the erection of steelwork.

The majority of fatal accidents are as a result of falls from height. In addition, many serious accidents occur due to workers being struck by falling materials.

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1.3.8.2 Introduction

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1.3.8.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify the hazards arising out of that work and the persons or groups who might be affected.

2

When hazards are identified, it is then the Contractor's duty to either eliminate the hazards or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

The Contractor must provide all employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

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1.3.8.4 Work at Height 1

By its very nature, the erection of steelwork will usually involve a degree of working at height.

2

These Regulations require that Contractors: (a)

avoid the need to work at height where it is reasonably practicable to do so

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(b)

where this is not possible use work methods or equipment to prevent falls

(c)

where this is not possible, use work equipment or other measures to minimise the distance or the consequences of falls

(d)

ensure that all work at height is based on a risk assessment and is carried out safely by competent persons

(e)

ensure that equipment used for working at height is appropriately selected and inspected as specified

(f)

ensure that measures are taken to prevent anyone being injured by falling objects

(g)

ensure that adequate emergency arrangements are in place in the event of an incident (rescue).

.

1.3.8.5 Provision and Use of Work Equipment Any work equipment used in the handling or erection of steelwork, such as tirfor winches, wire rope slings, lifting gear, lifting tackle, MEWPs and even hand tools, must comply with these Regulations.

2

They require that a Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

3

The Contractor is also required to provide employees with all necessary information, instruction and training to ensure that they are competent to use any work equipment provided.

4

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to competent and authorised workers only.

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1.3.8.6 Lifting Operations and Lifting Equipment Any lifting activity and the equipment used to carry it out must comply with the requirements of these Regulations. The term lifting equipment not only includes machinery such as cranes but also any device used to connect the machinery to the load, such as eye-bolts, hooks, slings. These are known as lifting accessories.

2

Briefly, these Regulations place legal duties on the Contractor to ensure that: all lifting equipment is stable in use and of adequate strength for the purpose for which it is being used - safe working loads

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(b)

lifting equipment used to lift persons, for example a passenger hoist, is designed for the purpose and is safe to use

(c)

lifting equipment is positioned and

(d)

installed so as to keep the load under full control

(e)

lifting equipment is marked with its safe working load

(f)

lifting activities are properly planned, appropriately supervised and carried out in a safe manner

(g)

lifting equipment (including lifting accessories) is subjected to a scheme of periodic thorough examination for which reports are raised.

1.3.8.7 Construction (Design and Management) CDM 1

Many risks can be eliminated, avoided or reduced by careful attention to design and planning aspects before construction work starts. Any remaining risks can be controlled by the

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effective management of health and safety risks during the construction phase. Both planning and management are key requirements of these Regulations. 2

These regulations place duties on (amongst others) the client, the contractor and designers, and provide a framework for the management of risks, including those inherent in the handling and erection of steelwork.

3

These Regulations require that:

(b)

all parties involved in a project co-operate with each other in the interests of health and safety

(c)

all parties involved in a project coordinate their activities in the interests of health and safety

(d)

only authorised persons are allowed on to site.

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everyone working on a project is competent to do what is required of them

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In addition to the design and general health and safety management issues outlined above, in the context of steel erection, these Regulations cover: the stability of structures

(b)

demolition and dismantling

(c)

the presence of overhead cables (and in some instances, buried services)

(d)

establishing traffic routes

(e)

the safe use of vehicles

(f)

temperature and weather protection

(g)

lighting (if working in reduced level of light)

(h)

are considered to be particularly relevant.

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(a)

Steel erection, by its very definition, involves creating structures, which these Regulations require to be stable at all times. In particular: all practicable steps must be taken to ensure that no person is put at risk by the collapse of any structure which may become unstable or weakened

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1.3.8.8 The stability of structures

(c)

any temporary means of supporting a permanent structure must be:

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structures must not be loaded to an extent that they become unsafe

(i)

designed and maintained to withstand any stresses and strains that are put on it

(ii)

only used for the purpose for which it was designed, installed and maintained

(iii)

not overloaded so as to render it unsafe.

1.3.8.9 Traffic routes and vehicles 1

Prior to and during steel erection, deliveries of steel on articulated lorries will be a feature of many jobs. In the context of this section, these Regulations place a legal duty on the person in charge of the site to ensure: (a)

that pedestrians and vehicles can move safely and without risks to health, so far as is reasonably practicable

(b)

there are sufficient traffic routes, all of which must be suitable for the vehicles using them

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there is sufficient segregation between pedestrians and moving vehicles but where this is not reasonably practicable: (i)

other means of protection are provided, and

(ii)

a means of warning pedestrians of the approach of vehicles, where the pedestrians would otherwise be at risk, is provided

(d)

that (vehicle) loading bays have one exit for the exclusive use of pedestrians

(e)

appropriate signs are erected in the interests of health and safety

(f)

steps are taken to prevent the unintentional movement of any vehicle

(g)

each vehicle must be operated in a safe manner with its load arranged safely

(h)

every vehicle is fitted with means of warning persons who may be at risk when the vehicle is moving.

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1.3.8.10 Manual Handling Operations

These Regulations require that where there is a risk of injury, Contractors must, so far as is practicable, avoid the need for employees to carry out any manual handling operations. Where this is not possible, the Contractor must make an assessment of the work to be carried out and take appropriate steps to reduce the risk of injury to employees.

2

Contractors must provide employees with adequate and suitable training in manual handling, and employees must follow any such information or instructions given and use the safe systems of work that have been put into place by their Contractor.

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It is anticipated that the amount of manual handling involved in steel erection has been significantly reduced due to the improved standards of design and modem methods of access and working.

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Design and planning considerations Contractors should follow:

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Structural stability

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The structure must be stable at all times from when the first piece of steelwork is put into position until it is completed.

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Temporary supports, such as bracing, guys or stays, must be used during the erection of any structure which may be unstable or liable to collapse before it is completed. Additionally, where any work is carried out which is likely to adversely affect the foundations or stability of any existing building or structure (or one under construction), all practicable precautions, such as shoring, must be taken.

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Temporary structures 4

Any temporary structure must be of good construction, adequate strength and stability, made of sound materials free from obvious defects and be properly maintained.

1.3.8.12 Safe means of assembly or making connections 1

Assembly of steelwork components or making connections should be planned so that erectors can do as much of the work as possible at ground level.

2

Where erectors have to work at a height, provision must be made for safe means of access to the connecting points and any other working places. Ideally, work will be carried out from

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MEWPs operating on a suitable floor surface. However, where this is not possible, design consideration should be given to: (a)

ensuring there is adequate working space and a suitable work platform for a crane

(b)

connections between steelwork components that are simple to make off-site or ground-level assembly or fabrication to reduce work at height

(c)

the provision of fixed work platforms and ladders

(d)

the provision of anchorage points for safety nets and fall arrest devices.

Steelwork components The size, weight and shape of individual steelwork components will influence safe handling and erecting. The designer should therefore consider the following steps: marking components as an aid to identification (also to prevent costly mistakes)

(b)

optimising the length of structural members in an attempt to reduce the number of connections at height

(c)

calculating the weights of components to assist in the estimation of safe crane capacities and the location of cranes

(d)

identifying the positions where components should be lifted

(e)

indicating centres of gravity where these are not readily evident

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1.3.8.13 Site features

Potentially hazardous features should be identified that will conflict with health and safety.

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Some typical examples include the following items.

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If there are any overhead power lines near the proposed erection site, the local electricity company should be consulted. Either the power lines should be made dead, temporarily rerouted or other suitable precautions taken to prevent any close approach to, or contact with, live overhead lines

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Buried services

As well as a visual inspection for marker posts or obvious signs, a check should be made with the owner or occupier of the land and the various utility companies, including electricity, gas, water, telecommunication and cable TV companies.

Other site features which require attention 5

These features include: (a)

lack of space for the handling and storage of steelwork

(b)

restricted (crane) oversailing rights and safety

(c)

restricted area(s) for vehicle movements

(d)

low resistance to ground bearing pressures

(e)

poor access onto the site

(f)

any buildings close to the site that may affect the erection process

(g)

any rights of access that may bring members of the public close to the erection site

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ground contamination from previous use of the land.

Other contractors and their activities 6

Certain activities or processes on, or adjacent to, the site may have the potential to adversely affect the health and safety of workers on site. For example, noxious gases, vapours or dusts may be given off from chimneys, stacks, tank vents and ventilation ducts. These may not cause a problem at ground level but may affect steelwork erectors working at a height.

Managing the safe erection of steelwork Following a detailed risk assessment of the work activity, the next step in ensuring safe work practices in erection is the preparation of a method statement.

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This important document should detail the proposed erection scheme and should form part of the health and safety plan for the project.

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Method statements

The amount of detail required in a method statement will depend on how big or complex the job is. However, method statements should be written for even small steel erection jobs. It is clear evidence that attention has been given to design and planning aspects, as well as being a plan to ensure that the project is completed without risks to health and safety.

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A typical method statement should include the following points: details of how the project will be managed and health and safety risks eliminated, avoided or reduced

(b)

information on the site, including any hazardous features, such as overhead electric power lines, and what effect these will have on the project

(c)

details of plant requirements such as cranes, MEWPs and other lifting equipment, and the competencies required to operate them

(d)

arrangements for the safe receipt, offloading, storage and handling of steelwork components on site

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the sequential method of erecting the structure and how stability will be ensured at all times

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details on where and how steelwork will be assembled prior to erection

(g)

how activities such as slinging, lifting, unslinging and the initial and final connecting of steelwork components will be carried out safely

(h)

the safety precautions to prevent falls from height. For example, arranging for as much assembling as possible to be done at ground level, minimising the number of connections to be made at a height

(i)

the means of providing safe access and a safe place of work by methods such as mobile towers, temporary platforms and walkways

(j)

details of the means of communication during lifting operations

(k)

any requirement for safety nets, safety harnesses and fall arrester devices (provisions for design features should be specified, for example, attachment points for ladders, safety nets and fall-arrest devices)

(l)

how people will be protected from falling objects. For example, use of screens, fans and debris nets, installation of barriers and warning notices at ground level

(m)

a contingency plan for dealing with any problems that may arise.

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Site access/egress The Contractor should check that all of the vehicles associated with the erection or dismantling of steelwork can access and egress the site safely. It is envisaged that the vehicles will mainly be cranes and delivery lorries (delivering steel and MEWPs).

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A safe location for lorries to park must be identified and communicated to employees. This area must not be immediately outside the site or on any access road if doing so would create an unacceptable obstruction or other hazards for passing traffic or pedestrians. On larger sites space should be allocated as a dedicated lorry or trailer park.

13

On sites where there is simply not space to park large vehicles, appropriate arrangements, such as a road or lane closure, must be made for delivery lorries (and possibly the mobile crane) to be parked on the public highway adjacent to the site boundary for the off-loading of the steel.

14

Where there is a loading/unloading bay for only a single lorry, a strict schedule of delivery times must be written, communicated to the steel delivery company and adhered to. In this instance it is highly advisable to identify a 'lorry holding area', to which lorries that 'miss their slot' can be sent pending the allocation of another unloading 'slot'.

15

Every effort should be made to avoid the need for vehicles to reverse, particularly out of the site gate and back on to a public road. Where this is not possible, suitable precautions must be taken, for example, the use of one or more signallers or an alternative traffic-control system.

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Where it is considered unsafe for vehicles and pedestrians to use the same site entrance, one or more separate pedestrian entrances must be provided, clearly indicated and kept free of obstruction.

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1.3.8.14 Housekeeping

Construction sites must, so far as is reasonably practicable, be kept in good order and a reasonable state of cleanliness.

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Platforms, gangways, floors and other places must not be obstructed by loose materials.

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Projecting nails or similar sharp objects in timber or other materials must be removed or knocked down to prevent injury.

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Materials must be stacked safely.

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1.3.8.15 Lighting 1

The following areas must be adequately and suitably lit: (a)

every working place

(b)

access to working places

(c)

where lifting operations are in progress

(d)

all dangerous openings.

1.3.8.16 Protection from falling material 1

At any place where people work, steps must be taken to prevent them from being struck by any falling material or article.

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Scaffold components, tools and other objects must not be thrown or tipped down from a height where they are liable to cause injury, but should be properly lowered.

1.3.8.17 Lifting and slinging Competent people must be used to operate lifting equipment and give signals in line with BS 7121.

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All critical lifts, including tandem lifts, should be carefully planned and supervised.

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Reference - BS 7121:2006 Code of Practice for safe use of cranes

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Appropriate precautions must be taken to ensure the stability of lifting appliances when used on soft, uneven or sloping ground. These could include measures such as ground levelling, use of mats or hard standing.

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A safe means of access and a safe workplace must be provided when off-loading components from delivery lorries. Two examples of recently developed safety systems are: a tensioned steel wire running the length of the lorry trailer, at above head-height of anyone standing on the trailer. Each slinger wears a safety harness and a restraintlanyard, the free end of which is clipped to the tension steel wire. In the event of a trip or stumble, the slinger is prevented from falling from the trailer

(b)

a 'U' shaped inflatable air bag or a 'bean-bag' that fits around the back and sides of the trailer to act as a soft-landing system, should anyone fall off the trailer.

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1.3.8.18 Offloading, stacking and storage of steelwork

Many accidents have occurred during the off-loading of lorries when the load-securing mechanism was released. This is because the load was either not stable when loaded or because it moved and became unstable during the journey.

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The stability of the load on the lorry, or in the stack, must be ensured at all times. Suitable timber wedges or packing pieces can be used as an aid to stability.

4

Precautions should be taken to prevent slingers being struck by the load. For example, taking up a safe position off the lorry before the load is lifted.

5

The stack must be constructed so that components can be removed without risk of someone being trapped or struck.

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There may be an advantage in using a suitable transportable storage rack (stillage) for smaller components.

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Anyone not directly involved in the off-loading activity should not be allowed into the area.

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1.3.8.19 Safe means of access and safe place of work 1

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To comply with these Regulations, consideration must be given to reducing the need to work at height. The following are a way of doing this: (a)

doing as much of the connecting work at ground level or from erected floor decks, as the work progresses

(b)

use of a releasing device so that lifting gear can be released remotely

(c)

ensuring that, wherever possible, inspection and testing is carried out at low level.

When people must work at height, consideration should be given to the following measures:

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(a)

installing permanent stairways, ladders, walkways and floor decking, so that these can be used by erectors as the work progresses

(b)

providing hard standings or floor slabs so that mobile access platforms can be used

(c)

providing temporary access and working platforms, including scaffolds, lightweight staging, purpose-built platforms with safe means of access

(d)

working from mobile elevating work platforms (MEWPs).

Whilst the increased use of MEWPs has brought about safer working at height, it has also created the need to ensure that: (a)

MEWP operators are adequately trained and competent

(b)

ground conditions on the site are properly surveyed and prepared to enable the safe use of such heavy plant without risk of sinking or overturning.

Traditionally, scaffolding was the main form of edge protection, which could only be installed, modified or removed by trained scaffolders, after the steelwork was in place. However, the development of various types of 'system edge protection' has provided opportunities for preinstalling edge protection before work at height commences. The use of such systems can also eliminate the need for successive trades to install their own edge protection and then remove it when leaving site, only for it to be replaced by the next trade's edge protection. The elimination of such duplication has obvious safety benefits.

5

It may be appropriate in some circumstances to use other means of access to height, such as the use of roped access techniques, which must be carried out by trained and competent persons, alternatively, access may be achieved by using a 'man-riding' basket suspended from a crane.

6

There may be occasions when it is necessary to use fall arrest rather than fall prevention measures, with safety nets or other soft landing systems being the preferred method of fall arrest.

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1.3.8.20 Beam 'straddling'

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There may be occasions where the work cannot be done from a MEWP or other platform and erectors may have to work from the steel. This is known as beam 'straddling'. This form of access is only permissible for specific short-duration jobs where the beam is of I beam section.

2

A full body harness with a twin-tailed lanyard system may be used. However users must ensure that this system is used correctly and that the second leg is not attached to the user's harness as this may interfere with the operation of the energy absorber.

3

The erector can sit astride the flange with the sole and heel of each foot resting on the bottom flange and both hands able to grasp either side of the top flange.

4

Alternatively, proprietary 'beam gliding' devices are available to improve ease of mobility.

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The risk assessment must consider how anyone carrying out this practice is going to be rescued following a fall.

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The use of a safety harness or lanyard requires a minimum clearance below the high-level place of work to allow the lanyard to function properly in arresting a fall. Expert advice should be sought.

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The safe system of work must also ensure the operative's safety:

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whilst getting up to the place of work and down again

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during the period of time at high level before the operative is able to 'clip on'.

If access has to be made inside a structural' steel box section, or any configuration of steelwork where ventilation is poor, it should be treated as a confined space and appropriate precautions taken. The atmosphere should be tested by a competent person, before entry is made, to ensure that there is sufficient oxygen present. Continuous monitoring for oxygen deficiency is strongly recommended. Tests for flammable or toxic gases or vapours and oxygen enrichment should be carried out as appropriate, depending on the proposed work activity. For example, oxy-propane cutting or burning may lead to a build up of toxic gases or toxic metal fumes, or there may be a leakage of propane or oxygen.

1.3.8.21 The weather A regular weather forecast should be obtained by the manager in charge of the erection programme. Erection should not take place where weather conditions impose an adverse effect, such as: wind strengths

(b)

rain or dew

(c)

poor visibility (fog, mist or glare)

(d)

Sand storms.

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If erection work is stopped, measures should be taken to ensure that the structure remains stable.

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After a stoppage due to the weather, stability of the structure should be checked before work is allowed to restart.

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Construction Site Safety 1.3.8 Appendix Safety checklist: steelwork Is the contractor responsible for erection competent?

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Has a risk assessment been undertaken for the project?

3

Does the contractor have a method statement?

4

Does it specify the sequence of erection and how the structure will be kept stable at all times?

5

What types of temporary support will be used?

6

Does everyone know the requirements for safe erection?

7

How will the structure components be erected and connected safely?

8

Will as many connections as possible be done at ground level?

9

Where work must be done at height, have safe means of access and safe places of work been planned?

10

Has the site been surveyed for hazardous features such as overhead power lines?

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Is there sufficient access for off-loading lorries?

12

Is there a planned delivery sequence of components?

13

Are there plans to deal with lorries that have to reverse?

14

How will components be offloaded, stacked and de-stacked safely?

15

Are the weights of individual components known?

16

Does all lifting gear that is to be used have adequate safe working loads?

17

Have crane capacities been calculated?

18

Have steps been taken to eliminate the need for manual handling?

19

Are the steel erectors competent? Have they been adequately trained?

20

Will all lifts be supervised by a competent person?

21

If MEWPs are to be used, are all the operators trained and competent?

22

Is it necessary to survey and prepare the ground so that MEWPs can operate safely?

23

Will work at height be carried out other than from a MEWP?

24

What measures will be taken to prevent or arrest falls?

25

Are emergency rescue procedures in place?

26

Have any special risks been identified, for example, work in confined spaces?

27

Is there a plan to monitor the weather?

28

Is there a contingency plan?

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Construction Site Safety 1.3.9

Roofing and Fragile Surface Practices

1.3.9.1 Roof work and fragile surfaces The main causes of accidents are falling off the edges of roofs and falling through holes, roof lights and other fragile surfaces.

2

Compliance with well-established safety procedures could save lives and prevent injuries. All roof work requires a risk assessment and, if the work is extensive, a method statement that sets out a safe system of work. Most accidents could be avoided if the most suitable equipment was used and those carrying out the work were given adequate information, instruction, training and supervision.

3

If work is going to be done on any roof, the Contractor is to make sure there is:

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safe access onto the roof, e.g. a general access scaffold, tower scaffold (preferably of the stairway design) or mobile access equipment etc

(b)

a safe means of moving across the roof, e.g. using proprietary staging or purposemade roof ladders.

(c)

a means of preventing falls when working on the roof, e.g. edge protection consisting of guard rails and toe boards, a proprietary access system or a MEWP.

(d)

measures to prevent falls through fragile materials (e.g. barriers or covers) and mitigate the consequences should a fall occur (e.g. nets).

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(a)

Independent scaffolds that provide safe access onto the roof, a safe working platform and the capacity for material storage (always check with the scaffold designer before stacking material at roof level) are the ideal solution.

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However, it is not always possible to use a general access scaffold. In these circumstances, for a sloping roof, edge protection erected at eaves level, with or without a scaffold platform, or for a flat roof, edge protection erected around the edges provides an alternative fall prevention measure. Figure 23 shows some of the options for sloping-roof edge protection and Figure 24 shows examples of flat-roof edge protection.

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Figure 23 - Typical sloping-roof edge protection

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Figure 24 - Example of flat-roof edge protection

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Irrespective of the type of edge protection used, safe access onto the roof and a safe way of lifting materials up to roof level must be provided and maintained.

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Alternatively, mobile elevating work platforms or proprietary access systems (see Figure 25 ), which are easy to transport from site to site and quick to erect, provide good access and should be considered as an alternative to fixed edge protection. Figure 25 - Proprietary access system for roof-work

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On sloping roofs, roof workers should not work directly on the tiles or slates. Roof ladders and proprietary staging should be used to enable safe passage across a roof. They must be designed for the purpose, of good construction, properly supported and if used on a sloping roof, securely fixed by means of a ridge hook placed over the ridge. They should be used in addition to eaves-level edge protection and if the work requires access with 2 m of the gable ends, edge protection will be needed there as well.

9

Short-duration work means tasks that are measured in MINUTES rather than hours. It includes such jobs as inspection, replacing a few tiles or adjusting a television aerial. Work on a roof is still dangerous even if it only lasts a short time and appropriate safety measures are essential.

10

For short-duration work it may not be reasonably practicable to provide full edge protection, but you will need to provide something in its place. The minimum requirements for shortduration work on a roof are:

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a safe means of access to roof level; and

(b)

a safe means of working on the roof (e.g. on a sloping roof, a properly constructed roof ladder, or on a flat roof, a harness attached to a secure anchorage and fitted with as short a lanyard as possible).

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Many roof assemblies are, or can become, fragile. Asbestos cement, fibreglass and plastic generally become more fragile with age. Steel sheets may rust. Sheets on poorly repaired roofs might not be properly supported by the purlins. Any of these materials could give way without warning. Do not trust any sheeted roof. Do not stand directly on any sheeted roof.

12

On fragile roofs, the work has to be carefully planned to prevent falls through the roof. All work should be carried out from beneath where practicable. Where this is not possible, consider using a mobile elevating work platform (MEWP), which allows the operatives to carry out the work from within the MEWP basket without standing on the roof itself (see Figure 26 ). NEVER try to walk along the line of the roof bolts above the purlins, or along the roof ridge, as the sheets can still crack and give way. The sheets are not designed to support your weight and you should therefore approach the roof as if the sheets were not in position.

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Figure 26 - A mobile elevating work platform being used to replace a roof sheet

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If access onto a fragile roof cannot be avoided, edge protection should be installed around the perimeter of the roof and staging should be used to spread the load. Unless all the work and access is on stagings or platforms that are fitted with guard rails, safety nets should be installed under the roof or a harness system should be used (see Figure 27 ).

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Figure 27- Workmen wearing harnesses attached to a work positioning line, which is fitted to the staging

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Roof openings and fragile roof lights are a particular hazard. Some roof lights are difficult to see in certain light conditions and others may be hidden by paint. Protection from falling through openings and fragile roof lights must be provided using either barriers or covers that

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are secured or labelled with a warning. If the work is the replacement of roof lights, nets slung close beneath the roof lights, or a harness attached to a work positioning line which is fixed to the staging, provides protection should a fall occur. 15

Do not throw materials such as old slates, tiles etc from the roof or scaffold - someone may be passing by.

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Refer to Section 11 – Part 2 (SAMAS) – 2.2 (2.2.9)

1.3.9.2 Industrial roof work Industrial roof work involves all the hazards already mentioned and in addition, falls from the 'leading edge' also need to be prevented. Leading edges are created as new roof sheets are laid or old ones are removed. Fragile and lightweight materials, such as liner trays which will buckle and give way under the weight of a person, can also be a problem and should be protected.

2

Work at the leading edge requires careful planning to develop a safe system of work, including measures to mitigate the distance and consequences of a fall. Work platforms or staging used in conjunction with nets is the preferred method, as nets provide protection to everyone on the roof. Nets should only be installed by trained and competent net riggers.

3

If this is not practicable, work platforms or staging (fitted with guard rails and toe boards) in advance of the leading edge can provide protection in some circumstances. However, these will need to be used in conjunction with harnesses attached to a work positioning line which is fixed to the work platform. If a harness is used, you must ensure that workers can attach themselves to the anchorage without putting themselves at risk of a fall. Using the harness in work-restraint mode is the preferred option, as this does not allow the operative to approach the leading edge and enter into a fall position. Close supervision of this system of work will be required as it is difficult for harnesses to remain clipped on at all times throughout the work activity.

4

When developing a safe system of work the Contractor needs to consider the following: how the first sheets will be laid - a separate platform may be required (a pack of roof sheets is not a safe working platform) - and how hip ends and other special details are to be fitted.

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how sheets will be raised to roof level - decide what type of lifting machinery, such as a crane or an inclined hoist, will be the preferred method. This will eliminate unnecessary risks when placing packs of sheets on the roof supports or when breaking open packs spread over the roof supports.

1.3.9.3 Roof truss installation 1

When installing roof trusses, their placement and associated bracing is a hazardous activity, which requires careful planning to ensure a safe system of access and protection against falls is implemented. You must provide a safe working platform around the perimeter of the roof together with measures to mitigate the distance and consequences of a fall should one occur. This can be achieved by providing a working platform or 'crash deck' immediately beneath the bottom members of trusses. Either conventional scaffolding or (if appropriate) proprietary plastic decking systems can be used for this. Alternatively, nets can be used providing a safe clearance distance can be achieved below the net and a suitable fixing point is available. Providing nets or soft landing systems is particularly important when installing temporary bracing or before boarding out along the bottom chord of the trusses, where access within them is required.

END OF DOCUMENT

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Section 11: Health and Safety Page 1 Part 1.04: Safe Use of Plant Equipment (Regulatory Document)

REGULATORY DOCUMENT ............................................................................... 1

1.4 SAFE USE OF PLANT EQUIPMENT ................................................................... 1 Abrasive Wheels .............................................................................................. 4

1.4.2

Portable Fixing Tools ..................................................................................... 16

1.4.3

Lifting Operations, Equipment and Accessories ............................................ 29

1.4.4

Mobile Elevating Work Platforms ................................................................... 69

1.4.5

Hoists and Hoist Towers ................................................................................ 86

1.4.6

Plant and Work Equipment .......................................................................... 100

1.4.7

Woodworking Machines ............................................................................... 120

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FORWARD

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This Section of the Regulatory Document (RD) was produced as a project deliverable under Ministry of Municipality and Urban Planning Contract Number P2009/3, entitled “Consultancy Services for the Preparation of Codes and Standards for Safety and Accident Prevention on Construction Sites”. During the latter stages of the project, the Committee responsible for the administration of the project decided that the RD and the associated Safety and Accident Prevention Management/Administration Systems (SAMAS) would be best delivered to stakeholders via the portal provided by the Qatar Construction Standards (QCS). The QCS includes references and certain sections which address occupational health and safety. To ensure that that users of the RD/SAMAS are fully aware of the where occupational health and safety issues are addressed in the QCS, the following table summarises where potential overlaps may occur. For consistency, it is recommended that in matters relating to occupational health and safety reference is made first to the RD/SAMAS. For the purpose of clarity, however, references are made in the relevant section of the RD/SAMAS to their comparable sections in the QCS and vice versa.

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Sr. No

QCS 2014 Section No.

Part No.

Part Name

1

1

7

Submittals

8

7.5.2

Health and Safety Organization Chart

2

1

7

Submittals

9

7.6.1

Health and Safety Plan

3

1

10

Health and Safety

All

All

All

4

1

11

Engineer's Site Facilities

10

11.4.6

Safety Equipment and Clothing

5

1

14

Temporary Works and Equipment

3

14.4

Test Certificates for Cranes and Lifting Tackle

6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

Safety and Management

10

4

1

General Requirements for Piling Work

7

1.6

Safety

11

4

4

Deep Foundations

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4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

4&5

1.6

Temporary Fencing

14

6

7

Asphalt Plants

15

7.8.13

Safety Requirements

15

6

14

Works in Relation to Services

4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

Painting and Protective Coatings

6

8.1.9

Safety

Trenchless Pipeline Construction

7

9.2.5

Safety Requirements

Pipeline Cleaning and Inspection Survey

4,5&6

10.1.7

Safety Requirements

11

Sewer Rehabilitation

9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

8

8

18

8

9

19

8

10

20

8

21

9

42

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Item Name

4.9.1.13 Protection of Testing Equipment

22

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37 & 38

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Page No. Item No.

9

1

General

19

1.2.16

Noise Levels and Vibration

23

19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1

General Provisions for electrical Installation

7&8

1.1.11

Fire and Safety Precautions

25

21

1

General Provisions for electrical Installation

14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5

Fire Resistance Period

28

29

3

Geotechnical Specifications

4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4

Safety Measures and Systems

32

29

7

Concrete Structures

6

7.1.10

Safety Railing

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Construction Site Safety 1.4.1

Abrasive Wheels

1.4.1.1 Key Points Abrasive wheel machines of all types have the potential to cause severe injury if they are not used with care.

2

Anyone who uses an abrasive wheel machine must be trained and competent to do so.

3

The potential for danger arises not so much from the machine itself but from the grinding wheel or cutting-off disc used with the machine.

4

Many accidents are caused by the abrasive wheel being rotated faster than it was designed to go, which results in it breaking up ('bursting') at high speed.

5

It is essential to check the compatibility of the abrasive wheel or cutting-off disc with the machine to which it is about to be fitted.

6

The fitting of any abrasive wheel or cutting-off disc to a machine ('mounting') must only be

7

Carried out by someone who is trained and competent to do so.

8

The person who is trained and competent to mount abrasive wheels or cutting-off discs need not be the same person who is competent to operate the machines.

9

Using an abrasive wheel machine has the potential to cause occupational health problems and usually the wearing of appropriate PPE will be required.

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1.4.1.2 Introduction

Abrasive wheels are potentially dangerous if not used correctly. Most accidents result from selecting the wrong type of wheel or from over-speeding. It is essential that the right abrasive wheel for the job is chosen; that it is correctly mounted by a competent person; that it is run at the correct speed and that guards and eye protection are used.

2

In most circumstances abrasive wheels rotate at very high speeds and contact with the revolving wheel can cause serious injury. When using a grinding wheel, a stream of hot abrasive particles is thrown off, which can cause injury, particularly to the eyes. Finally, there is always a risk of the wheel disintegrating or 'bursting' as it revolves. Fragments of the wheel can be projected a great distance, at high velocity, in every direction.

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1.4.1.3 Types of abrasive wheel An abrasive wheel is generally defined as a wheel, cylinder, disc or point having abrasive particles, and intended to be power driven. It may consist entirely of abrasive particles, or be of metal, wood, cloth, felt, rubber or paper, with a surface covered with abrasive material. It may also be formed of a ring or segments of abrasive materials. These types of abrasive wheels are used for shaping material via grinding operations.

2

Other types of abrasive wheel are those used for cutting rather than grinding operations. These are circular metal blades, usually with diamond impregnated tips, used for cutting through concrete, steel, etc.

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1.4.1.4 The Management of Health and Safety at Work 1

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or other people might encounter as a result of the work being carried out.

2

When hazards are identified, it is the Contractors duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as it is reasonably practicable to do so.

3

The Contractor must provide employees with: (a)

comprehensible and relevant information on any risks that exist out of the work activity

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(b) 4

adequate training to enable employees to work safely.

The employee, in turn, has a duty under these Regulations to tell their Contractor of any work situation which presents a risk to their health and safety or to the health and safety of any other person who may be affected.

1.4.1.5 Personal Protective Equipment high-impact eye protection (possibly a full-face visor) to BS EN 166

(b)

hearing protection

(c)

possibly hand/forearm protection, depending upon the material that is being cut

(d)

possibly respiratory protection,

(e)

depending upon what is being cut and whether the machine is fitted with a particle collection/extraction system.

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Where risks to health and safety cannot be adequately controlled by other means, Contractors must: (a)

identify appropriate and suitable PPE that will control the risks to an acceptable level

(b)

provide the PPE free of charge to those who are at risk

(c)

provide the users of the PPE with adequate instruction and training with regard to:

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PPE will include some or all of:

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(ii) the purpose for which it has been issued and the manner in which it is to be used (iii) maintaining the PPE in good working order. The Contractor must take all reasonable steps to ensure that employees use the PPE provided as directed.

4

Employees for their part must: use any PPE that has been issued as instructed and in accordance with any training received

(b)

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report any loss or defect in the PPE to the Contractor.

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(c)

return the PPE to any storage area that has been assigned to it, after use

1.4.1.6 Control of Vibration 1

The use of most types of abrasive wheel machine will involve the user either holding the material to be worked or the machine itself whilst the work activity is carried out. This has the potential of subjecting the person doing the job to hand/arm vibration.

2

These Regulations place various requirements on Contractors including: (a)

establishing if there is a risk from exposure to vibration

(b)

eliminating the risk at source or reducing it to as low as is reasonably practicable

(c)

implementing appropriate control measures if the exposure action value is reached

(d)

taking appropriate actions if the exposure limit value is reached

(e)

providing health surveillance to any employee when the risk assessment indicates that there is a risk to health

(f)

providing at-risk employees with adequate information, instruction and training.

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1.4.1.7 Choosing the correct wheel 1

BS 4481 Part 2:1983 includes a system of marking for abrasive wheels, which has been adopted by the UK Abrasives Industries Federation. This specifies the type and nature of the abrasive, grain size, grade and structure, as well as the nature of the bond.

2

Many types and grades of abrasive wheel are available, and the correct selection is important. As a general rule, soft grade wheels are most suitable for use on hard materials, and hard grade wheels on soft materials. Coarse grains are for the rapid removal of material, and fine grains for polishing.

3

The two common British markings in this class are: (a)

A.30.R.BF Suitable for general use on ferrous metals.

(b)

C.24.R.BF Suitable for general use on stone, brickwork, concrete, plastic and nonferrous metals.

The use of an unsuitable wheel may result in the wheel face becoming loaded as the pores are clogged by the material being removed. If the wheel is too hard or too fine it may become glazed or polished. The consequence, in both cases, may be that the operative will press too hard, in an attempt to get the work done, and cause the wheel to break.

5

It is important that only reinforced resin-bonded abrasive wheels should be used with portable grinding machines.

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British Standard system for the marking of abrasive wheels (BS 4481)

* Optional symbols The symbols 0 and 6 are the manufacturer's own

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1.4.1.8 Wheels 'bursting' 1

The two main causes of abrasive wheels bursting are: (a)

over-speeding

(b)

the incorrect mounting of wheels.

1.4.1.9 Over-speeding Abrasive wheels must not be run in excess of the maximum permissible speed recommended by the manufacturer. This should be clearly marked in rpm on all wheels over 55 mm in diameter.

2

For smaller wheels, a notice stating the maximum speed permissible should be displayed on or adjacent to where the machine is being operated. Any type of record may be kept, from computer database to a written record. The only restrictions are that a hard copy of the information must be available on request.

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1.4.1.10 Speed of spindle

Every power-driven machine for use with abrasive wheels should have a notice fixed to it, specifying the maximum and minimum spindle speeds.

2

Machines that are not marked with their spindle speed must not be used.

3

Sometimes these markings are very small. If this is the case, consideration should be given to painting or engraving the spindle speed clearly on the machine.

4

Always keep the markings clean and in good condition so that they are easy to read.

5

Care must be taken to see that the maximum speeds are never exceeded. Governors, or other devices to control or limit speed, must be properly maintained and in good working order.

6

The speeds of wheels may be checked using stroboscopic timing lights.

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1.4.1.11 Peripheral speeds

As an abrasive wheel wears down, its peripheral speed is reduced and this, in turn, reduces its efficiency.

2

A wheel operated at too low a speed will not cut properly and there will be a tendency to press the workpiece hard against the wheel. This may damage the wheel and cause it to burst.

3

Care must be taken to operate the wheel at the optimum speed recommended by the manufacturer.

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1.4.1.12 Mounting of wheels 1

In order to be able to demonstrate compliance with legislation, abrasive wheels should only be mounted by a trained and competent person appointed to this duty by the Contractor.

1.4.1.13 Maintenance 1

In addition to checks immediately before and after each use, every machine should be regularly and frequently serviced by a competent person in accordance with the

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manufacturer's instructions. A record of this maintenance should be kept. 2

It is good practice to record the type and serial number of all abrasive wheel machines in a maintenance log, together with the date each machine is due for service. When servicing has been carried out, ensure that details of any work done are entered in the log, together with the date that the next service is due.

3

All records should be kept up to date.

1.4.1.14 Appointment of a competent person It is strongly recommended that each appointment to mount abrasive wheels is recorded as a signed, dated entry in a register or by a certificate attached to that register. Records may be kept in an electronic format, providing a hard copy can be printed on request. Particulars of the class and description of the abrasive wheels for which the person is competent should be stated. A copy of the entry (or certificate) should be given to the person appointed.

2

Note: The suggested layout for a Register of Appointment is attached at Appendix 1. A copy of a suggested Certificate of Appointment is attached as Appendix 2.

3

A Contractor may revoke the appointment at any time, with a signed and dated entry in the register.

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1.4.1.15 Training

Training for the mounting of abrasive wheels must only be given by a competent person, which often involves attending an external course. It must cover the grades, types and marking of wheels; the use, hazards, speeds, storage, handling, inspection, testing, dressing, adjustments; and the functions of associated components such as flanges, blotters, bushes and locking nuts.

2

Employees who are being trained in the use of abrasive wheels must be provided with appropriate information, instruction and supervision.

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1.4.1.16 Mounting the wheel

The following procedure should be followed when mounting an abrasive wheel:

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Procedure

(a)

ensure the power to the tool is 'OFF'

(b)

clean the abrasive wheel with a brush and check for any signs of damage. In no circumstances should a damaged wheel be used

(c)

check that the spindle bearing is not worn

(d)

check that the maximum wheel speed is greater than the maximum spindle speed

(e)

check that the wheel fits easily and snugly onto the spindle. The correct brushes should be used if required

(f)

check that straight-sided wheels are mounted between the flanges, with a diameter of not less than one-third that of the wheel. The flanges should be recessed on the side which is next to the wheel, to ensure that the clamping pressure is not exerted near to the hole

(g)

ensure that the driving flange is secured to the spindle

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(h)

check that washers or blotters of paper, or other compressible material, are fitted one either side (one only on a wheel with a depressed centre). Blotters ensure that the clamping pressure is distributed evenly over the wheel, and will reduce wear on the flanges

(i)

when tightening the nut on the spindle, use the correct size of spanner. Use hand pressure only. This will ensure that the flanges drive the wheel and prevent slip

(j)

use only the correct locking nuts.

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1.4.1.17 Diamond blades

As with bonded abrasive wheels, people working with diamond blades must be properly trained and competent. Most of the safe procedures and precautions for using bonded abrasive wheels on hand-held machines apply to diamond blades. Additional advice and information can be obtained from the suppliers and manufacturers.

2

Diamond blades are directional and must be mounted so that they rotate in the direction marked on the blade.

3

Diamond blades can be used on hand-held machines at peripheral speeds of up to 100 m/s, provided that the machine is designed for this speed and the marked maximum permissible operating speed of the blade is not exceeded.

4

Under no circumstances must the blade be allowed to overheat.

5

Periodically, it may be necessary to redress the blade by making cuts in a special dressing block or abrasive block.

6

These wheels can last a comparatively long time. Before use and with the power disconnected, make a special point of checking the condition of the spindle bearings as these can deteriorate considerably during the lifetime of a diamond-cutting wheel.

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1.4.1.18 In-use considerations Guards - fixed and hand-held machines 1

The guard should be so designed, and sufficiently robust, to contain any fragments in the event of the wheel bursting.

2

The guard must be securely attached to the body of the machine, properly adjusted and maintained.

3

The guard or shield supplied by the manufacturer must be adjusted to permit exposure of the minimum amount of wheel or disk to enable the job to be carried out. It must not be left off or altered in any way.

Employees are required to report any defects in work equipment, including abrasive wheels, guards or tool rests, to their Contractor.

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Rests should be secured and adjusted so that they are as close as practicable to the wheel, i.e. no more than 3 mm away. If the gap between the wheel and the rest is too great, the workpiece may become trapped and an accident may result.

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It is good practice to continue to display cautionary notices concerning the dangers of abrasive wheels, wherever abrasive wheels are used or changed.

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1.4.1.19 Health considerations Protection of eyes 1

During cutting or grinding processes, a stream of dust or abrasive particles and hot sparks is thrown off. These can cause serious injury to the eyes.

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Because there is an obvious risk of eye injuries when an abrasive wheel is being used, eye protection should be provided in accordance with either goggles or a face shield or visor, to BS EN 166.

Respiratory protection 3

Depending upon what material is being cut, it is possible that the user of an abrasive wheel may be vulnerable to inhaling hazardous dust. With fixed machinery such as bench grinders or fixed concrete saws, it may be possible to reduce airborne dust to a safe level by such measures as: (a)

4

installing a fixed local exhaust ventilation system, for example in workshops

This would also serve as a useful reminder to employees of the training they have received. purchasing abrasive wheel machines which incorporate a facility for wet cutting or the attachment of a stand-alone dust extraction/collection unit

If such dust suppression measures are not practical, it will be for the Contractor, or the person to whom the responsibility is delegated, to assess the hazardous nature of the dust and provide suitable respiratory protective equipment (RPE), consulting a supplier of PPE if necessary to establish what is needed

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(a)

The very nature of carrying out grinding or cutting activities using abrasive wheels is likely to subject the person doing the job to a degree of hand-arm vibration. In extreme cases, handarm vibration can lead to permanent and disabling injuries. Contractors must assess the risk to employees who carry out such work and put preventative and protective measures in place to ensure that the health of employees who carry out this type of work is not adversely affected.

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Vibration

Grinding and cutting operations using abrasive wheel machines will inevitably result in an increased level of noise, both from the machine itself, for example a petrol-driven disc-cutter, and from contact between the cutting disc or grinding wheel and the material being worked upon. In many cases the level of noise generated will exceed the lower exposure action value, meaning that unless other control measures can be put in place, personal hearing protection must be made available and worn. Depending upon the level of noise and the proximity of other people, it may be necessary for them also to wear the hearing protection.

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1.4.1.20 Other safety considerations 1

The machine must have an efficient starting and stopping device that is easily accessible and which can be readily operated.

2

The floor area of the workplace must be kept in good condition, free of loose material, and should not be slippery.

3

Abrasive wheels should be properly stored, flat and preferably in their boxes and in accordance with the manufacturer's guidance. Care must be taken to see that any labels are retained, and not soiled or defaced so as to make them illegible.

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Construction Site Safety 1.4.1 Appendix 1 Specimen Sheet for a Register of Appointment Appointment of persons to mount abrasive wheels

Revocation

Date of revocation of appointment

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Signature of occupier or his agent

Signature of occupier or his agent

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Class or Date of description of appointment abrasive wheels for which appointment is made

(2)

(3)

(4)

(5)

(6)

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Name of person appointed

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Appointment

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Construction Site Safety 1.4.1 Appendix 2 Abrasive Wheels Certificate of Appointment to mount abrasive wheels Name Is hereby appointed to mount the following classes or descriptions of abrasive wheels _________________________________________________________________________________

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Signature of occupier or occupier's agent:

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Signature of occupier or occupier's agent:

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Date .............................................

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Construction Site Safety 1.4.1 Appendix 3 Abrasive wheels Safety checklist Who is responsible for the selection and the supervision of equipment using abrasive wheels; are they competent?

2

Have operatives received suitable instruction and training in the use of abrasive wheels equipment, and are they competent to use it?

3

Are the manufacturer's recommendations and company rules relating to the control and use of abrasive wheels being observed?

4

Are safety signs and notices displayed where cutting or grinding operations take place?

5

Are the abrasive wheels that are being used suitable for the type of work being carried out?

6

Have all abrasive wheels been mounted by a competent person?

7

Was the competent person appointed by the Contractor in writing, and has an entry been made in an appropriate register?

8

What types and classes of abrasive wheel or disc is the appointed person entitled to fit and mount?

9

Have two blotters been supplied with all flat wheels and discs? (Some wheels may not require blotters, therefore refer to the manufacturer's guidance for the specific wheel to be mounted.)

10

Are wheels of more than 55 mm in diameter marked with the maximum rotational speeds in rpm?

11

Are smaller wheels accompanied by details of their maximum rotational speed?

12

Is the maximum permissible spindle speed clearly marked on the machines in rpm?

13

Are checks made to ensure that abrasive wheels are not operated in excess of the maximum permissible speeds?

14

Are the correct flanges being used?

15

Is the guard fitted compatible with the machine?

16

Is the guard of the correct size, and not been exchanged or altered?

17

Are only reinforced discs used on portable hand-held machines?

18

Are the correct locking nuts used?

19

Are grinding machines complete with guards of the correct size and with tool rests?

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20 21

Angle grinder with cutting disc and adjustable guard and depth gauge

22

Are guards and tool rests correctly adjusted and secured?

23

Are machines properly maintained?

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Is local exhaust ventilation required and, if so, is it available?

25

Are other dust suppression measures necessary and, if so, have they been taken?

26

What facilities exist to have the spindle or wheel speed checked?

27

Has BS EN 166 eye and other necessary PPE protection been provided for the operator?

28

Is the PPE properly used?

29

Is RPE necessary and, if so, is it provided and used?

30

Have precautions been taken to safeguard other persons who may be affected by grinding operations?

31

What precautions are taken to ensure that the floor area is free from loose materials and maintained in a safe condition without risk?

32

Are the storage facilities for abrasive wheels and machines adequate?

33

To whom should operatives report defects?

34

Are all defects reported to the proper person?

35

What action is taken when defects are reported?

36

Has the problem of noise been considered?

37

Is a noise assessment necessary?

38

Are persons who are being trained, properly supervised?

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Construction Site Safety 1.4.2

Portable Fixing Tools

1.4.2.1 Key points Portable fixing tools are used to drive fixing devices into a base material using either cartridges or a gas canister providing the propellant.

2

They can be extremely dangerous if used incorrectly. Operatives must be trained and competent and be of a sufficiently mature and responsible disposition.

3

Poor technique, or the use of incorrect equipment, will result in poor or defective fixing.

4

The tool, type of cartridge or fuel cell, type of fixing and the base material must all be compatible.

5

In most cases, items of additional PPE, in addition to helmet, boots and hi-viz, will have to be worn.

6

At the end of the job all unused cartridges must be accounted for.

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1.4.2.2 Introduction

Portable fixing tools use the power of an explosive charge or a gas propellant to drive a fixing device into position. They are particularly useful if there is a large number of repetitive fixings to be made, where a portable fixing tool reduces the time and labour expended in this area. However, the resemblance of the tools to the shape and action of a gun can lead to their misuse, especially by young and inexperienced workers.

2

It should always be remembered that portable fixing tools are potentially lethal if they are used recklessly or incompetently.

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1.4.2.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or other people might encounter as a result of the work being carried out.

2

When hazards are identified, it is the Contractors duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

4

These Regulations also require that the Contractor provides employees with adequate information, instruction, training and supervision to be able to carry out any work safely and without risk to their health.

5

Employees, for their part, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any others who may be affected.

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1.4.2.4 The Provision and Use of Work Equipment These Regulations require that the Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

2

Contractors must ensure that where the safety of work equipment depends upon the way it is installed, it is inspected as necessary.

3

These Regulations require that where the use of any equipment involves a specific risk to the health and safety of employees, use must be restricted to competent and specified workers. This is of particular relevance to the user of portable fixing tools.

4

Employees must be provided with information, instruction and training in the use of work equipment, where necessary for their health and safety.

5

Proper training (which is offered by all tool manufacturers) and continual care in their issue and use is therefore essential.

6

Before portable fixing tools can be used, a risk assessment must be carried out.

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1.4.2.5 The Control of Vibration at Work

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The use of any percussive tool, such as one repeatedly operated by firing a cartridge or fuel cell, has the potential to subject the person doing the job to hand/arm vibration.

2

These Regulations place various requirements on Contractors including:

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establishing if there is a risk from exposure to vibration

(b)

eliminating the risk at source or reducing it to be as low as is reasonably practicable

(c)

implementing appropriate control measures if the exposure action value is reached

(d)

taking appropriate actions if the exposure limit value is reached

(e)

providing health surveillance to any employee when the risk assessment indicates that there is a risk to health

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(a)

providing at-risk employees with adequate information, instruction and training.

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1.4.2.6 Personal Protective Equipment 1

2

PPE will be needed including: (a)

high-impact eye protection (possibly a full-face visor) to BS EN 166-B

(b)

hearing protection.

Where risks to health and safety cannot be adequately controlled by other means, Contractors must: (a)

identify appropriate and suitable PPE that will control the risks to an acceptable level

(b)

provide the PPE free of charge to those who are at risk

(c)

provide the users of the PPE with adequate instruction and training with regard to: (i)

the risks that the PPE will protect against

(ii)

the purpose for which it has been issued and the manner in which it is to be used

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The Contractor must take all reasonable steps to ensure that employees use the PPE provided as directed.

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maintaining the PPE in good working order.

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Employees for their part must: (a)

use any PPE that has been issued as instructed and in accordance with any training received

(b)

return the PPE to any storage area that has been assigned to it, after use

(c)

report any loss or defect in the PPE to the Contractor.

1.4.2.7 The safe use of cartridge-operated tools

adequate information, instruction, training and supervision

(b)

competent and responsible users

(c)

the compatibility of the base material, the type of fixing and the cartridge strength

(d)

restricting access to the work area during fixing activities

(e)

the provision and use of appropriate PPE

(f)

carrying out activities in accordance with BS 4078-1, Code of practice for safe use

(g)

using cartridge-operated tools that comply with BS 4078-2.

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(a)

Note: Cartridge tools must not be used in areas where a flammable atmosphere or risk of dust explosion may exist.

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A cartridge-operated tool works by using a firing cap or cartridge to provide propellant to drive a fixing home. The primary factors which will ensure the proper and safe use of cartridge tools are:

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1.4.2.8 Types of tool 3

There are two main types of cartridge-operated tool. (a)

Indirect-acting. The driving force is transmitted to the fixing by means of the expanding explosive gas acting on a piston.

(b)

Direct-acting. The explosive force of the cartridge acts directly on the fixing, driving it along the barrel into the wall or material.

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1.4.2.9 Power level of tools Cartridge tools are generally classed as high power and low power.

2

Low power is defined as giving the pin a kinetic energy not greater than 3.5 m/kg/f and a velocity not greater than 98.5 m per sec.

3

High power applies to any values greater than those above. Using high power tools can result in dangerous through-shoots. This is where the fixing is fired right through the material.

4

Most of the commonly available tools are low power and indirect-acting. These are by far the safest. There are high power tools for special applications, and some old high power (directacting) tools are still in use.

5

Hammer-activated tools are nearly always low power.

6

Some modern tools have provision for varying the power level (within the low power range) by means of an adjustment which changes the size of the gas expansion chamber. There are also interchangeable pistons for different fixings or depths of penetration. Tools incorporating these features require a smaller range of cartridges.

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1.4.2.10 Safety devices

All tools should incorporate a contact pressure safety device, which prevents them being fired unless the muzzle is pressed hard against the workface. They should always incorporate a drop-firing safety device which prevents the tool from firing when it is dropped onto a hard surface.

2

In addition, some tools are equipped with an unintentional firing safety device. This prevents the tool from firing if the trigger is pulled before the tool is pressed against the work surface.

3

It should only be possible to fire the tool when it is correctly pressed against the work surface.

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1.4.2.11 Cartridges

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Cartridges are designed for specific brands or types of tool and are not interchangeable, even if they are of a similar type or appearance.

2

Cartridges are available in different strengths. It is preferable to start with a lower strength cartridge for a test fixing and then change to a more powerful cartridge if the depth of penetration is not sufficient.

3

BS 4078 requires the strength of the cartridges to be marked on the packaging and each cartridge to be colour-coded to indicate its strength.

4

The colour codes set out in BS 4078 are as follows:

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Cartridge strength Extra Low (XL) Low (L) Low/Medium (LM) Medium (M) Medium/High (MH) High (H) Extra High (XH)

Colour Brown Green Yellow Blue Red White Black

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5

It should be noted that the code is not universally followed, and that colour-coding alone must never be relied on as an indicator of the cartridge strength. Cartridges should be retained in the packaging (which identifies their strength) and not carried loose. Both cartridges and fixing nails are now available on plastic strips.

6

Proper controls must be put in place to account for all dispensed and unused cartridges.

7

Unused, or unserviceable cartridges which cannot be fired, are hazardous and in no circumstances should be exposed to fire or heat or be subject to mechanical impact.

8

The supplier should be contacted to discuss suitable arrangements for the return/disposal of any unused or unserviceable cartridges. Cartridges should be returned to their original packaging so that they can be properly identified.

.

1.4.2.12 Fixings

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Fixings are generally either drive nails, eyelet nails or threaded studs. Designed to penetrate wood, steel and concrete, they have special characteristics of strength, hardness, shape and size which make them suitable for the purpose to which they are to be put. Ordinary nails and screws must never be used as substitutes.

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Attempting to fix into unsuitable materials with cartridge tools is dangerous. Before firing the first fixing, a simple test should be made by driving a fixing of the intended type into the base material with a hammer. The result will show whether the material is suitable. No attempt should be made to fix into unsuitable materials. The table below provides general guidance.

Conclusion

Plaster, plywood, lightweight blocks

Sinks in easily

Too soft

Marble, some rock, hardened steel, weld metal

Fixing blunted

Too hard

Glass, glazed tiles, slates, some cast-iron

Material cracks or shatters

Too brittle

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1.4.2.13 Suitability of base materials

Sound wood, concrete, Clear impression of mild steel fastener point

Suitable

1.4.2.14 Hazards in use 1

Hazards from the use of cartridge tools generally arise from one or more of the following three factors: (a)

lack of competence, knowledge or training

(b)

misuse, whether this be deliberate or due to ignorance of proper use

(c)

poor maintenance, rendering the equipment defective or unsafe.

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Two conditions which specially need to be guarded against are through penetration, where the fixing goes through the material emerging in free flight on the other side, and ricochet, possibly towards the operator, where the fixing is deflected after firing.

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1.4.2.15 Causes of through penetration: cartridge too undertaken

powerful

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2

fixing into voids in the structure

3

the material being fixed into is too thin

4

changes in the type or consistency of the material being penetrated

5

not establishing the density of the material being fixed into.

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Penetration due to a change in the type of material

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To avoid these hazards:

check the suitability of the material for cartridge-fired fixing

7

if necessary, make a trial fixing using a low-powered cartridge

8

check the area behind the material or structure into which the fixing is being fired, and guard the area so as to prevent the access of unauthorised persons

9

use an indirect acting tool.

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1.4.2.16 Causes of ricochet:

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firing into a hole of a previously attempted fixing

2

attempting to fix into excessively hard materials, such as hardened steel or welded areas

3

cartridge tools not held square onto the work surface, causing the pin to strike at an angle and then be deflected

4

attempting to fix too near to an edge

5

hitting a reinforcing rod or dense aggregate hidden just under the surface

6

ricochet due to firing too near to edge

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To avoid ricochets: (a)

fixings should be at the recommended distance (or greater) from failed attempts

(b)

do not fix into unfamiliar materials without first checking their suitability for cartridge fixing

(c)

tools should be at right angles to the work surface. The whole rim of the splinter guard should be firmly placed against the workface so as to stabilise the tool and not leave gaps. (See diagrams below.)

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The risk of ricocheting is reduced by the use of low-powered, indirect-acting tools. If highpowered tools are used, there is a risk that the fixing can be deflected and come back towards the operator.

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1.4.2.17 Fixing into concrete

The advice of cartridge tool manufacturers should be sought before attempting to fix into concrete which is over two years old or any other special type of concrete.

2

Depth of material. Generally, concrete should be at least 100 mm thick or three times the depth of the fixing penetration, to avoid fixings breaking through the back surface.

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Fixing breaking through

Penetration. Concrete varies in hardness, and trial fixings may be necessary to establish the optimum penetration.

4

Spading in concrete is caused by the initial compressive impact of the tool and results in a crater being formed around the fixing. It may be due to the fixing being too large or through using a cartridge that is too powerful. Spalling can reduce holding strength of the fixing by up to 20%.

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Spalling of concrete

5

Edge failure is the result of attempting to fix too near to the edge of the material, causing it to break away. The minimum distances given below should be observed.

6

Fixing distances. Always leave at least 75 mm between the edge of the material and the nearest fixing, or from a failed attempt.

Minimum distances between fixings into concrete

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Fixing into masonry requires greater penetration. Fixings should not be made into mortar joints unless no other choice exists, and then only after seeking advice from the cartridge tool manufacturer.

1.4.2.18 Fixing into steel 1

Fixing distances. The minimum fixing distances are 12 mm from an edge of the material being fixed into and 25 mm from any other fixing or failed fixing, or 2.5 times the fixing shank diameter from an edge and 6 times the shank diameter from another fixing respectively (where this is greater than the distance detailed above).

The shank diameter of a fixing should always be less than the thickness of the steel being fired into.

1.4.2.19 General precautions

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Penetration. For maximum holding strength, fixings (whenever possible) should penetrate just through the steel being fixed into.

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Minimum distance between fixings into steel

Recoil of a cartridge tool can lead to loss of balance if working from an unstable workplace. In this instance, only low-power tools should be used. Operators not familiar with cartridge tools, or with the type of tool to be used, should test the tool for recoil before use. In all circumstances, an adequate and safe footing is a necessity. Makeshift platforms should not be used.

2

Misfires. In the event of a misfire, the cartridge tool should be kept pressed in position against the workface for at least 30 seconds, to allow for any delayed detonation. Following this time period, the cartridge must then be removed strictly in accordance with the manufacturer's instructions. Cartridges which have misfired should be stored in a metal box and returned to the supplier.

3

Note: Misfired cartridges should not be removed from the tool by levering under the rim. Some types are rim detonated and could be fired by this action. Only the proper extraction tool as supplied by the manufacturer should be used.

4

Loading of tools should be carried out immediately prior to use. Once the tool is loaded, it must never be pointed towards other people or at any part of the operator's body. Unused cartridges must be removed from the tool as soon as possible.

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1.4.2.20 Storage and issue of tools 1

Only responsible and competent persons should supervise and check the acquisition, issue, use, return and

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maintenance of cartridge-operated tools. 2

Cartridge-operated tools and cartridges should be stored in a place which is secure, dry and cool. The issue of such tools and cartridges should be strictly controlled, and licensed if necessary. Storage box

The following points should be clearly noted and understood: (a)

cartridge tools should only be stored in an unloaded state

(b)

different strengths of cartridge should be clearly identified and kept separate

(c)

the use of different makes of equipment on one site should be limited as far as possible

(d)

the manufacturer's instructions on the safe use of the cartridge tool should be available.

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3

Lighter duty gas powered tools can be used for the fixing of timber and other low density materials. These fixing tools are generally lighter in weight and use a battery and fuel cell, either propane or other gas, to act as a propellant rather than a cartridge. The fuel cell, typically a small aerosol canister, is mounted within the tool. The safety issues that need to be considered when using a gas powered tool are:

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1.4.2.21 Gas powered tools

operators must be trained. Usually this can be provided by the supplier of the equipment. Operators must also be in possession of the relevant equipment instructions with which they must be familiar

(b)

the tool and the fuel cells must not be exposed to extremes of heat nor used within a flammable atmosphere

(c)

during use, harmful fumes are expelled and therefore the tool should be used in a well ventilated area

(d)

when firing, the operator must be in a stable position and holding the tool at right angles to the work

(e)

firing must not take place when others are behind the work. As with cartridge tools, through-penetration can occur

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if a malfunction occurs, unlike when using a cartridge tool, the tool can usually be fired again. However, the manufacturer's instruction manual should be consulted

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(g)

because of the mode of operation and speed of use, the tool can become hot (reference should be made to warnings of hot areas on the tool).

1.4.2.22 Personal protective equipment 1

2

Personal protective equipment, complying with the relevant British Standards, should be used by operatives using cartridge-operated and gas-operated tools, as follows: (a)

eye protection to BS EN 166-B must be provided and worn at all times when handling cartridge-operated tools, their cartridges or gas-operated tools

(b)

noise levels will vary with the make of tool but all tools create a high intensity, short duration noise. Suitable hearing protection should be worn

(c)

safety helmets to BS EN 379 should be worn while cartridge tools are in use.

The safety of other persons in the vicinity of where cartridge-operated or gas-operated tools are being used, a factor which should have been covered in the risk assessment, must be considered and all necessary precautions taken.

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1.4.2.23 Selection, training and supervision

operatives should be properly and adequately trained and be competent in the use of the equipment and aware of the hazards which may arise

(b)

they should be tested for colour blindness (cartridge-operated tools only)

(c)

it is recommended that only persons over 18 years of age are allowed to use portable fixing tools

(d)

operatives selected to use these tools should be of a mature and responsible disposition

(e)

adequate close supervision must be provided where necessary, for example when the operator of a portable tool is inexperienced.

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(a)

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Training can usually be sourced from the supplier or manufacturer of the equipment.

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The selection and training of personnel should take the following points into consideration:

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Construction Site Safety 1.4.2 Appendix Portable fixing tools Safety checklist Has a suitable and sufficient risk assessment been carried out?

2

Has adequate information, instruction, training and supervision been provided?

3

Is the activity carried out in accordance with BS 4078-1?

4

Does all cartridge-operated tool equipment comply with BS 4078-2, (BS EN 792 for gaspowered fasteners) including the provision of splinter guards?

5

Are the operatives selected for training in the use of portable fixing tools of a mature and responsible disposition?

6

Who is responsible for the maintenance, issue and return of equipment including any unused cartridges?

7

Are operatives properly trained and aware of hazards associated with portable fixing tools, especially penetration, ricochets, misfiring, and the misuse of tools?

8

Are safe systems of work in operation? Do they cover the above hazards?

9

Are checks made to ensure that procedures are being observed and especially to ensure that loaded tools are not left lying about?

10

Are all cartridges and fuel cells kept in a cool, dry place, under lock and key?

11

Are cartridges clearly marked to indicate their strength?

12

Is the correct PPE available as required and is it being worn correctly?

13

Is the place where the work with fixing tools is being carried out safe for the tool user and for any other people who may be in the vicinity?

14

Is there a need to create an 'exclusion zone' around the work area?

15

Where will cartridge-operated tools and their associated cartridges be securely stored on site?

16

Will fixing tools and their cartridges and fuel cells be stored in accordance with the manufacturer's instructions?

17

Is the tool correct and suitable for the job?

18

Are tools equipped with suitable safety devices?

19

Are operatives fully aware of cartridge colour codes?

20

Are operatives aware of the different types of fixings?

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Construction Site Safety 1.4.3

Lifting Operations, Equipment and Accessories

1.4.3.1 Key points Many accidents occur during lifting operations because they were not properly thought through in advance.

2

All lifting operations must be carried out by, and under the control of, trained and competent persons.

3

The safe working load (SWL) of any item of lifting equipment or lifting accessory must never be exceeded.

4

All equipment and accessories used for lifting operations must be subjected to a schedule of inspections and thorough examinations.

5

In addition to the equipment and accessories used, attention must also be paid to site features such as overhead cables, unstable ground conditions and adjacent properties.

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Section 9, Part 7 of the QCS covers lifting equipment.

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Experience has shown that lifting operations can be hazardous work activities if not properly planned and carried out. Safe lifting operations will depend upon: The availability of suitable lifting equipment, that is properly maintained

(b)

the provision of adequate information, instruction, training or supervision for everyone involved

(c)

thorough pre-planning of each lifting operation

(d)

compliance with safe systems of work as detailed in risk assessments and method statements (lifting plan).

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1.4.3.2 Introduction

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Note: Section 1, Part 14.4 of the QCS covers the certification of lifting equipment and

These Regulations require that safe systems of work are developed, accidents that have occurred during lifting operations indicate that all too often these are not in place or not complied with if they are in place.

3

Unsafe working and accidents result from:

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(a)

a lack of training or knowledge of the equipment

(b)

poor maintenance of the equipment

(c)

the correct (or recommended) plant or equipment not being available

(d)

the misuse of plant and equipment

(e)

insufficient or inaccurate information on the load

(f)

insufficient or inaccurate information on underground hazards, such as buried services

(g)

unstable ground collapsing under the weight of the crane and its load

(h)

failure to take account of adverse weather conditions

(i)

poor slinging of the load

(j)

rushing to get the job done.

Note: BS 7121-1 General gives advice on the safe use of cranes but excludes manually-

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operated cranes and those mounted on waterborne vessels, except where a land-based crane is temporarily fixed to such a vessel. 5

It details safe systems of work and the control of lifting operations, which include site preparation, along with the rigging and de-rigging of cranes.

6

The Code of Practice to BS 7121 also introduces the term 'signaller' in place of 'banksman'. Throughout the following text any reference to a banksman has been replaced with signaller.

1.4.3.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or other persons might encounter as a result of the work being carried out.

2

When hazards are identified, it is then the Contractor's duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

4

Employees, for their part, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other persons who may be affected.

5

The Regulations require that, additionally, the Contractor provides employees with adequate information, instruction, training and supervision to be able to carry out any work safely and without risks to their health.

Before any lift is carried out, a suitable and sufficient risk assessment must be carried out under these Regulations, although where lifting activities are repetitive with broadly the same hazards and levels of risk, a single risk assessment to cover all the lifts might be satisfactory in some situations.

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1.4.3.5 Lifting Operations and Lifting Equipment 1

The main requirements are: (a)

lifting equipment and accessories must be of adequate strength and the lifting equipment stable, for each lift undertaken

(b)

lifting equipment used for lifting persons is constructed and used so as to protect the safety of the person(s) being carried

(c)

lifting equipment must be positioned or installed so as to prevent the lifting equipment or the load striking a person, or the load otherwise becoming out of control

(d)

the load must be under full and proper control at all times

(e)

lifting equipment must be equipped with suitable devices to prevent any person falling down a shaft or hoistway

(f)

lifting equipment and accessories must be clearly marked with their safe working load and other markings if designed for lifting persons

(g)

every lift must be properly planned by a competent person, properly supervised and

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(i)

reports of thorough examination must be made and retained, with all defects notified to the Contractor who must take appropriate actions.

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1.4.3.6 The Provision and Use of Work Equipment All lifting equipment and accessories for lifting are classified as work equipment and must therefore also comply with these Regulations.

2

These Regulations require that Contractors only provide work equipment that is suitable for the job and ensure that it is maintained and kept in good working order.

3

Contractors must ensure that where the safety of work equipment depends upon the way it is installed, it is inspected as necessary.

4

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to competent and specified workers.

5

Dangerous parts of machinery must be adequately guarded, preferably by fixed guards that cannot be defeated or removed.

6

Employees must be provided with information, instruction and training in the use of work equipment, where necessary for their health and safety.

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1.4.3.7 Work at Height

The use of some lifting equipment, for example tower cranes, will inevitably involve employees having to work at height, the legal definition of which includes getting up to the high-level work place and getting down again. Even standing on the tracks of a crawler crane would be classified as working at height if a fall from that place could result in personal injury.

2

The key provisions of these Regulations are (briefly) that Contractors should:

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where it is reasonably practicable, avoid the need to carry out work at height

(b)

where such work cannot be avoided, to select the most appropriate work equipment for the work and to prevent falls

(c)

reduce the distance, and potential consequences, of any fall

(d)

ensure that the work is properly planned, risk-assessment based and carried out safely by competent persons

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equipment used for working at height is appropriately selected and inspected as specified

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(f)

establish danger areas from which people must be excluded, when there is a danger of them falling or being struck by falling objects

(g)

measures are taken to prevent anyone being injured by falling objects.

1.4.3.8 Construction (Design and Management) CDM 1

CDM has implications for the way in which lifting operations are carried out: (a)

designers must ensure the health and safety of anyone engaged in lifting operations, for example by designing-in lifting points on components that will have to be craned into place

(b)

designers must provide sufficient information regarding their designs, such as notifying the weight of any component that has to be craned into place

(c)

there must be safe places of work, including getting to and from the place of work

(d)

traffic routes must be suitable for the vehicles that will have to pass over them, for example, mobile cranes must be used and moved in a way that pedestrians are not

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(e)

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1.4.3.9 Definitions Appointed person: A person who has the competence, adequate training, authority and experience to take overall responsibility and control of a lifting operation, having been appointed by the management of the organisation or organisations that require the load to be moved.

2

Competent person (for the purposes of inspection and examination): A person who has the practical and theoretical knowledge together with actual experience of what they are to examine so as to enable them to detect errors, defects, faults or weaknesses, which it is the purpose of the examination or inspection to discover; and to assess the importance of any such discovery.

3

Crane co-ordinator: A person who plans and directs the sequence of operations of cranes to ensure that they do not collide with other cranes, loads and other equipment (for example, concrete placing booms, telehandlers and piling rigs).

4

Crane supervisor: A person who controls the lifting operation and ensures that it is carried out in accordance with the appointed person's safe system of work.

5

Crane operator: A person who operates the crane for the purpose of moving and positioning loads or erection of the crane.

6

Lifting accessory: A lifting beam or frame, chain sling, rope sling or similar gear, a ring, link, hook, interlocks, plate clamp, shackle, swivel or eyebolt, and any loose equipment used with lifting gear.

7

Lifting equipment: A piece of work equipment for lifting or lowering loads including a crab, winch, pulley block or gin wheel (for raising or lowering), a hoist, crane, shearlegs, excavator, dragline, piling frame, aerial cable way, aerial ropeway or overhead runway, goods hoists, mobile elevated work platforms, scissor lifts, vehicle hoists, ropes used for access, forklift trucks, lorry loaders (hiabs) and passenger lifts.

8

Mobile crane: A crane capable of travelling under its own power, but does not include a crane that travels on a line of rails.

9

Plant and equipment: Any plant, equipment, gear, machinery, apparatus or appliance, or part thereof.

10

Safe working load (SWL): The maximum load that can be safely lifted by any item of lifting equipment, such as a crane or hoist, or any accessory for lifting.

11

Note 1: The safe working load includes the weight of the hook block and all the lifting gear. The weight of these should be deducted from the declared safe working load of the lifting equipment to obtain the net load that can be safely lifted.

12

Thorough examination: An examination by a competent person in such depth and detail as the competent person considers necessary to enable them to determine whether the equipment being examined is safe to continue in use.

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1.4.3.10 Safe systems of work 1

A safe system of work should be devised and effectively communicated to all those involved in a lifting operation. It must include: (a)

thorough planning of the operation, along with the selection, provision and use of suitable cranes and equipment

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(c)

ensuring that all equipment has been maintained, tested and examined as necessary

(d)

operation of all equipment by trained and competent people

(e)

supervision of the lift by trained and competent people, with the authority to progress or stop a job as necessary

(f)

safe slinging of the load by a trained and competent person

(g)

the provision of all test certificates and other documentation relevant to the equipment being used

(h)

the prevention of unauthorised use or movement of equipment, both by workers or members of the public who may be trespassing

(i)

an effective means of communication between all members of the team during lifting operations

(j)

the safety of all persons, both those involved in the lift as well as those not involved in the lift but who may be affected by the lifting operation.

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1.4.3.11 Construction and support

Every crane and item of lifting equipment must be properly made and strong enough to carry out the work for which it is intended.

2

Foundations, stages, scaffolds, derrick masts and anchorages that have to carry a load must be of good construction and adequate strength. All temporary support structures should be certified by a competent temporary works engineer and a 'Permit to Load' issued before any support is loaded.

3

Winch frames must be made of metal. Separate crane jibs must be clearly marked to identify which crane they are part of.

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1.4.3.12 Platforms

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Platforms for crane drivers and signallers must be large enough to allow the person to do their work properly, close boarded or plated and fitted with access ladders or steps.

2

Where a risk assessment indicates that there is a possibility of injury resulting from a person falling from the platform of a crane, suitable guard-rails and toe-boards should be provided to prevent such an occurrence. Guard-rails should be at least 950 mm above the working platform. The gap between the guard-rails and between the lower - guard-rail and toe-board must not exceed 470 mm. Guard-rails and toe-boards may be removed for temporary access.

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1.4.3.13 Cabin 1

Generally speaking, a crane should be provided with a cabin to give the driver protection from the weather. The cabin should afford an unrestricted view of the work in hand and permit access to any machinery contained within the cab, for maintenance, etc. Where practicable, it should be cooled in hot weather and heated in cool weather.

2

Cabins are not required, however, when the plant is indoors or otherwise protected (unless it is mobile) and will not lift more than 1 tonne or where, in the case of a hoist, it can be operated from a landing platform or inside the cage.

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1.4.3.14 Drums and pulleys 1

The size of a drum or pulley must match the size of the rope or chain being used. The rope or chain must be anchored to the drum and there should be never less than two 'dead' turns remaining on the drum.

1.4.3.15 Brakes, controls, etc. Cranes, winches, etc. must be fitted with brakes capable of holding and controlling the maximum load. Controls on all lifting devices must be clearly marked and designed so that they cannot be operated accidentally.

2

Cranes with derricking jibs

3

If the derricking motion of a crane is driven by the hoist motor through a clutch, and can only be controlled by the hoist brake, an interlock must be fitted to prevent dual operation.

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Ladders, platforms or handholds must be provided to give safe access to all parts of the crane or lifting appliance that need inspection or regular maintenance, and from which a person may fall from height.

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1.4.3.16 Access

1.4.3.17 Hired cranes

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Where a crane is hired, the responsibility for ensuring compliance with these Regulations lies with: the hire company to ensure work equipment is maintained, inspected and tested as appropriate, and to provide information to the hirer

(b)

the person hiring the crane to ensure they have selected suitable work equipment and that it complies with all relevant legislation.

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Where the hirer arranges for the crane hire company to carry out a 'contract lift', the crane hire company takes on the total responsibility for all aspects of the safety of the lifting operations.

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The responsibilities for hired and contract lifts are clarified below:

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Hired crane (hired and managed). The employing organisation should:

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(a)

carry out all work in accordance with BS 7121

(b)

supply the appointed person

(c)

plan the lift and operate a safe system of work

(d)

ensure that the crane hired is of a suitable type and capacity

(e)

check the credentials of the crane company and certification supplied.

The crane owner has a duty to: (a)

provide a crane that is properly maintained, tested and certified

(b)

provide a competent driver.

Contract lift (fully contracted). The employing organisation should specify: (a)

that all work is to be undertaken in accordance with BS 7121

(b)

that the lifting contractor is to supply the appointed person

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(c)

what information and/or services will be provided to the lifting contractor by the employing organisation.

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The lifting contractor is responsible for: (a)

supplying the appointed person

(b)

planning the lift, and operation of a safe system of work

(c)

organisation and control of the lifting operation.

1.4.3.18 Siting The site engineer, in consultation with the appointed person, usually decides on the siting of cranes or other lifting appliances. In the case of mobile cranes, the operator is responsible for ensuring that the movement and position of the crane are both safe and suitable under the direction of the crane supervisor and in accordance with the appointed person's safe system of work.

2

The crane operator should check that any ramps, slopes, gates, archways, buildings, trees or overhead lines do not present an obstacle or danger, and that refuelling or other service vehicles can gain access without causing a hazard.

3

A minimum 600 mm-wide clearance between travelling or slewing cranes and any fixed object (guard-rail, adjacent building, etc.) must be maintained. Where this is not practical, any place where a person might be trapped must be blocked by enclosing it with barriers.

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1.4.3.19 Overhead power cables 1

Particular care should be taken when siting cranes or other lifting appliances close to overhead power cables. The jib or boom does not need to touch a live power cable, a 'flashover' can occur over some distance depending on the voltage carried by the overhead cables and the level of moisture in the air.

2

The minimum recommended safe working distance away from overhead cables is the length of the jib of the crane, plus 9 metres if the cable is slung on wooden or metal poles and 15 metres if the cable is slung on pylons. This is measured with the jib pointing towards the cable, even when the crane will be working in the opposite direction.

3

If the minimum safe working distance cannot be maintained, the electricity supply company should be consulted to enable a safe system of work to be devised.

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The 'danger area' must be clearly marked off with stakes, flags, or similar indicators and, where it is necessary to pass below overhead power cables, 'goal posts' should be set up to indicate the maximum clearance height, as specified by the local electricity supply company.

5

Materials, including rubbish, should not be deposited in this area.

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1.4.3.20 Stability

A crane must have a stable and level base. The stability and load-bearing capacity of the ground must be sufficient to carry the most severe static and dynamic loads, taking into account such factors as the slewing torques, wind stresses and shock loading, as well as the weight of the crane and its load.

2

Care must be taken to see that the ground is firm and stable. Excavations which may not have been correctly filled in, as well as cellars, culverts, tunnels and shafts, may all reduce the stability of the ground and constitute a hazard to machinery and heavy loads.

3

It is also important to identify underground services and to carry out any temporary protection measures that may be required. The failure of a water main due to overloading, for example, can dramatically reduce the load bearing capacity of the ground.

4

The same principles apply when a crane is sited on a street or roadway for the purpose of working into a site.

5

Adverse weather, such as rain (producing soft ground) and strong winds, can rapidly affect the stability of a crane, and no crane should be used without these factors first being considered.

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1.4.3.21 Outriggers 1

The majority of mobile cranes are fitted with outriggers to increase the area of the supporting base. Outriggers are effective only if they are deployed correctly.

2

The safe rule is to use outriggers for all lifting duties (except where 'free on wheels' duties are required). ALL the outriggers must be extended

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fully and equally, on both sides. 3

If the stability of the ground is in any way suspect, suitable grillage must be used under each outrigger to reduce the ground area loading.

4

Where operating on a slight slope cannot be avoided, the operating area should be built up to give a level base (see diagram below). A slope of as little as 1 ° can significantly affect the stability and capacity of a crane, particularly where long jibs are in use.

1.4.3.22 Ballast, anchorage, etc. Cranes may need to be anchored to the ground or other foundations, or have counterweights or ballast to prevent them overturning. The anchorage or ballast should be checked each time the crane is erected, and after bad weather.

2

Before a crane is put to work, any new anchorage or ballast must be checked by applying a load 25% greater than the maximum rated load. If this test shows the crane cannot be worked safely with its normal load, it may still be used, if it is sufficiently derated. Such tests may only be carried out by a competent person. A modified loading diagram should then be fixed to the crane where it can be seen by the operator. Other lifting control documentation, such as the lift plan and method statement, should also be modified accordingly. A record of the test should be kept.

No crane or other lifting appliance may be erected unless under the supervision of a competent person, such as the operator or crane supervisor.

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1.4.3.23 Rigging and de-rigging

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The de-rigging of a crane must also be carried out under the supervision of a competent person, normally the crane operator, plus any other persons as recommended by the manufacturer.

3

Care must be taken to see that nobody stands under any jib section while the connecting pins are being withdrawn. People have been killed through doing so.

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1.4.3.24 Rated capacity indicators, etc. 1

Rated capacity indicators (previously known as automatic safe load indicators), radius load indicators and motion limit switches, together with their audio-visual warning systems, are fitted to cranes and other lifting appliances. Their purpose is to prevent any item of lifting equipment from operating outside its safe operating parameters. Under no circumstances should these devices be overridden or disabled.

2

During rigging (including the fitting of jib extensions and changes in reeving) it will be necessary to reset these warning indicators to take account of load conditions and operating radius. They must be tested by a competent person before use.

3

These requirements do not apply to guy derricks, small cranes (less than 1 tonne SWL), any

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hand-operated crane used in crane erection, and some hydraulic cranes. 4

They must be inspected by a competent person on a weekly basis, and inspections recorded.

1.4.3.25 Crane markings All cranes and other lifting appliances must be clearly marked with their maximum safe working load (SWL). If the lifting radius can be varied, an indicator must be fitted which shows the safe load at each operating radius.

2

All cranes or lifting appliances which are designed for lifting persons should be identified as such. Cranes and lifting equipment that are not designed for lifting persons, and might be used in error for this purpose, should also be clearly marked to this effect.

3

All cranes and other lifting appliances must carry clear identification marks.

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Lorry loader cranes must be fitted with an interlocking system (or equivalent engineering solution) to prevent cranes from operating without their stabilisers extended.

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1.4.3.26 Lorry loader cranes - interlocks

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1.4.3.27 Lifting operations

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Control of lifting operations

A person, other than the crane operator, should be appointed to take responsibility for the organisation and control of any lifting operations on behalf of the management.

2

They should be adequately trained and have the necessary experience to be deemed competent. The appointed person should be formally notified in writing of their appointment.

3

The appointed person must:

assess the proposed lift to identify the hazards and corresponding risks, provide for planning, selection of equipment, instruction and supervision to enable the work to be carried out safely ensure that all tests, inspections, examinations and maintenance have been carried out, and that there is a procedure for reporting defects and taking any necessary corrective action

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(c)

ensure that the crane supervisor is fully briefed on the relevant sections of the lift plan and contents of method statements

(d)

have the authority to carry out their duties and to stop the operations if they think there is a danger.

4

The appointed person's duties, but not their responsibilities, may be delegated to another competent person.

5

Drivers of cranes and other lifting appliances, and others involved in lifting operations, including signallers, must be adequately trained, experienced and of a mature disposition. The recommended age is 18 years or over, unless under the direct supervision of a competent person for the purpose of training.

1.4.3.28 Signals 1

If a driver cannot see the load during the whole lifting operation, they must have one or more

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trained signallers or some other signalling system (e.g. radio) to enable them to handle the load safely. 2

Signallers must be in a safe position, have a clear view of the path of the load and have effective communication with the driver. Signals must be clear and distinct. Mechanical or electrical signals should be kept in good order and safeguarded against accidental operation.

3

It is very important that clear and precise words of command are given so that there can be no misunderstandings.

4

A positive decision is needed on the use of words; for example, which word you would use: up or raise or lift or hoist

(b)

similarly,

(c)

lower or down or rest, etc.

The use of hand signals should be equally clear and everyone involved in the lift must be made aware of whether the hand signals specified in: (a)

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BS 7121 Safe use of cranes Part 1 (as shown in Appendix 7).

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1.4.3.29 Restriction on use

A hoisting mechanism should be used for - raising and lowering loads vertically and for no other purpose, unless it is designed to do so, competently supervised and can be done without overstressing the crane structure or mechanism or endangering its stability.

2

Crane jibs must not be worked at a radius greater than that specified on the test certificate.

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1.4.3.30 Safe working load

In no circumstances must the load on the lifting equipment exceed the safe working load (SWL), except when under test by an authorised competent person.

2

When lifting near to the SWL, the load should be raised a short distance only and the operation stopped to check stability and safety before continuing. Wind-loading will affect how near to the SWL a crane can operate. Care must also be taken when planning to lift loads out of water, as the load may suddenly increase beyond the SWL since the support previously given by the water no longer exists.

3

When two cranes or other lifting appliances have to be used for one load, each must work within its safe load, and must remain stable throughout the lift. Multiple lifts of this type must be supervised by a specially appointed competent person (see tandem lifts on the next page).

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1.4.3.31 Loads Slinging loads 1

Many accidents associated with lifting operations are caused by faulty slinging (for example, overloading, use of the wrong type of sling, unbalanced or insecure loads). This results in the load falling or tipping out of control with damage to plant, machinery and to the load.

2

The crane operator will often have to rely on the slinger or signaller, who should be trained, competent and aware of the possible hazards arising from the use of lifting accessories.

3

Loads must be correctly slung and made secure to prevent any part of them slipping and

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falling. The slinging of loads must only be carried out by someone who has been trained and is competent to do so. Many crane accidents feature loads that fall from height because they were not correctly slung.

5

Precautions must be taken to prevent the load striking, or becoming snagged on, any obstacle or causing other items to fall from height.

6

As far as possible, loose materials (bricks, slates, etc.) should ideally be banded and on pallets when being lifted. If not, they should be lifted in a properly constructed box or other container.

7

If loose materials are carried on a hoist, side pieces should be fitted to prevent anything falling. Wheelbarrows and trucks must be prevented from moving and should not be overfilled.

8

Loads should not be suspended or carried over areas occupied by persons. However, where this is not practicable, a safe system of work should be developed to minimise any risks to those below the load.

9

The safe system of work should include, for example, the prevention of access to the danger area below a suspended or moving load, by barriers or other means, ensuring the load is adequately secured and that the operator is in control of the movement at all times.

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Cranes are not designed to pull loads free from their attachment to their surroundings. The additional loading stress cannot be accurately determined and, when a load does break free, the sudden shock can result in damage to the boom or crane machinery, failure of the sling, failure of the wire, whiplash and other dangers.

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Anchored loads

In circumstances where the centre of gravity of a load is not known or where it is known to be off-centre, these factors must be allowed for when planning the lift. An example is the lifting of long columns from the vertical, where the load could become unstable and topple the crane. A written procedure setting out a safe system of work should be prepared to cover such operations.

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1.4.3.32 Tandem lifts 1

Tandem lifts (lifting a load using two or more cranes simultaneously) is a specialist activity. This type of lift must only be planned and supervised by someone who has been trained and is competent in the techniques and calculations involved. The main factors to be considered when planning multiple lifts are the total weight and distribution of the load, its centre of gravity, the weight and capacity of any lifting accessories and synchronisation of the crane motions.

1.4.3.33 Demolition and dismantling work 1

Lifting loads from a place that is significantly above ground level demands the utmost care and, in particular, an accurate assessment of the weight of the load and its point of balance. By the time the load is 'on the hook' it may be too late to call a halt and start again. Loads should be raised about 150 mm and held, while the stability is assessed, before proceeding.

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1.4.3.34 Carriage of persons 1

Some items of lifting equipment, such as MEWPs or suspended cradles, are specifically designed for the lifting of persons and this type of equipment should be used wherever possible.

2

However, it is sometimes necessary to adapt equipment that is primarily designed for lifting materials to lift persons. An example of this is the fitting of a temporary working platform to the forks of a forklift truck. In such circumstances the working platform must:

conform to the requirements of working at height with regard to guard-rails and toeboards

(c)

be securely fixed to the forks so that it cannot become detached or otherwise unstable

(d)

prevent access to otherwise exposed dangerous parts of the forklift truck

(e)

be protected against overhead hazards.

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These Regulations require that all work equipment designed for carrying persons: be constructed to prevent a person using it from being crushed, trapped, or falling from the carrier, either whilst in transit or carrying out work from the carrier

(b)

be equipped with suitable devices to prevent the 'person carrier' falling

(c)

is such that a person trapped in a carrier is not exposed to danger and can be freed.

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Furthermore, if a 'man-riding' cradle suspended from a crane is being used, BS 7172 Part 1 advises that the cradle: (a)

is prevented from spinning or tipping

(b)

is controlled as described in the section on tower cranes.

1.4.3.35 Maintenance

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(a)

Contractors to ensure that work equipment (which includes lifting equipment and accessories) is maintained in an efficient state, in efficient working order and in good repair.

2

Therefore, lifting equipment and accessories for lifting must be properly maintained, although the frequency of maintaining work equipment is not specified.

3

As far as lifting equipment and lifting accessories are concerned, maintenance will normally be carried out in accordance with the manufacturer's instructions, using 'check-sheets, lubrication charts, etc. Maintenance must be carried out by a competent person who is familiar with the equipment and has the knowledge and experience to detect existing or potential faults.

4

The extent of the maintenance activities will vary between different types of lifting equipment depending upon its complexity. For example, maintaining a tower crane at one end of the scale and a gin-wheel at the other. Where the equipment has a maintenance log, it must be kept up to date.

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1.4.3.36 Thorough examination and inspection Thorough examination 1

These Regulations place a duty on Contractors to ensure that all lifting equipment and lifting accessories are subjected to a schedule of thorough examinations by a competent person at

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intervals not exceeding: (a)

six months for lifting equipment used for lifting persons and all lifting accessories

(b)

12 months for other lifting equipment.

The competent person might decide, for a variety of reasons, that a schedule of more frequent examinations is appropriate.

3

A thorough examination must also be carried out after any other event likely to have affected the safety of any lifting equipment or accessories or where the equipment has been out of use for a long period.

4

Furthermore, where the safety of lifting equipment depends upon the way it has been installed (as for the many items of temporary lifting equipment used on construction sites, such as tower cranes), it must be thoroughly examined after assembly and before being put into service at a new site or a new location on the same site.

5

The competent person must have sufficient practical and theoretical knowledge and experience of the lifting equipment to enable defects and weaknesses to be detected, and their importance in relation to the safety of the equipment to be assessed.

6

The competent person should also be sufficiently independent of the operation to ensure that there is no fear or favour in any recommendations made as a result of the thorough examination.

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1.4.3.37 Inspection

These Regulations also require that, where appropriate, as determined by a risk assessment, intermediate inspections of lifting equipment are carried out although the frequency of inspections is not specified. Depending upon the complexity of the equipment it might be appropriate to put in place two levels of inspection: daily and weekly.

2

Again, these inspections must be carried out by someone who is competent to do so although, in most cases, the same depth of technical knowledge will not be required as for thorough examinations. In some cases, for example carrying out a daily pre-use inspection of a mobile crane, it would be reasonable to expect the operator to be able to carry out the inspection.

3

Some factors that will determine the frequency and 'depth' of any inspection are; if the equipment is being used in a hostile environment

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(b)

if failure becomes more likely due to repeated use

(c)

the critical nature of some components, such as the 'rated capacity indicator'

(d)

the potential for the equipment to be tampered with, for example a mobile crane left overnight in a public place.

Some of the things covered by inspections include, but are not limited to: (a)

the soundness of materials, attachments, fittings, outriggers, jibs, ropes and hooks

(b)

the testing of the rated capacity indicator, the correct settings of cams, linkages and switches, and the correct working of audio-visual warning signals

(c)

the mechanical condition of the lifting equipment

(d)

routine maintenance (lubrication, tyre pressures and hydraulic fluid level).

In summary, any lifting equipment which is used in conditions commonly found in the building and construction industry should not be used unless it is:

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(a)

mechanically sound and free from any defects affecting its safe operation

(b)

properly maintained

(c)

regularly inspected, either weekly or to an agreed programme, when in use, usually by the operator, or other authorised person

(d)

thoroughly examined every 12 months (every six months when used for lifting people) by a competent person and after any exceptional circumstances likely to affect the safety of the lifting equipment

(e)

tested and thoroughly examined

Following any repairs or alterations which may affect the strength or stability of the lifting equipment.

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1.4.3.38 Reports These Regulations establish a regime of good maintenance and record keeping, whilst allowing the competent person to determine the schedule of inspections and thorough examinations.

2

An essential requirement, under these Regulations and good business practice, is to maintain records of maintenance and the results of inspections, thorough examinations and tests.

3

Evidence of inspections, thorough examinations and tests must accompany lifting equipment and accessories for lifting when they are hired, leased or loaned to other users.

4

Where thorough examinations or tests are carried out by the user during the period of hire, lease or loan, the owner of the lifting equipment or accessory must be informed of the results of each thorough examination or test.

5

The format in which the records of inspections, thorough examinations and tests are kept is not specified in these Regulations. However, records must be readily accessible, although they can be stored in an electronic format providing a hard copy can be produced on request.

6

Reports of thorough examinations should contain the information in Appendix 6 of this section.

7

Again, the records can be held in electronic form, but must be readily available to the user of the lifting equipment or accessory for lifting provided that the following safeguards are incorporated into the system.

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(a)

The records must be capable of being reproduced as hard copy when required.

(b)

The information must be secure against loss or unauthorised interference.

(c)

The information must be authenticated only by a person who is in a position to declare that the information is correct.

1.4.3.39 Tower cranes 1

Tower cranes can present particular safety considerations when used on site. (a)

Generally they are self-erecting and dismantling, or erected and dismantled using a large mobile crane for which provision has to be made in terms of space and stable ground conditions.

(b)

Portable tower cranes, often controlled remotely from the ground, need to be treated the same as a mobile crane.

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(c)

They require detailed attention to the foundation (static crane) or rails (mobile crane); manufacturers or suppliers should be consulted.

(d)

In many cases they have the capacity to over-sail adjacent properties and areas to which the public have access;

Arrangements will have to be made: (a)

Where the right to over-sail adjacent property is not given, it may be necessary and feasible to: (iv)

rearrange the siting of the tower crane(s)

(v)

review the type of crane required, for example a luffing-jib crane might be the only solution.

The required airspace must be confirmed with regard to the proximity of adjacent structures, overhead power lines or other obstructions.

(c)

The requirement for airspace may need to be discussed with any local airport to establish that there will be no intrusion into, or unacceptably near to, aircraft flight paths.

(d)

There may be a requirement for an aircraft warning light or beacon on the highest point of the crane; the colour intensity and whether it is on steady or flashes will depend upon the local rules for any flight path affected.

(e)

On sites where more than one tower crane is erected, there may be overlapping arcs of operation when slewing; anti clash devices should be fitted.

(f)

As a result of the above, the cranes should be erected with their jibs at different heights; crane slewing operations will have to be co-ordinated.

(g)

Electrically powered cranes will require a heavy duty power supply and the crane must be effectively earthed to protect against electrical faults and lightning strikes, including earthing of the appropriate rails.

(h)

High winds can temporarily stop tower crane operations; each crane should be fitted with an anemometer (wind-speed indicator).

(i)

In high winds, tower cranes must be left in 'free slew' with their hooks raised.

(j)

If used for lifting persons, a tower crane must:

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only be capable of lowering the load under power controlled conditions, i.e. not under 'free-fall'

(ii)

be equipped with an automatic braking system, e.g. a 'dead-man's' handle type of control.

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(k)

A rescue plan must be in place in the event of an accident or incident, for example, the operator becoming ill. The emergency services have no obligation to carry out such rescues and are often not able to assist because of the height of the rescue and because of restricted access for large vehicles such as fire service turntable ladders.

(l)

Tower cranes must be secured against unauthorised access, including climbing the tower and unauthorised use.

(m)

A lifting plan approved by an appointed person must be in place.

1.4.3.40 Excavators used as cranes 1

Excavators, loaders and combined excavator loaders may be used as cranes in connection with work directly associated with an excavation, and any other application where this type of equipment can be used.

2

All work is subject to a suitable and sufficient risk assessment, subsequent control measures

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and capabilities of the work equipment. The risk assessment should take account of the fact that when a machine is in the object handling mode (being used as a crane), it will be necessary for the slinger to approach the machine to hook the load on and off. This person will be in what is regarded as a hazardous area and much nearer to the machine than anyone would be in normal circumstances. The slinger is at risk of being struck by the load, bucket or excavator arm if the excavator moves or slews rapidly. Excavator operators and slingers must be made aware of these dangers; effective communication and constant vigilance are essential.

4

The risk assessment must also establish whether the machine is suitable for the proposed task. The weight of the bucket (if still fitted) plus the quick hitch must be added to the weight of the load to establish if the machine will be working within its safe working load. Ideally, unless there are good reasons for not doing so, the bucket will be removed to improve the machine operator's visibility.

5

The risk assessment must also address:

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the need for the lifting operation to be ideally segregated from other work activities taking place in the vicinity, particularly where it is necessary for the machine to travel with a raised load

(b)

the ground conditions, particularly where a tracked excavator will carry out the lifting operation. Such machines have no means of levelling themselves and are therefore dependent upon the ground being sufficiently level to track across it and carry out the lifting operation safely.

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(a)

The safe working load must be clearly marked on the machine and any lifting accessories, such as a quick hitch. A rated object handling capacity table must be available in the cab.

7

If the rated lifting capacity for an excavator (or the backhoe of a backhoe-loader) is greater than 1 tonne (or the overturning moment is greater than 40,000 Nm), the machine must be fitted with:

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a boom lowering control device on the raising boom cylinder(s) (a safety check valve), which meets the requirements of BS 6912:1, and

(b)

an acoustic or visual warning device, which indicates to the operator when the object handling capacity or corresponding load moment is reached.

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(a)

Chains or slings for lifting must not be placed around or on the teeth of the bucket. Accessories for lifting may only be attached to a purpose-made point on the machine.

9

Whilst BS 7121 may not specifically refer to excavators used as cranes, compliance with all the appropriate parts of BS 7121 would be required.

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1.4.3.41 Security when not in use 1

The manufacturer's handbook will contain recommendations for securing the crane when it is not in use, to minimise the chance of tampering, vandalism and damage.

2

The measures to be taken will vary for different types and makes of crane, and may also vary depending upon the length of time that a crane will be out of use.

3

However, in general: (a)

Do not leave loads suspended

(b)

Do remove operating keys

(c)

Do lock cabs and, where appropriate, prevent unauthorised access using other means.

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1.4.3.42 Strong wind conditions 1

Crane manufacturers' operating instructions will specify a maximum wind speed for safe operation.

2

This may be a single wind speed for all configurations of the crane or may vary, depending on the jib length, the radius, the load and other factors.

3

The manufacturers' instructions will also indicate the actions to be taken to leave the crane in a safe manner if the wind does exceed the maximum safe operating speed.

4

A copy of the Beaufort Scale, that outlines the visible signs of various wind strengths, is included in this section at Appendix 8.

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1.4.3.43 Accessories for lifting Ropes, chains, eye bolts and slings are all examples of accessories for lifting. They must be clearly marked with their safe working load.

2

All lifting accessories must also be: properly constructed and maintained

(b)

free of any defect or damage likely to affect their strength

(c)

regularly maintained and inspected

(d)

thoroughly examined

(e)

securely attached to the lifting equipment, for example the crane, and the load

(f)

used within their safe working load.

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Accessories used for lifting must be inspected and thoroughly examined, with records kept as specified in Appendix 5.

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1.4.3.44 Marking

Every rope, chain, etc. must be clearly marked with its SWL and carry an identifying mark. Where this is not possible then a coding system, such as a tag or colour code, should be used to allow the user to determine the safe working load. A lifting accessory may also be marked with its own weight which is a consideration when assessing the total load to be lifted.

2

Where the SWL depends on the configuration of a lifting accessory, such as a two leg chain, then the SWL for each configuration should be clearly marked on the equipment using a tag or by a chart available at the point of use.

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1.4.3.45 Overloading 1

Ropes, chains, etc. must never be overloaded except under test and as authorised by an experienced and competent person.

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1.4.3.46 Preventing damage 1

The edges and corners of a load should be packed to prevent sharp edges damaging lifting ropes, chains or slings.

1.4.3.47 Hooks All hooks used for lifting must be fitted with a safety catch, or should be moused, or so shaped as to prevent the sling eye or load coming off the hook

1.4.3.48 Slings

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Slings must be attached correctly to the lifting equipment by an approved method, either by securing the ring directly onto the hook if size permits, or by use of a suitable shackle, fitted with the pin of the shackle on the hook and the load suspended from the bow.

2

The correct method of slinging will vary with the types of load, the different materials or items lifted. It is essential to see that the load is secure. Care must be taken to see that slings are not damaged, and suspect or defective slings must be discarded.

3

Dog ropes or tag lines, securely attached to the end of the load, should be used when handling long or large loads, to direct the load into position and prevent it spinning. Tag lines should be as short as possible.

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See the slinger and signaller safety checklist in Appendix 4 to this section.

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Multiple slings (two-legged, three-legged, etc.) must be connected by a ring or shackle and the load properly distributed so that no leg is overloaded.

5

When in use, the angles between sling legs should be less than 90°. At angles greater than this, the strain on each leg increases very rapidly to a point where they may break because of overloading.

6

With a simple two-legged parallel sling, the load on each leg is half the total load. As the angle between sling legs increases, the load on each sling leg increases to approximately double at an angle of 120°.

7

With a sling angle of 90°, the SWL of the sling should be at least 43% greater than the nominal weight of

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How the load in each sling leg increases as the angle between the sling legs is increased

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(Refer to manufacturer's SWL tables)

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1.4.3.49 Repaired ropes, chains, etc.

Any chain sling, etc. that has been altered or repaired by welding must be examined and retested, and an inspection or examination carried out before taking it back into use. The record should be kept until the next scheduled thorough examination.

2

Knotted ropes, chains or slings and those which have been shortened or joined by nuts and bolts through the links must not be used.

3

Any chain, sling or lifting equipment or accessory for lifting which is thought to have suffered a loss of strength or is otherwise defective should be withdrawn from use and quarantined. The equipment should be scrapped or re-examined by a competent person who will recommend that either it can be put back into service or must be disposed of.

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1.4.3.50 Construction of slings 1

Slings are available in a wide range of styles made from many different materials to suit particular purposes.

2

Chain slings are made from various grades of steel. They can stretch and the links, rings or hooks may become distorted and fracture if subject to excess stress.

3

Chain slings should only be shortened by using the correct shortening clutches. Chains must not be knotted or joined by nuts and bolts. Hooks must be of the 'C' type or fitted with a safety latch.

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Wire rope slings are made from drawn steel wire. Each leg of the sling will have an eye formed at either end. Wire rope slings may be damaged when 'kinked' sharply or if put under stress when twisted. Steel wire rope may be damaged by corrosion through poor care and storage.

5

Wire ropes should never be used if more than 5% (1 in 20) of the wires can be seen to be broken in any 10 x diameter, length.

6

Wire ropes should also not be used where they have been flattened such that there is a 10% reduction in rope diameter.

7

Wire rope slings must not be made up on site using bulldog grips.

8

Wire ropes and slings are of many different types of construction, each having properties related to usage. It is therefore important, when ordering an item, to specify the intended use.

9

Fibre rope slings might be made from natural fibres (manila, sisal, hemp) or synthetic fibres. Slings made from natural fibres can be prone to rotting. Only purpose-made slings, clearly marked with their SWL, should be used on site.

10

On no account should slings be fabricated from lengths of rope found laying around site. Fibre rope slings are more easily cut or damaged, and should be visually examined by a competent person every time before use to ensure they are serviceable. Natural fibre ropes should not be used for making up slings on site.

11

Synthetic fibre ropes do not rot but can be affected by some chemicals. Care should be taken to avoid contamination with alkalis or acids. Suspect or contaminated synthetic fibre ropes and slings must not be used.

12

Flat lifting slings are used where special lifting operations are required and afford a certain amount of protection to the load.

13

Flat and round slings may be made of woven synthetic materials (such as nylon, polyester, polypropylene and terylene) with 'eyes' sewn in, or plastic-coated wire mesh, or formed by a series of plaited wire ropes between two end fittings. These might also be covered with a plastic material. All woven materials are prone to damage and should be regularly checked for serviceability. Slings should be protected from sharp edges and placed evenly about the load, not twisted. Care must be taken to see that the SWL is not reduced by having a sling angle greater than 90°.

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1.4.3.51 Shackles 1

Two types of shackle are commonly used in lifting operations. They are the Bow type shackle and Dee type shackle, both of which are available with threaded or plain pins.

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2

Only bow type shackles may be used to suspend a load from a hook. The shackle must be positioned with the pin across the hook and the load suspended from the bow. If necessary, spacers should be fitted over the pin to centralise the shackle on the hook.

3

Overloading, out of balance loads and misuse can distort shackles; they should be checked regularly for shape and wear.

1.4.3.52 Eyebolts Eyebolts are made to screw into or through a load and may be plain (dynamo) or have collars, with or without links. The plain eyebolt is good only for vertical loading. Even when a collared eyebolt is used, the safe working load is reduced if the load to which it is attached initially lifted at an angle.

2

Collared eyebolts with links may be used providing the angle of load to the axis of eyebolt thread does not exceed 15°. Over 15°, safe working loads must be derated in accordance with BS 4278: Specification for eyebolts for lifting purposes.

3

When installed, the collar must be at right angles to the hole, should be in full contact with the surface, and be properly tightened.

4

The load should always be applied in the plane of the eye, never in the other direction. If necessary, washers or shims should be inserted below the collar to ensure that the eye is correctly aligned when tight.

5

Extreme care must be taken to ensure that metric threaded eyebolts are not inserted in imperial threaded holes. Although these might appear to match, it is an interference fit only, and the mechanical strength may be almost nothing.

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1.4.3.53 Bulldog grips (wire rope grips) Bulldog grips, if used properly to make an eye with a thimble, provide a simple and effective means of securing the ends of wire ropes instead of splicing or socketing. The final SWL will be about 75% of that of the wire. It is essential that the correct size and type of grip is used, that the wire is clean and that the correct torque is applied when tightening the grips.

2

Bulldog grips must be fitted with the 'U' bolt on the dead or tail end of the line (non loadbearing end). There must be no deviation from this practice.

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Correct method of fitting wire rope grips Note: The number of wire rope grips shown in the above illustration is insufficient. The figure is schematic only.

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Wire rope grips meeting the requirements of BS EN 13411 are efficient when correctly installed by a competent person. Generally, when using wire rope grips, the previous numbers of grips should be used and they should be tightened to the relevant torque. However, in all cases, the manufacturer's recommendations, in addition to the advice given in the standard, should be closely followed.

Maximum nominal rope diameter (mm)

Required number of wire rope grips

Tightening torque required (Nm)

5

3

2.0

6.5

3

3.5

8

4

10

4

12

4

14

4

16

4

19

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6.0

20.0 33.0

4

68.0

5

107.0

5

147.0

30

6

212.0

34

6

296.0

40

6

363.0

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9.0

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4

The wire should be in good condition and all threads and nuts should be suitably greased.

5

The first bulldog grip should be fitted as close as possible to the thimble and, thereafter, at a spacing of no greater than six times the rope diameter.

6

Nuts must be tightened to the relevant torque:

7

(a)

when the rope is assembled

(b)

when taken into use

(c)

on the application of the load

(d)

at periodic intervals when in continuous use.

If the above criteria are not followed, then the strength of the eye and thimble will be considerably reduced. If the criteria are neglected for an extended period, the eye and thimble may fail.

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Wire rope grips must not be used to make lifting slings, long splices, or to join two wire ropes, other than with thimbles or eyes.

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For intermediate diameters of rope, the next larger size wire rope grip should be used, except as follows: (a)

the size 5 mm grip should only be used on a nominal 5 mm diameter rope

(b)

for 11 mm diameter rope, use four 10 mm rope grips tightened to a torque of 14 n/m.

1.4.3.54 Spreader and equaliser beams Spreader beams are used to support long or wide loads during lifts. They eliminate the hazard of a load tipping, as well as wide sling angles and any tendency of the sling to crush the load.

2

Equaliser beams are used to equalise the load in sling legs and to keep equal loads when making multiple leg lifts.

3

Both types of beam are normally manufactured to suit a particular purpose. Care should be taken to see that the correct beam is used.

4

The capacity of a beam with multiple attachments will be specified by the manufacturer. Generally, it will depend on the distance between the attachment points, for example, if the distance between attachment points is doubled, the lifting capacity is halved. Care must be taken not to exceed safe working loads at the various slinging points.

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Construction Site Safety 1.4.3 Appendix 1 General lifting operations Safety checklist Before starting work Ensure that adequately trained, competent persons are available to plan, carry out and supervise the lift.

2

Ensure that a suitable and sufficient risk assessment has been carried out, which considers all aspects of the lift including environmental factors such as the proximity of obstructions, underground services, overhead cables and structures.

3

Ensure that lift plans and method statements for the lifting operation are developed as appropriate.

4

Ensure that appropriate protection measures are put in place.

5

Ensure that all temporary works supporting lifting equipment, such as foundations, have been certified by a competent temporary works engineer and a 'permit to load issued'.

6

Ensure that a current thorough examination and/or test record has been issued and is available for each item of lifting equipment and accessory.

7

Ensure that the SWL of the lifting equipment and accessories is adequate for the weight of the load.

8

Ensure that all lifting accessories are clearly marked with their safe working load.

9

Ensure that correct and up-to-date copies of the Sling Chart and Safe Working Load tables are available, when using multi-leg slings.

10

Ensure that the method of communication is agreed and understood by everyone involved in the lift.

11

Ensure that a suitable rack is available for storing slings, etc. when they are not in use. Wire ropes should be stored in a dry atmosphere.

12

Ensure that the weights of loads to be lifted are known in advance, and that load weights are clearly marked.

13

Ensure that the ground conditions are sufficiently stable to take the weight of the lifting equipment and any load.

14

Ensure that a trained and competent slinger is available.

15

Ensure that a trained and competent signaller is available if required.

16

Ensure that all personnel involved in the lifting operation have been briefed and understand the risks, methods or work and the equipment to be used including emergency arrangements.

17

Ensure that the appropriate permissions have been gained if it is necessary to position any crane on the public highway (or other public place) to carry out lifting operations.

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Whilst work is in progress 18

Ensure that copies of the Sling Chart and Safe Working Load tables are being used where necessary.

19

Ensure that the correct techniques are being used for the attachment to the appliance and slinging.

20

Ensure, wherever possible, that the angles of slings are no more than 90°.

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Ensure that regular inspections, thorough examinations and tests of the equipment are carried out, as appropriate, and records maintained (see Appendix 5).

22

Limit the use of endless wire rope slings.

23

Ensure that slings are protected from sharp corners of loads by suitable packings.

24

Ensure that slingers understand that 'doubling up' slings does NOT 'double up' the safe working load; avoid this practice if possible.

25

Prevent strops, slings and ropes from being dragged along the ground.

26

Ensure that hooks used for lifting are NOT also carrying unused slings.

27

Ensure that any unused leg of a

28

multi-sling is correctly hooked back. The correct sling only should be used.

29

Ensure that unfit slings are removed from the site, and a responsible person informed.

30

Ensure that the crane hook is positioned above the load's centre of gravity.

31

Ensure that the load is free before lifting and that all legs have a direct load.

32

Ensure that 'snatch' loading does NOT take place.

33

Ensure that NO ONE rides on a load which has been slung and is being lifted.

34

Use tag lines to stabilise long or large loads.

35

Ensure that the load is landed onto battens to prevent any damage to slings, and to assist their easy removal.

36

Ensure that NO ONE is under a load which is being lifted.

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Construction Site Safety 1.4.3 Appendix 2 Mobile cranes Safety checklist

Before starting work Carry out the checks detailed in Appendix 1, plus: Consider whether a 'contract lift' is the best and safest option.

2

Check that the selected crane has been supplied. Check that the correct operating information and a competent operator have been supplied along with it.

3

Check that the ground is capable of taking the loads of the outriggers, crane, load or wind. If in doubt, get ADVICE from specialist companies.

4

Ensure that the approach and working areas are as level as possible.

5

Ensure that there is adequate protection from live electrical cables.

6

Ensure that the area is kept free of obstructions, and is adequately lit.

7

Ensure that the weights of the loads are known, and that the correct lifting gear has been ordered and is available.

8

Ensure that no 'crush zone' exists between the crane and any fixed object; if there is, erect barriers.

9

Check there are no restrictions on the access, i.e. check size(s) of vehicles.

10

Check that the company has provided enough information about the safe use of the crane.

11

Check that there is an up-to-date record and that inspections, thorough examinations and tests have been carried out as necessary.

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Whilst work is in progress

12 13 14

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Carry out the checks detailed in Appendix 1, plus: Check that daily and weekly inspections are being carried out. Ensure the crane is operating from planned and approved positions only in accordance with lift plans and method statements. Ensure that the signaller is available for each lift.

15

If outriggers are being used (blocked duties), ensure that they are fully extended, locked and adequately supported.

16

Check that tyres are at the correct pressure and in good, clean condition and that tracks are properly maintained.

17

Check that the crane is kept at a safe, predetermined distance from any open excavations or live overhead electricity cables.

18

Check, when travelling, that the load is secured and carried as near to the ground as possible and that tag lines are used.

19 20

Check that the rated capacity and radius indicators are in working order. Check that loads are not being slewed over any persons and that persons are not standing or walking under the load.

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Check, when travelling on sloping ground, that the driver changes the radius to accommodate the movement of the load.

Construction Site Safety 1.4.3 Appendix 3 Tower cranes Safety checklist Before starting work Carry out the checks detailed in Appendix 1, plus: Check that the appointed person has put in place a lift plan.

2

Check that the selected crane has been competent engineer supplied. Check that the correct operating information has been supplied along with it.

3

Ensure that the crane will be capable of lifting the required loads at the maximum required radius of operation.

4

Check that the ground is capable of taking the weight of the crane, the load and wind load. If in doubt, get ADVICE.

5

Ensure that any foundations have been designed and certified by a and a 'permit to load' issued.

6

Ensure that adequate ballast or counterweight units are in position and are correctly secured.

7

Check that a diagram or notice indicating the position and weight of removable ballast is prominently displayed.

8

Ensure that the approach and the base are as level as possible.

9

Check that the limit switch and other devices are installed to limit the travel of the bogie. Ensure that limit switches have also been installed to limit the crane travel on rails.

10

Ensure that the work area is kept free of obstructions, particularly where the crane operates on rails.

11

Ensure that there is an adequate power supply properly installed, earthed and tested. Where the crane operates on rails, ensure that they are also earthed.

12

Ensure that the weight of each load is known, and that the correct lifting accessories are available.

13

Ensure that a competent operator, who is sufficiently fit and has good eyesight, is available.

14

Ensure that a competent, trained signaller is available, and that the method of communication is understood by all involved in the lift.

15

Check that there are no restrictions on the access, i.e. check size(s) of vehicles for rigging/de-rigging.

16

Ensure that all necessary precautions with regards to live overhead electric cables have been taken.

17

Where necessary, ensure that all work areas are adequately lit.

18

Where appropriate check that any building or temporary works to which the crane is tied can support the loading.

19

What is the crane's free standing height? Check that the supplier has provided information with reference to the crane, etc.

20

Where appropriate, check that over-sailing and airspace rights have been agreed.

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21

Check that warning has been given of the slewing activities and that property has been protected, as necessary.

22

Check that there is an up-to-date record of inspection, thorough examination and test.

23

Check that there is a rescue plan in place and that it is acceptable in terms of practicality.

24

Check the competency, including training and qualifications, of the competent persons involved in lifting operations.

Whilst work is in progress Ensure that the works are being carried out in accordance with the lift plan.

26

Check that the daily and weekly inspections are being carried out and recorded.

27

Check that the rails, if used, are level, in line and being guarded.

28

Check the position and condition of the sleepers, etc. (Look for washouts.)

29

Check that the buffers are in place and that they are secure (if on rails).

30

Check that the bogie is blocked and chocked when not in use (if on rails).

31

Check that no nuts or bolts are missing or loose.

32

Check that crane ties, if used, are securely fixed in position.

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Check that the wind speed indicator is in working order. What wind speed is allowed for safe working?

34

Check that, when not in use, the crane jib is free to slew with the wind. Check that power supplies are off; loads lowered, hooks raised and doors locked.

35

Check the slewing movements in relation to people or adjacent property, etc.

36

Check that earth bonding strips are in place.

37

Where more than one tower crane is in operation with overlapping arcs of operation, ensure that crane activities are co-ordinated.

38

Ensure that the load rating chart is in place and being complied with.

39

Ensure that the rated capacity indicator is in working order.

40

Check that the SWL is plainly marked at different operating radii along the jib.

41

Ensure that all lifts are within the jib radius.

42

Ensure that operators know the weight of loads being lifted.

43

Ensure that loads are being lifted and not dragged, and that they are not swinging and creating a hazard.

44

Ensure that the operator is at the controls whenever a load is suspended.

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Construction Site Safety 1.4.3 Appendix 4 Slinger and signaller safety checklist Inspect to ensure that: 1

slings and other chains are not shortened by tying knots in them or by wrapping them round the crane hook fibre or rope slings are not damaged

3

chains are not joined by means of bolts or wire

4

wire ropes are not sharply bent or flattened at any point

5

wire ropes are never in contact with hot metal or acids that will damage them

6

wire ropes are never used singly when hooked by a spliced eye. (The cable is liable to untwist, allowing the splices to open and slip)

7

the proper pin is used in all shackles and the correct type of shackle is being used

8

all end links, rings or shackles ride freely on any hook on which they are used

9

the wind strength is safe for lifting operations to start.

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Reject:

any slings of insufficient length which create a wide angle between legs

11

extra long slings which seriously reduce the headroom

12

any wire ropes that have become damaged or rusty

13

any fibre or rope slings that are damaged or frayed.

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When loading

Ensure the slings are protected from sharp-edged loads by packing soft wood or other suitable material between the load and the sling. (Bricks are not suitable packaging material.)

15

Ensure the load is evenly distributed to avoid excessive stress on one side of the sling.

16

DO NOT let any load rest on a wire rope; it may crush the strands and render the rope unsafe.

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Before lifting 17

Ensure that the load is securely slung.

18

Always see that the crane hook is centrally placed over the load to prevent it swinging when the load is being raised, and that the load is in balance.

19

Position the hands well away from any chains or ropes before the crane takes the load.

20

Check that the load is free for lifting.

21

Give warning to all persons to keep clear of the load.

During lifting 22

Use only British Standard 7121 signals.

23

Always lift slightly, then pause to see that the load is safe and balanced.

24

Ensure signals are given by the person responsible for the lift, and nobody else.

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25

Ensure hooks and slings not in use are carried on the carrying hook, since they may cause the sling carrying the load to ride on the nose of the hook.

26

Never ride on a crane load, or allow any other person to do so.

27

Whenever possible, keep the load clear of people.

28

Ensure chains, slings, hooks or loads are never dragged along the ground.

When unloading 29

Make sure there is a firm foundation for the load, and make provision for the removal of all slings.

30

Stack

securely

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provide

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Construction Site Safety 1.4.3 Appendix 5

Inspection and thorough examination

Thorough examination

as

Inspection

Reports

Lifting equipment and accessories for lifting

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Lifting equipment and accessories for lifting

If appropriate and at suitable intervals between Before first use, unless a record Lifting equipment accompanies the lifting thorough examinations. equipment. Installation conditions (Suitable intervals, unless require assurance that it is safe otherwise laid down, would to use: be every week.) Carried  after installation out by a competent person.

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Lifting equipment



after assembly. When exposed to conditions causing deterioration:



lifting persons - every six months



other lifting equipment every 12 months.

User or owner

Follows the thorough examination. Report authenticated. Format - register or certificate, electronic form (easily retrievable). Provided to the user, and to the person from whom the equipment has been hired or leased in writing. Kept available for inspection. Kept available until next examination carried out or for two years, whichever is the longer.

In accordance with an examination scheme drawn up by a competent person. Carried out by a competent person. Accessory for lifting

If appropriate and at intervals Before first use. When exposed between thorough examinations. to conditions causing Carried out by a competent deterioration: person.

 every six months, in accordance with an examination scheme drawn up by a competent person. Carried out by a competent person.

Accessory for lifting

Report kept available until next inspection report made. Made in writing and provided to user. Thorough examination record for two years after report made.

Health and Safety Executive

Following thorough examination identifying an imminent risk of serious personal injury. Report in writing.

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Construction Site Safety 1.4.3 Appendix 6 SCHEDULE 1

INFORMATION TO BE CONTAINED IN A REPORT OF A THOROUGH EXAMINATION The name and address of the Contractor for whom the thorough examination was made.

2

The address of the premises at which the thorough examination was made.

3

Particulars sufficient to identify the lifting equipment including where known its date of manufacture.

4

The date of the last thorough examination.

5

The safe working load of the lifting equipment or (where its safe working load depends on the configuration of the lifting equipment) its safe working load for the last configuration in which it was thoroughly examined.

6

In relation to the first thorough examination of lifting equipment after installation or after assembly at a new site or in a new location-

(b)

(if such be the case) that it has been installed correctly and would be safe to operate.

whether it is a thorough examinationwithin an interval of 6 months

(ii)

within an interval of 12 months

(iii)

after the occurrence of exceptional circumstances.

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In relation to a thorough examination of lifting equipment other than a thorough examination to which paragraph 6 relates(a)

(if such be the case) that the lifting equipment would be safe to operate.

In relation to every thorough examination of lifting equipment(a)

identification of any part found to have a defect which is or could become a danger to persons, and a description of the defect; particulars of any repair, renewal or alteration required to remedy a defect found to be a danger to persons;

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(c)

in the case of a defect which is not yet but could become a danger to persons(i)

the time by which it could become such a danger;

(ii)

particulars of any repair, renewal or alteration required to remedy it;

(d)

the latest date by which the next thorough examination must be carried out;

(e)

where the thorough examination included testing, particulars of any test;

(f)

the date of the thorough examination.

9

The name, address and qualifications of the person making the report including the Contractor they are employed by.

10

The name and address of a person signing or authenticating the report on behalf of its author.

11

The date of the report.

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Construction Site Safety D3. Appendix 7 Recommended crane signals

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Reproduced from BS 7121 Safe Use of Cranes Part 1

Note: The signaller should stand in a secure position, where they can see the load and can be seen clearly by the crane driver, and they should face the crane driver if possible. Each signal should be distinct and clear.

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Construction Site Safety 1.4.3 Appendix 8 Wind strengths and effects (Beaufort Scale) Windforce number

Description of wind

Wind effect locally

Speed Km/h ≤1

Speed m/sec

0-1

0

Calm

Calm, smoke rises vertically.

1

Light air

Direction of wind shown by smoke drift, but 1.1-5.5 not by wind or weather vanes.

2

Light breeze

Wind felt on face. Leaves rustle. Wind or weather vanes move.

5.6-11

2-3

3

Gentle breeze

Leaves and small twigs in constant motion. 12-19 Wind extends light flags.

3-5

4

Moderate breeze Wind raises dust and loose paper. Small branches move.

5

Fresh breeze

6

Strong breeze

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1-2

5-8

Small trees in leaf begin to sway. Little crested wavelets form on inland waters.

29-38

8-11

Large branches in motion. Umbrellas used with some difficulty.

39-49

11-14

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20-28

7

Near gale

Whole trees in motion. Becoming difficult to 50-61 walk against the wind.

14-17

8

Gale

Twigs break off trees. Progress is generally 62-74 impeded.

17-21

9

Strong gale

Chimney pots, slates and tiles may be blown 75-88 off. Other slight structural damage may be caused.

21-24

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Construction Site Safety 1.4.4

Mobile Elevating Work Platforms

1.4.4.1 Key points Mobile elevating work platforms (MEWPs) are a safe and convenient alternative to scaffolds when working at height, providing they are used correctly by trained and competent operators.

2

On some types of machine it will be necessary for the operator and any passengers to wear a safety harness and lanyard, the free end of which must be clipped to a strong point on the machine.

3

Operators and passengers must never clip the free end of the lanyard to the structure against which they are working.

4

Normally, MEWPs should only be operated from the controls in the basket or on the platform.

5

The ground level controls should only be used in an emergency such as the operator becoming incapacitated when the machine is elevated.

6

MEWPs are classified as 'work equipment' and 'lifting equipment for carrying people' and must therefore be subjected to an appropriate schedule of inspections and thorough examinations.

7

MEWPs must not be used to carry any load above the stated safe working load.

8

When calculating the total load carried, consideration must be given to any additional materials 'taken on board' when elevated, such as a quantity of removed roof tiles.

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1.4.4.2 Introduction

The term mobile elevating work platform (MEWP) covers pedestrian-controlled, selfpropelled and power-operated mobile elevating work and access platforms.

2

MEWPs are designed to provide temporary working platforms that can be easily moved from one location to another. They are particularly suitable for tasks where the use of a ladder would be unsafe and the erection of a scaffolding platform too time-consuming or impracticable in relation to the job to be done. Some machines have specialised applications.

3

When using MEWPs (as with all other types of work equipment), the Contractor has a legal duty to provide, as far as is reasonably practicable, a safe place of work and the necessary information, instruction, training and supervision ' for operators..

4

The manufacturer or hire company who supplies any type of MEWP to a contractor must provide familiarisation training on the type of machine they are supplying. The Contractor of the machine operator, however, has a legal duty to ensure the operator's overall competence and assess the risks arising out of the work activity for which the machine is to be used. It is essential that no one should be allowed to use the equipment unless they have been instructed and trained by a competent person on the specific type of equipment to be used, and have themselves been judged competent to use it.

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1.4.4.3 The Management of Health and Safety at Work 1

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

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2

When hazards are identified, it is then the Contractor's duty to either eliminate the hazard or to put control measures in place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

4

Employees, for their part, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other person who may be affected.

1.4.4.4 The Provision and Use of Work Equipment All MEWPs are classified as 'work equipment' under these Regulations and Contractors must:

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ensure that the equipment is suitable for the intended task

(b)

maintain and keep the equipment in good working order (or ensure that it has been properly maintained if a hired-in machine)

(c)

ensure the equipment is subjected to a scheme of regular inspections (or has a valid certificate of thorough examination if a hired-in machine)

(d)

provide competent supervision.

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(a)

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to competent and specified workers.

3

Dangerous parts of machinery must be adequately guarded, preferably by fixed guards that cannot be defeated or removed.

4

Employees must be provided with information, instruction and training in the use of work equipment, where necessary for their health and safety.

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All MEWPs are classified as 'lifting equipment' (for lifting people) under these Regulations. The main requirements of these Regulations are that: lifting equipment and accessories must be of adequate strength and the lifting equipment stable, for each lift undertaken

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1.4.4.5 Lifting Operations and Lifting Equipment

(b)

lifting equipment used for lifting persons is constructed and used so as to protect the safety of the person(s) being carried

(c)

lifting equipment must be positioned or installed so as to prevent the lifting equipment or the load striking a person or the load otherwise becoming out of control

(d)

the load must be under full and proper control at all times

(e)

lifting equipment and accessories must be clearly marked with their safe working load and other markings if designed for lifting persons

(f)

every lift must be properly planned by a competent person, properly supervised and carried out safely

(g)

lifting equipment must be subjected to a programme of inspections and thorough examination as is appropriate

(h)

reports of thorough examinations must be made and retained, with all defects notified to the Contractor who must take appropriate actions.

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1.4.4.6 Work at Height The fact that a MEWP is in use is indicative that someone is going to work at height. The key provisions of these Regulations are (briefly) that Contractors must: where it is reasonably practicable, avoid the need to carry out work at height

(b)

where such work cannot be avoided, make sure to select the most appropriate work equipment for the work and to prevent falls

(c)

reduce the distance, and potential consequences, of any fall

(d)

ensure that the work is properly planned, risk-assessment based and that it is carried out safely by competent persons

(e)

establish danger areas from which people must be excluded, when there is a danger of them falling or being struck by falling objects

(f)

ensure that measures are taken to prevent anyone being injured by falling objects.

(g)

Employees who work at height, for example MEWP operators, must:

(h)

report to the Contractor any situation that they consider to be unsafe to themselves or to anyone else

(i)

use any work equipment, such as a MEWP, in accordance with the training and instructions provided.

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1.4.4.7 Personal Protective Equipment

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These Regulations require that, where a risk has been identified by a risk assessment and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment (PPE) is used by employees. In essence, PPE may only be used as a last resort.

2

In the context of using MEWPs, PPE will include items of fall-arrest equipment, such as harnesses and lanyards, although consideration must also be given to the provision of PPE that protects against hot, cold and wet weather in the appropriate circumstances.

3

Whilst the Contractor must, as far is reasonably practicable, ensure that any PPE supplied is correctly used or worn, the employee, in turn, has a duty to properly use or wear the equipment, follow any information, instruction or training which they have been given, and know the procedures for reporting loss or defect to their Contractor.

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1.4.4.8 Types of MEWP 1

2

The basic types of mobile elevating work platform are: (a)

scissor lifts

(b)

telescopic booms or jibs

(c)

articulating and telescopic booms. All of these may be:

(d)

towable units

(e)

vehicle-mounted

(f)

self-propelled, or

(g)

pedestrian controlled.

The main functional differences between the three basic types of platform are described below.

Scissor lift: This type of appliance gives a vertical lift only. It may be fitted with outriggers, depending on its size and the height to which it extends.

4

Hydraulic extending boom (telescopic): This type gives both vertical height and outreach. The working platform may also be manoeuvrable.

5

All boom-type MEWPS are generally known as 'cherrypickers'.

6

Articulating and telescopic or multi-boom articulated: These types of equipment are usually vehicle mounted. They give a wide range of reach and height, with good platform mobility. They are nearly always equipped with outriggers. There are specialised types, for instance, machines that enable access to the underside of bridge arches from the roadway above.

7

Some units have a 'travel while elevated' ability and fourwheel drive. Rough terrain MEWPs have been specially developed for construction site work.

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1.4.4.9 Sizes 1

Sizes and capabilities vary considerably. Small, one-person platforms are available, with safe working loads of about 100 kg, and working heights of a few metres.

2

At the other end of the scale, platforms may be over 4 m x 2 m in size and have safe working loads in excess of 1,000 kg. Extending boom heights exceeding 60 m are obtainable and the outreach of some units can exceed 30 m.

3

The work activity which results in the use of MEWPs must, of course, have been subject to a risk assessment.

1.4.4.10 Causes of accidents MEWPs can provide safe access and safe working at heights, and are often safer than ladders or other access equipment. However, there have been a number of serious accidents in which operators have been thrown from MEWPs, particularly 'cherry pickers'. This can be caused by such events as the moving basket snagging an obstruction or the operator simply leaning too far beyond the guard-rail. In many cases, the wearing of a safety harness and short restraint lanyard, clipped to a strong point inside the basket, would have prevented the accident. This advice relates primarily to 'cherry pickers' but it is also relevant to scissor lifts if the operator is at risk of falling, for example, as a result of leaning too far over the guard-rail.

2

The typical 'cherry picker' consists of one or more pivoted arms. Movement from a single pivot causes the basket to move through an arc. To make the basket move in a straight line, for example up or down the face of a building, the operator must adjust more than one control either alternately or simultaneously. Accidents can occur when the operator is too 'heavy handed' with the controls, or the actual movement of the basket in relation to the degree of control movement is too coarse. This may cause the basket to move further and more rapidly than anticipated, or the operator may not be able to compensate quickly enough for the 'arc' movement. This may result in the basket striking, or being obstructed by, a nearby structure. If this occurs and power continues to be applied, the basket could become jammed and it is possible that a structural failure of part of the machine or a sudden movement of the basket could throw the operator out.

3

Other significant causes of accidents are: when a nearby vehicle or mobile plant strikes the MEWP, for example, if part of the boom encroaches into a traffic route or if road traffic skids into the machine on wet or icy roads

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(b)

entrapment of the operator below a fixed object whilst elevating the basket or platform

(c)

failure of the levelling system or a major component of the MEWP

(d)

an unexpected movement or overturning due to incorrect installation, or soft or uneven ground

(e)

falls from height whilst climbing from a MEWP onto a roof or other high level place. (MEWPs are intended for use as work platforms and not as a substitute for stairs to gain access to upper levels)

(f)

lack of information, instruction and training resulting in collisions whilst manoeuvring

(g)

where the nature of work being done from the basket may mean that operators are likely to lean out. This may happen, for example, when operators: (i)

inadvertently, or for reasons of speed and convenience, overreach or stretch from the basket and overbalance, or

(ii)

are handling awkward workpieces which may move unexpectedly

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(h)

where rapid movement of the machine is possible

(i)

where there are protruding features which could catch, impede or trap the basket.

4

Error of judgement by operators, or a lack of sufficient information, instruction, training and supervision can cause rapid movement of the basket and collision whilst manoeuvring. Whilst many incidents have been attributed to 'operator-error', these errors are foreseeable and should be considered as part of the Contractor's risk assessment.

5

The Contractor's risk assessment should, therefore, consider: information, instruction, training and supervision

(b)

competence and operator suitability

(c)

the degree of fine control that is necessary and available for the safe movement of a MEWP

(d)

the condition, suitability and maintenance of the MEWP

(e)

the need for, and use of, fall-arrest or fall restraint equipment.

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1.4.4.11 Controlling the risks

Having assessed the risks, Contractors and others responsible for the use of MEWPs must implement measures to control those risks.

2

The precautions for safe working from a MEWP include: ensuring that a MEWP is suitable for the job to be undertaken, as revealed by a risk assessment

(b)

ensuring guard-rails and toe-boards are fitted to the platform or the basket

(c)

ensuring the machine is never overloaded

(d)

using stability devices provided, i.e. outriggers, to make the machine stable

(e)

the provision of designated anchorage points for the attachment of lanyards

(f)

locking-out controls (other than those in the basket) to prevent unintentional operation

(g)

correct planning of the proposed task

(h)

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instructions when to enter or leave a basket, such as when it is fully lowered

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(j)

instructions for emergency procedures, such as rescue should the operator be incapacitated

(k)

use, as and where necessary, of suitable fall restraint equipment or, in high-risk situations, fall-arrest equipment.

1.4.4.12 Fall protection Work restraint system 1

Whereas fall-arrest equipment allows a person to fall but arrests the fall before the person hits the surface below, work restraint equipment prevents the fall from happening.

2

The main feature of work restraint equipment is that a shorter lanyard is used which restricts the operator's limit of travel to the confines of the basket or platform.

3

Lanyards should be carefully selected, taking into account the features of the machine on which they are to be used, to ensure that the user cannot get into a situation where a fall

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could occur. 4

BS EN 358 specifically states that such devices are not intended to arrest a fall.

Fall-arrest system 5

This passage of text refers predominantly to the use of 'cherry pickers', although in some circumstances parts could also be relevant to the use of scissor lifts.

6

Where a decision has been taken to rely on fall-arrest equipment as a means of preventing injury, it will be necessary for the operator to wear a full body harness and a lanyard equipped with an energy absorber. Vital considerations are: the height at which work is being carried out must be such that it allows the lanyard to arrest the fall and the energy absorber to deploy before the wearer hits the surface below. A minimum working height of 5 metres is recommended if fall-arrest is to operate successfully

(b)

the anchor point on the machine must have been designed to withstand the shockloading of arresting a fall. Many anchor points fitted to MEWPs are only rated for work restraint. If the anchor point is not marked with its rating, contact the manufacturer to find it out

(c)

users of harness and lanyard must have been trained in their use, inspection and care

(d)

in arresting a fall, a 'cherry picker' will flex, which could eject other occupants and materials out of the basket. This could also overturn the machine if it is operating towards the extent of its lateral operating-envelope

(e)

a check must be made that the structure has no projecting features that the falling person would strike during the fall

(f)

how the person who has fallen will be rescued after the fall has been arrested. This may be as simple as another operator gently lowering the boom of a 'cherry picker' using the ground level controls until the fallen person is at ground level.

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A safety harness must never be attached to anything outside the platform; operation of the controls in this situation could leave the user suspended in mid air (see illustration above).

8

An exception to wearing a harness whilst operating a mobile elevating work platform is when the machine is working over or near water. If a harness is being worn in such circumstances and the MEWP toppled into the water, the operator could be dragged under the water and drowned. The wearing of harnesses in such situations is not recommended, although operators should wear life jackets.

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1.4.4.13 Safe operation of MEWPs Safety helmets 1

Safety helmets must be worn if there are overhead obstructions in the area of operation or if there is a possibility of injury resulting from falling objects. On all building and construction sites, the wearing of safety helmets is mandatory. Chin straps should be worn to prevent the helmet slipping off and falling to a lower level and perhaps injuring someone.

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Safe working load 2

The safe working load (SWL) specified by the manufacturer must not be exceeded. The maximum number of persons permitted on the platform may also be given but, if it is not, 8590 kg of the SWL should be allowed for each person.

3

Care must be taken not to exceed the SWL with tools and equipment when work is being carried out from the platform.

4

Examples of how this can also be caused are:

(b)

the removal and lowering of fans, motors, pipework, window frames or other equipment from high level onto the platform prior to removing them for repair, maintenance or replacement

(c)

the temporary storage of removed materials, such as roof tiles

(d)

any form of shock loading.

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(a)

It is usual for a single SWL to be specified for all conditions of height or reach.

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Height and reach

The figures given by manufacturers are the maximum possible; allowance has already been made for the physical height and reach of the operator.

7

If it becomes evident that the task requires a range of travel that is outside the reach of the machine, work must be stopped and the job reassessed. Steps, ladders, hop-ups or boxes must never be used on the platform or in the basket to gain extra height or reach.

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Operating envelope

All configurations of MEWPs have an operating area or envelope. With scissor lifts, the operating envelope will be determined by the maximum height and width of the platform; with articulated booms, it is a more complex shape.

9

As maximum height and maximum reach are not usually available at the same time, care is needed to ensure that the intended work area is within the machine's operating envelope (see diagram below).

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Ground conditions 10

MEWPs are often fitted with outriggers or stabilisers and these must always be fully deployed and used as recommended by the manufacturer. Attempting to operate the unit too close to a building or obstruction can make it impossible to fully extend the outriggers, and therefore unsafe to use.

11

Before deploying stabilisers or outriggers, check: (a)

that the machine is either level, or can be levelled up

(b)

that the ground is firm, without hidden voids and will support the loading with the use of adequate packing if necessary

(c)

that the machine will not have to pass over a cellar, basement, sewer, drain, manhole, old trench, uncompacted backfill or anything else that might collapse; consider the possible need for a ground survey.

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Travelling in operational mode

Travelling with the platform occupied or boom extended should only be undertaken when this mode of operation is within the machine's specified capabilities. Travel must never take place with outriggers or stabilisers extended, unless the machine is designed to function in this way.

13

Before travelling, a check should be made to ensure:

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no ramps, trenches, holes or other ground obstructions lie in the path of travel

(b)

no overhead electrical or other (communication) cables, building projections or other overhead hazards will be encountered

(c)

adequate warning has been given to people on the ground

(d)

a signaller or other responsible person is employed, if necessary

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nothing has been left unsecured and liable to fall off no trailing hoses, cables, wires on the unit or other snagging hazards are in the path of travel.

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Travelling up and down inclines and traversing slopes should only be undertaken within the limits laid down by the manufacturers.

15

Specially designed units, designated as 'rough terrain', can operate (usually without any stabilisers or outriggers) on construction and other sites where ground conditions may not permit a standard type vehicle to be used.

1.4.4.14 Tandem use 1

Under no circumstances should two platforms be linked together or bridged. However, in some circumstances, manufacturers can advise on the interlocking of platforms and controls so that one set of controls operates both platforms, allowing directional stability to be maintained at all times.

2

If a unit is being used in conjunction with a crane or some other appliance, a safe system of

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work must be planned and implemented; it should clearly define individual responsibilities and set out precise arrangements for communication. Wind and wind speeds 1

A MEWP must not be used in wind speeds exceeding those specified by the manufacturer. One commonly specified wind speed upper limit is that of 48.28 km/h (Beaufort Scale Force 6 -Strong Breeze) or about 12.5 m per second. This is also generally accepted as the maximum wind strength in which an operator can work without undue discomfort.

2

Other problems associated with operating in windy conditions include: the funnelling effects of winds between buildings, where actual wind speeds may be double that measured in the open

(b)

in the vicinity of large slab-sided buildings, high wind speeds and eddy currents may be created at the corners and on the side facing the wind

(c)

the effect of height - wind speed may be 50% greater at a height of 20 m than it is at ground level; modern machines are fitted with a wind-speed sensor which, if activated, only enables the working platform to be lowered

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(a)

(b)

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Percentage to be added to ground level windspeed to correct for working height.

(d)

Height above ground at which platform will be used.

wind chill factor. On a calm day 10°C is cool but not unpleasant, but with a wind of 32.19 km/h the temperature experienced on the face and hands is 0°C. If the day is cold, about freezing, the temperature experienced on the skin can be down to minus 15°C, making it almost impossible for the operator to work safely unless properly clothed and equipped for the circumstances.

3

Problems may also arise when handling sheet materials, panels and other materials light in weight in relation to their area. They can act like 'sails' and seriously affect the stability of a mobile elevating work platform due to the excess wind loading. If such materials are to be used, due allowance should be made, especially in gusty conditions.

4

Because of the difficulty in accurately estimating wind speeds by the observation of trees, windblown litter, smoke, etc., a hand-held anemometer should be used where necessary.

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Use on roads 5

People trained to operate a vehicle-mounted MEWP on site may not drive it on a public road, unless they hold the appropriate licence.

1.4.4.15 Prohibited uses MEWPs must not be used: (a)

as jacks, props, ties or supports

(b)

primarily for the transportation of goods or materials

(c)

as an alternative to passenger hoist (for example, transporting workers to a high level floor slab)

(d)

as a crane or lifting appliance.

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Such uses are either outside the designed use and safe working limits of the machine, or would bring it under other statutory provisions, such as those applicable to cranes and hoists.

3

Platforms must not be tied to buildings or other structures to gain additional support. The operation of the controls in such circumstances could cause an accident or create another hazard.

4

Extra height should not be gained by using ladders, stepladders or similar devices on the platform or in the basket of a MEWP. If the machine itself does not reach the required height, it is the wrong machine for the job. An alternative machine must be obtained or an alternative (safe) means of access devised.

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1.4.4.16 Operator requirements

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Physical fitness

People nominated or applying for training as operators should meet the following general requirements: must have full physical mobility

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(d)

must have good hearing in case warning signals are given

(e)

must have the correct colour vision for colour-coded controls (the Ishihara colour test may be relevant)

(f)

must have the ability to accurately judge space and distance

(g)

must have good eye-to-hand co-ordination, and sufficient dexterity to operate the controls

(h)

must have good eyesight, with glasses if necessary. The ability to read a car number plate at 25 m is usually satisfactory

(i)

must have a stable disposition.

must have sufficient agility to climb in and out of the platform must have a good head for heights, and not be subject to vertigo or acrophobia (fear of heights)

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Fainting or dizziness may render people unsuitable as operatives.

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Duties of operators 3

The main duties of operators are: (a)

to operate the machine safely and without risks to themselves or anyone else who may be affected by the works which are being carried out

(b)

to operate the machine in compliance with the manufacturer's instructions and any other training given, and to ensure that it remains safe and stable

(c)

not to abuse, ignore or override any safety device or equipment

(d)

to report all defects, faults or dangerous situations

(e)

to stop work and seek advice in any conditions that they consider could be unsafe to themselves or anyone else.

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Training No-one should be allowed to operate a MEWP unless they have demonstrated their competence on the machine and have had proper and adequate training, unless they are under the direct supervision of a competent person as a part of their training.

5

A wide range of MEWPs is now available, and operators should be trained specifically for the type of machine in use that they are required to use. For example, a person competent to operate a scissor lift would need separate and specific training and become competent before they could use an articulated boom unit ('cherry picker').

6

Both knowledge and skill should be tested during training to ensure that the operative has achieved a satisfactory standard of competence.

7

For all types of unit, three main stages of training can be identified:

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basic understanding of the operating principles, and the knowledge necessary for the day-to-day operation of the platform

(b)

task-specific training and practice on the type of machine concerned, if possible under all foreseeable operating conditions

(c)

properly supervised on-site familiarisation to gain experience and confidence.

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It is important to ensure that operatives fully understand the functions of limit switches and interlocks, and the serious dangers which can be caused by defeating or overriding them.

9

Most manufacturers provide some form of training or offer training courses.

10

When units are hired, it is important to ensure that the hire company provides adequate operative familiarisation training unless trained operators on that type of machine are already available.

11

The demonstration of equipment by a manufacturer's or hire company's representative should not in itself be regarded as sufficient training for those who are to operate it. In addition, the ability and experience of demonstrators and instructors should be verifiable, especially in respect of the user's proposed mode of use of the equipment.

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Other points 12

Operatives should only be permitted to use the type of unit they have been trained and authorised to use.

13

After training, an 'in-Contractor license' should be issued and adequate records kept of initial and any further training.

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The safety element of the training must include safety awareness and recognition of hazards.

1.4.4.17 Hazards 1

Some of the more common hazards associated with the use of MEWPs are outlined below. The list should not be regarded as exhaustive.

Work on or near a highway A collision with another vehicle. Always use barriers, lights, cones, notices, guards, or arrange traffic diversions.

3

The knuckle or elbow of an articulated boom encroaching into a traffic lane. Always ensure adequate space is available.

4

Standing and operating the platform in a traffic lane. Ensure that adequate safety provisions have been made.

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Overhead electrical cables

Electric shock from contact with, or electric arcing due to close approach to, overhead electric cables is often fatal.

6

Always maintain a safe distance from overhead electrical cables. The absolute minimum distance, measured from the furthest point of outreach to the ground level barrier or point directly beneath the nearest conductor, must be at least 6 m (when there is not work or passage under the lines), although most electricity companies recommend 9 m.

7

High winds can cause cables to sway and significantly reduce this distance.

8

No part of any machine should be closer than 15 m to any overhead line on steel pylons (9 m if on a wooden or steel pole) unless by arrangement with the electricity company.

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Falls of people or materials 9

Ensure that fall-arrest or work restraint equipment is worn at all times.

10

Do not allow any loose materials to accumulate on the platform.

11

If there is any danger of tools being dropped from the platform or basket by the operator then, where practical, the tools should be securely tethered to a point within the basket; alternatively, the area beneath the platform should be regarded as a danger area.

Entrapment of people 12

All moving parts and mechanisms should be properly and securely guarded.

13

All operators should be made aware of the hazards and procedures for avoiding entrapment between the platform and any fixed obstruction.

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Overturning Check for soft ground, drains and other unsuitable ground conditions before deploying the outriggers or stabilisers; check for the hazard before siting the machine.

15

Beware of overloading, especially if the platform or basket is being used at maximum outreach to remove fans, motors or other heavy loads. Always observe the safe working load.

16

Be careful when operating on a slope, even with the machine properly levelled by using the stabilisers or outriggers.

17

Always check that the machine is stable before operating.

18

Be careful when travelling with the platform raised, especially on poor ground conditions.

19

Unless the machine is specifically designed to travel while the outriggers or stabilisers are deployed, never attempt to travel in this manner.

20

Be careful not to collide with any obstruction or other vehicle.

21

Modern machines are fitted with a 'tilt sensor' which, if activated, only enables the working platform to be lowered.

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Restricted or enclosed spaces

Extra care is needed when working in, or maneuvering into, restricted or confined spaces to avoid collisions and or entrapment. A full and precise understanding of all controls is essential.

23

If the self-propelled unit has an internal combustion engine, remember that the exhaust fumes will cause a hazard in any confined or enclosed space.

24

Batteries for units should not be charged in enclosed spaces. There is a hazard of explosive hydrogen gases being given off.

25

LPG powered vehicles should not be refuelled in a confined space. Any spillage of fuel will quickly and dramatically expand into a large gas cloud. The gas will then accumulate at the lowest point and create an explosive hazard.

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Interference with vehicles in public places 26

Additional interlocks or guards may be necessary to prevent the operation of, or tampering with, ground level controls by unauthorised persons or children.

27

Care should be taken against the risk of entrapment as a result of inquisitive people, and especially children, getting too close or underneath. Scissor lifts are particularly hazardous.

Other hazards 28

Never attempt to use a unit which has a nearly flat battery. This could result in the operator being stranded aloft, in which case an emergency descent procedure would be required.

29

Avoid knuckles, joints and hoses becoming encrusted with paint, blasting grit, cement or plaster. This can be avoided by using gaiters which are usually supplied by the manufacturer.

30

Beware of the sideways thrust or torque from a drill or hand tools, or the recoil or thrust of

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cartridge tools. Whenever and wherever possible, the platform should be square onto the work. If it is sideways on, any thrust or recoil will push the platform away from the workface. Boom length will increase this effect.

1.4.4.18 Inspections and thorough examinations The maintenance of MEWPs is an essential feature in ensuring their safety when in use. These Regulations require a competent person to draw up a schedule for maintenance, taking into account the machine's mode of use, its frequency of use and the conditions under which it is used.

2

These Regulations require the minimum of a thorough examination before being used for the first time and, thereafter, every six months or when exposed to conditions that may cause deterioration.

3

Records of such inspections should be kept until the next thorough examination or for a period of two years.

4

However, the following inspections are recommended.

5

Daily inspections at start of work, usually carried out by the operator. They should check the following:

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tyre pressures and wheel nuts

(b)

brakes and steering

(c)

fuel, oil, water, hydraulic fluid and battery levels

(d)

lights, warning devices and communications

(e)

structure for visible defects

(f)

all operating controls

(g)

all hydraulic fluid lines for any leaks, however small.

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(a)

(a) (b)

a check of all items covered under the daily inspection an operational check of all functions of the machine a close visual examination of the chassis and structure.

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Weekly inspections by a competent maintenance fitter or operator after a specific number of hours of use. They should be:

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A record that these inspections have been carried out should be kept. .

8

At six-monthly intervals or after 1,000 operational hours, or as recommended by the manufacturer, a thorough examination should be made by a competent person and a written report issued. A similar examination is recommended after an accident, major repair or modification.

Maintenance work on scissor lifts 9

Special care is needed in the care and maintenance of this type of MEWP. No work or inspection should take place within the stack of a scissor lift unless scotches or chocks are used to prevent any entrapment hazard arising from mechanical or hydraulic failure leading to movement of the elevating/lowering mechanism.

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Construction Site Safety 1.4.4 Appendix

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Mobile Elevating Work Platforms

Safety checklist

Has a risk assessment for the work been carried out?

2

Has the daily inspection been completed?

3

Are lanyards always clipped to a strong point on the machine?

4

Ensure that the wind speed is not excessive.

5

Are the correct signs and barriers erected?

6

Is the operative competent, authorised and fully fit?

7

Does the operator have access to a copy of the manufacturer's operating instructions?

8

Ensure that the safe working load will not be exceeded.

9

Ensure that it is all clear overhead.

10

Ensure that the ground conditions are satisfactory.

11

Ensure a current record of the last thorough examination is available prior to use.

12

Are all outriggers and stabilisers safely deployed?

13

Make sure that the machine is level.

14

Ensure as far as possible that there are no cellars, drains or other voids beneath the area where the machine will be working.

15

Make sure that all tools and materials are secure.

16

Is a work restraint system or fall-arrest system necessary and, if so, is it available and used?

17

Make sure that the platform is not slippery or obstructed.

18

Ensure that all work is within the specified reach of the unit.

19

If movement of the machine is planned, ensure that the route is clear and safe.

20

Ensure that there are no restricted or confined space hazards.

21

Ensure that no part of the machine will encroach into a traffic route.

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Ensure that the machine operator is aware of the location of all fixed structures to avoid the risk of entrapment.

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Construction Site Safety 1.4.5

Hoists and Hoist Towers

1.4.5.1 Key points Such equipment must only be designed (where appropriate), erected and operated by trained and competent persons.

2

Partially completed hoists used to move scaffolding during scaffold erection offer special challenges.

3

It is vital that the design of the hoist includes how the hoist will be supported or tied into existing or temporary structures.

4

Hoists that are designated for the carriage of goods only must not be used for carrying passengers.

5

Materials which are unhanded or otherwise loose must not be loaded onto inclined or other types of mobile hoist in such a way that they can fall off.

6

Under no circumstances should the safe working load of a hoist be exceeded.

7

The safe working load will be displayed on a notice attached to the hoist; this is usually expressed as a number of persons for passenger-carrying hoists.

8

Particular safety precautions apply to hoist towers to ensure the safety of passengers (where applicable) and others working nearby.

Note:

Section 9, Part 7 of the QCS covers lifting equipment.

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1.4.5.2 Introduction

Hoists of various types are widely used on construction sites. These range from complicated goods and passenger (tower) hoists, mobile hoists and inclined hoists, and still include the humble gin wheel. As pressure increases to become more efficient and reduce manual handling, hoists are an increasingly vital part of many construction operations. The smooth and rapid movement of persons and materials assists in efficient management of projects. Even where other methods of moving materials around site are to be used, for example by a tower crane, it is not unusual to find a hoist used solely to assist the scaffold" erection process.

2

The number and type of powered hoists available for hire has increased significantly and their use may require a lifting plan to be drawn up by a competent person. This would need to consider possible exclusion zones under the hoist in the event of the load dropping, safe slinging methods, the appropriate lifting accessories, and so on. These are a different set of risks compared with, for example, loads being carried within the enclosed cage of a goods hoist.

3

Risks can arise from a late decision to use a hoist to solve a previously unforeseen problem during the construction phase, for example, if planning to use a hoist attached to a scaffold system that is already in place but which was not originally designed to take the additional loadings. There is a need for careful planning and possibly discussions with the scaffold designer before simply allowing a hoist to be hired and fixed to the scaffold.

4

The installation of hoists requires good planning and co-ordination and must be undertaken by competent individuals. All hoists must be supplied and, where appropriate, erected, altered and dismantled by people who are aware of these Regulations and the relevant British and International Standards. Special attention must be given to ground conditions to ensure adequate support for the hoist. The forces imposed on the structure by the hoist, its loads and inclement weather, particularly high winds, must also be taken into account. Hoist operators must be adequately trained, competent and authorised; and should be specifically

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responsible for ensuring that the hoist is not overloaded or otherwise misused. 5

Except for manually operated hoists and any that have an independent power supply, the requirement for a dedicated power supply to the hoist must also be considered. Power requirements may also mean the need for generators, which introduces potential noise and fuel storage and spillage issues.

1.4.5.3 Health and Safety at Work (Construction Sites) Contractors must provide and maintain plant and systems of work that are, so far as is reasonably practicable, safe and without risk to health.

2

Contractors have a duty to provide their employees with all necessary information, instruction, training and supervision which is necessary to ensure, so far as is reasonably practicable, the health and safety at work of the employees. This applies in respect of all systems of work and all work equipment. In the appropriate circumstances, this duty is also extended to cover subcontracted employees.

3

Employees have a duty to take reasonable care of their own health and safety and the health and safety of others who may be affected by what they do.

Where a hoist tower has to be attached to an existing structure, the client's biggest problem is likely to be the provision of information on the location and load-bearing capacity of secure anchorage points. Given the complexity, size and loading of many systems, this will mean providing detailed information on the existing structure, which may necessitate the commissioning of specialist reports. These would be passed on to the designers and contractors to form part of the pre-construction information. Hoists impact on designers in two ways:

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1.4.5.4 Construction (Design and Management) CDM

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whoever designs the hoist installation must be a competent designer as defined within these Regulations and therefore will assume all of the designer's duties under CDM

(b)

if the design concept is that the materials movement would be by hoist then it must be feasible to erect one. What will the hoist tie to? Are there additional security aspects that need to be considered? Have the attendant logistics for deliveries been considered, for example, can a road closure be obtained?

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Whoever appoints a contractor to provide a hoist will have to consider their competence. CDM contains details of the type of questions to ask to verify organisational and individual competence.

3

When considering the competence of potential contractors, relevant points for consideration would be:

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(a)

to establish how they would check the installation has been designed and installed correctly

(b)

the extent of the training they provide to users

(c)

the handover and subsequent inspection arrangements.

Whilst many site managers are competent to carry out weekly inspections of, for example a simple scaffold hoist, more complex hoists will require additional expertise.

1.4.5.5 The Management of Health and Safety at Work 1

These Regulations formalise the need for risk assessments. Each assessment must be made by competent people and must consider all aspects of the work. A significant factor for

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consideration is where the works will be carried out on occupied premises and where there is the potential for interaction between the construction activities and other people such as the public or the occupier's employees.

1.4.5.6 The Provision and Use of Work Equipment These Regulations require that all work equipment supplied by the Contractor must be safe and without risk to health when properly used, is correct and suitable for the job, and maintained in good working order. In respect of this module, this applies to hoist towers, inclined and other types of mobile hoist, including hired machines and those purchased second-hand.

2

Contractors must provide employees with adequate and appropriate training so that they may use the work equipment safely and without risks to their health, and without risk to the health and safety of any other person who may be affected.

3

Generally, these Regulations require:

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work equipment to be suitable for the job

(b)

proper maintenance of work equipment

(c)

thorough examination after installation before first use and at further suitable intervals by competent persons

(d)

proper recording of inspection results

(e)

its use restricted to specified persons, where necessary

(f)

adequate information to employees concerning risks

(g)

suitable and adequate training on the work equipment

(h)

the guarding of all dangerous parts

(i)

protection against specific hazards

(j)

effective controls, stop controls and emergency controls

(k)

adequate lighting

(l)

appropriate warnings.

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1.4.5.7 Lifting Operations and Lifting Equipment By definition, all types of construction hoist are classified as lifting equipment under these Regulations. The main requirements of these Regulations are that:

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(a)

lifting equipment and accessories must be of adequate strength and the lifting equipment stable, for each lift undertaken

(b)

lifting equipment used for lifting persons is constructed and used so as to protect the safety of the person(s) being carried

(c)

lifting equipment must be positioned or installed so as to prevent the lifting equipment or the load striking a person

(d)

the load must be under full and proper control at all times

(e)

lifting equipment must be equipped with suitable devices to prevent a person falling down a shaft or hoistway

(f)

lifting equipment and accessories must be clearly marked with their safe working load and other markings if designed for lifting persons

(g)

every lift must be properly planned by a competent person, properly supervised and carried out safely

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(h)

lifting equipment must be subjected to a programme of inspections and thorough examination as is appropriate.

2

Reports of thorough examination must be made and retained, with all defects notified to the Contractor who must take appropriate actions.

1.4.5.8 Work at Height 1

The use of any kind of hoist will inevitably involve either persons working at height or loads being raised to height. In almost all cases the erection, dismantling, servicing, loading or unloading of hoists will require that persons work at height.

2

The relevant requirements of these Regulations are: Contractors to ensure that work at height is planned, supervised and carried out in a safe manner by competent person

(b)

work at height is carried out using appropriate work equipment, particularly that which provides collective fall protection

(c)

suitable and sufficient steps are taken to prevent falling objects which are likely to cause injury to any person

(d)

where there is a risk of a person being struck by a falling object, steps are taken to prevent unauthorised access into that area.

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When it has been decided (possibly as early as the tender stage) that a construction (tower) hoist will be required on site, requirements must be quantified with regard to: consideration of the locations for siting the hoist

(b)

the loads to be carried in terms of weight and whether goods only or passengers are to be carried

(c)

the likely loading on the structure and whether any enabling work or structural changes are required

(d)

any constraints in the position where the hoist can be erected and whether other features such as scaffolds must be modified to accommodate the hoist

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the loading on the hoist's foundations

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1.4.5.9 Pre-planning (hoist towers)

2

At an appropriate point both the user of the hoist, for example the Contractor, and the supplier of the hoist should each assign an 'appointed person' who must liaise with each other to ensure that all aspects of the hoist selection, delivery, erection and use are carried out safely. The user's appointed person may need to rely upon the experience and competence of the supplier's appointed person in order to fulfil their responsibilities.

3

The detailed requirements of these roles, both of which require specific training and previous relevant experience, are considered to be outside the scope of this module. If necessary, readers should refer to BS 7212:2006.

4

A full and detailed risk assessment should be carried out before a hoist is positioned. A method statement can then be developed, which must then be agreed with the user.

1.4.5.10 Site survey 5

Prior to delivery of the hoist it will be necessary for both appointed persons to visit the site to establish the practicalities of installing it. During the site survey the supplier's appointed person will determine the appropriate type of hoist required, based upon criteria and

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information on the intended usage of hoist provided by the user's appointed person.

(a)

co-location with materials storage areas

(b)

avoidance of hazardous features such as overhead cables

(c)

the need for safe access at all levels

(d)

safe access to the cage or platform at ground level

(e)

the need for foundations and drainage.

In selecting the most appropriate hoist, the supplier's appointed person will have to take into account such factors as: the space constraints of the area

(b)

access implications relating to the size and weight of the hoist components

(c)

ground conditions

(d)

the proximity of site features such overhead power lines, railway tracks, adjacent public thoroughfares etc.

(e)

other work that will take place whilst the hoist is in place and how the site might change during this period

(f)

foreseeable extremes in weather conditions.

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The findings of the survey will determine the optimum position for the hoist, based upon such factors as:

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1.4.5.11 Erecting hoists

Hoists which rest on the ground must only be erected on a firm base, adequately supported and secured. All materials supporting the hoist must be strong enough to support the weight of the completed hoist structure and its maximum load, and be free from defects.

2

The erection of the hoist must be carried out in accordance with a method statement that has been discussed and approved by the user, as the proposed method and timing may impact upon other site activities.

3

In many ways, this is the most dangerous part of the work. Anyone not directly involved in erecting the hoist should keep clear of the area.

4

However, planning how the hoist will be erected and deciding 'who is responsible for what' is key to implementing a safe system of work. This is particularly important where the hoist will be built in conjunction with the erection of a scaffold. It is essential that the erection, and later modification and dismantling, of hoists are properly planned, adequately supervised and carried out in a safe manner by competent persons.

5

Where the hoist is attached to and supported by a scaffold, the scaffold must be designed to take account of the imposed loadings. This becomes more important where the use of a larger capacity hoist is being considered. These can lift weights of 1000 kg to heights of up to 60 m and can obviously exert significant loading on the hoist anchorages and scaffold ties.

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1.4.5.12 Use of part-erected hoists 1

It is common practice for scaffolders to build three or four lifts of scaffold, raising the components by hand, followed by the hoist company erecting the hoist to the height of the scaffold. Further erection of the part-completed hoist is co-ordinated with the scaffold contractors so that it can be used for hoisting scaffold components, as it follows the scaffold up. In such circumstances, normal safe working practices may not be practical. For example,

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the rules regarding the interlocking of landing gates cannot be applied when some of the gates have not been installed. Detailed guidance is available and it is strongly recommended that anyone faced with this situation on their site obtains and reads it. The guidance is published jointly by the UK National Access and Scaffolding Federation.

1.4.5.13 Safety of hoistways, platforms and cages Where necessary to prevent injury, hoistways and/or the hoisting machinery must be segregated by a substantial enclosure at ground level. Suitable barriers must be installed at all other access points, over the full height of travel, and wherever persons could be struck by any moving part, to prevent injury and/or falls.

2

Consideration must be given to the area around the base of the hoist with regard to loading and unloading materials, and whether a ramp or pit is required to facilitate access to the platform.

3

The area between the cage or platform and the host structure (the threshold) must be suitably protected to prevent any person or material falling through the gap at each landing.

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1.4.5.14 Landings

Where access to a hoist tower is required at several levels, consideration must be given to the space requirements at each landing with regard to loading and unloading the hoist. It is essential that each landing and threshold (the area between the platform and landing) can withstand the loads that will be imposed, with particular emphasis on items such as pallet trucks which can impose significant point-loading.

2

The mechanical or electrical features of the hoist should ensure that:

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the gates at any landing point cannot be opened unless the cage or platform is at that landing point

(b)

the cage or platform cannot be set in motion unless all of the landing gates are closed and latched.

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Winches for hoists must be constructed so that a brake is applied when the control lever or switch is not held in the operating position (the dead-man's handle concept), or if the power fails.

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1.4.5.15 Winches

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1.4.5.16 Handover 1

Once erected, the hoist will be subjected to a thorough examination, after which the supplier's appointed person should arrange to formally hand over the hoist to the user's appointed person.

2

The user's appointed person should arrange for all trained operators to be present at the handover of the hoist to receive:

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(a)

familiarisation training on the use of the hoist in normal operations

(b)

instruction on what to do in emergency situations

(c)

instruction on how to carry out the daily pre-use inspections and weekly inspections.

A handover report, containing details of the instruction given, should be passed to the user's appointed person.

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1.4.5.17 Operation of hoists It is essential that only operators who have been trained in the use of the hoist are allowed to operate it. The operator should: (a)

know the rated load of the hoist

(b)

be able to accurately assess the weight and distribution of any load brought on to the hoist, and therefore identify if it is overloaded

(c)

have access to accurate wind-speed figures and be aware of any limitations placed on the hoist

(d)

be able to lower the hoist to the next landing in the event of a power failure (passenger carrying hoists only)

(e)

carry out daily pre-use checks and weekly inspections, and take the appropriate follow-up action as necessary. On some complex hoists, it will be necessary for the weekly inspection will be carried out by an employee of the hoist company.

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Each hoist should only be capable of being operated from one position at any one time. Where the operator is not carried on the platform or cage, they must have a clear view at all levels from the operating position or, if they have not, arrangements must be made for signals to be given to them at each level.

3

Whatever the system of signalling used, it must be distinct and clear to the person being signalled.

4

It is reasonable to expect that the hoist operator and the person(s) giving signals are at least 18 years of age. Irrespective of their age, hoist operators must be trained and competent unless under constant supervision by a competent person, for the purpose of training.

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The platform of a goods hoist must carry a notice stating: the safe working load

(b)

that passengers must not ride on the hoist.

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1.4.5.18 Safety notices

Cages for passenger hoists must carry a notice stating: the safe working load

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the maximum number of passengers that can be carried

1.4.5.19 Carriage of persons in hoists 1

No person should be carried by a hoist, unless it is a designated passenger lift and it is provided with: (a)

gates that shut to prevent persons falling out or being trapped between the cage and any other part

(b)

an efficient interlocking device which ensures that gates can only be operated when the cage is at the landing place, and that the cage cannot be moved until the gate is closed

(c)

an efficient automatic overrun device to ensure the cage will come to rest at its lowest point of travel.

2

The construction of the cage must be such as to protect passengers from falling objects.

3

No person should be allowed to travel in a hoist that is designated a 'goods only hoist'.

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1.4.5.20 Security of loads All loads must be secured to prevent any part slipping and falling.

2

Loose materials, for example, bricks and slates, must be lifted in a properly designed box, cage or other container. If loose materials are carried on the platform of a hoist, side boards must be fitted or other precautions taken to prevent anything falling. Wheelbarrows must be prevented from moving and must not be overfilled.

3

If hiring a powered scaffold hoist, consideration must be given as to how loads will be slung. Hoisting a wheelbarrow full of render using fabric slings is not likely to be considered as an acceptable or safe solution. Some of these now have a lifting capacity of 1000 kg and are far removed from simple powered gin wheels. The use of the proper lifting accessories, which can be hired-in with the hoist, is strongly recommended.

4

The slinging of loads may become an issue and whilst the suppliers may call the equipment a hoist, some are more akin to cranes, and users may, depending upon the nature of the load, need to be trained in safe slinging techniques.

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1.4.5.21 Inspection and thorough examination of hoists Inspection 1

These Regulations recommend that construction hoists are subjected to the following regime of checks and inspections, by a competent person who has been trained to the appropriate level. (a)

Daily pre-use checks, carried out by a person who has been trained to do it. This will often be the hoist operator who has been trained by the hire company.

(b)

A more thorough weekly inspection, which, depending upon the complexity of the hoist, may be carried out by the trained hoist operator. A greater degree of

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2

In either case, any defect discovered should be reported to the user of the hoist and, where necessary, the hoist put out of use until rectified.

3

In addition, passenger or goods hoists must be tested each time:

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(a)

the height of the hoistway is altered or

(b)

gates or ties are added or removed to check for safe operation of the hoist.

Hoists which are not in regular use may need a special programme of checks, carried out by a competent person.

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All hoists must be thoroughly examined by a competent person: before first use on site

(b)

after substantial alteration, modification or repair

(c)

after any exceptional circumstance, such as accidental overloading, and

(d)

at least every six months if used for carrying passengers, or

(e)

at least every 12 months if used for carrying goods.

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Thorough examination

Accessories for lifting must be thoroughly examined at least every six months.

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If, as a result of any thorough examination, a risk of imminent personal injury is identified, a copy of the report must be sent without delay to the Qatar Enforcing Authority.

8

Note: Where manufacturers recommend inspection at different intervals to the statutory periods, such recommendations should be followed and records kept.

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1.4.5.22 Keeping of reports, records, etc. These Regulations require that all testing, inspections and examinations are carried out by a competent person, and records kept by ways or means best suited to the needs of the Contractor concerned.

2

This enables the keeping of records in an electronic format provided that:

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(a)

the correct information is kept as is required by these Regulations

(b)

it is secure against loss or unauthorised interference

(c)

it is capable of being provided as a printed copy

(d)

it is authenticated by a competent person.

The reports or copies would normally be stored at the premises where the lifting equipment, in this case a hoist or hoists, is being used. Where this is not possible due to space constraints or for security reasons, then reports can be stored elsewhere, such as on a computer, provided that they are readily accessible.

1.4.5.23 Mobile hoists 1

Mobile hoists and conveyors are now commonly used throughout the construction industry. They can be easily transported to the site, are quickly erected and require little operating space. They may be fitted with buckets, skips, platforms or cages.

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Different models allow for basic height variations of between 8 metres and 30 metres, although much greater heights can be reached with extensions. Load capacity varies with the model but lifting capacity of 500 kg is not untypical.

1.4.5.24 Scaffold cranes or barrow hoists These are lifting appliances within the meaning of these Regulations

2

Care must be taken to see that they are not overloaded and are only attached to scaffolds in strict accordance with the manufacturer's recommendations and the scaffold design.

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1.4.5.25 Inclined hoists

These are lifting equipment within the meaning of these Regulations. They are particularly useful for trades such as bricklaying and traditional roofing, and indeed on a larger project they have the potential to eliminate a significant amount of manual handling.

2

Inclined hoists are also known as roof tile or brick carriers. New developments include telescopic and slewing functions. Load capacities go up to 200 kg and lateral extensions may be up to 35 metres.

3

Inclined hoists are specifically designed for use at angles between 10° and 85°, and they may also incorporate a hinged section to allow the hoist to follow the pitch of a roof.

4

They also provide flexible solutions to the problems of removing demolition waste in refurbishment situations. As they are in effect a conveyor belt system, care needs to be taken to ensure that the guards to the rollers are in place to ensure that fingers and/or clothing can not be dragged in. These are so called 'in running nips' and particularly where the motor driving the hoist is powerful the potential for serious injury is significant.

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1.4.5.26 Gin wheels

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In many cases provision has to be made to raise tools and light materials manually with a rope and gin wheel or single block. Whilst these are still in common use, modern variants are available, which incorporate an automatic locking mechanism to prevent the load from going into free-fall if the hoisting rope is accidentally released.

2

The following provisions and requirements apply to gin wheels connected to a scaffold:

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(a)

poles and hooks should be strong enough to take the load which is to be lifted and be properly secured to prevent movement

(b)

all ropes should comply with the relevant British or International Standard and fit the wheel correctly. They should be marked with a tag confirming their safe working load

(c)

preferably, the gin wheel should be suspended from a ring-type fitting passed over the end of the supporting tube and secured against lateral movement by scaffold fittings. If using a hook type, it

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(d)

any joints in standards should be made with sleeve couplers

(e)

gin wheels should be suspended not more than 750 mm from the outer support

(f)

hooks used for supporting materials should be safety hooks and spliced into the rope

(g)

the maximum loading should be no more than 50 kg at 750 mm from the outer support.

Inspection and thorough examination Whilst of simple construction, gin wheels are categorised as lifting equipment so must be thoroughly examined before use and then at least every 12 months, with a test certificate issued.

4

Similarly, the lifting accessories used -such as the rope, hook and shackles -must be thoroughly examined before use and then at least every six months.

5

Given the scope for the harsh treatment of this type of equipment, all parts of a gin wheel assembly should be thoroughly examined at least every six months.

6

The extent of any thorough examination should reflect the risks that would arise from its failure.

7

Where scaffolds are not available, other suitable anchorages must be provided if necessary by using counterweights.

8

If the appliance to be attached is a gin wheel, a safety factor of not less than three must be allowed when calculating the weight of the counterweight.

9

If the load to be lifted is G (in kilograms), twice G must be allowed because of the downward pull on the tail rope when raising the load; to this 0.5 G is added for friction.

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To calculate the counterweight required, the following formula should be used: W = 3(2.5 x G x 0) T

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Where:

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W = Counterweight T = Tail length (metres) G = Greatest load to be lifted 0 = Overhang (metres) Reference BS 1261, BS EN 698, 699, 700 and 701

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Construction Site Safety 1.4.5 Appendix 1 Hoist towers safety checklist Pre-planning Have design calculations been obtained to ensure that the host structure can withstand the loads

2

Have the risks associated with having the hoist delivered, erected, used, modified and dismantled been assessed?

3

Have relevant other parties been informed of how these activities will affect the work that they have to do?

4

Has a method statement been agreed between the hoist company and the user?

5

Have the hoist company and the user each selected an 'appointed person'?

6

Has there been sufficient liaison between both appointed persons?

7

Have arrangements been made for the installation and testing of an adequate and safe electrical power supply?

8

If the hoist is not electric, have arrangements been made for the safe storage and decanting of petrol?

9

Is a foundation necessary and if so:

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is a design necessary?

(b)

is the extent of enabling work known?

(c)

must arrangements be made for drainage?

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Protection and access

Is the hoistway and any moving parts of its machinery protected by an enclosure?

2

Is the hoist tower completely enclosed on all four sides with wire mesh (except any landing)?

3

Have appropriate measures to taken to ensure safe access to the cage or platform at ground level?

4

Is it not possible to set the hoist in motion whilst any gate at ground level or at any landing is open?

5

Can the gates at any landing point only be opened if the cage is at that landing point?

6

Is any gap between the platform and tower (threshold) closely boarded?

7

Are landing stages kept free of plant or materials?

8

Is the hoist fitted with an overrun device at its highest point?

9

Is the hoist fitted with an efficient device capable of supporting the platform and load in the event of a failure of ropes or lifting gear?

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Loadings 1

Are loadings placed on a hoist tower as recommended by the manufacturer?

2

Are all loads evenly distributed?

3

Are loads prevented from displacement?

4

Are all wheelbarrows chocked?

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5

Is a safe working load notice displayed on the platform or cage and can it be clearly seen at all levels?

6

Is the safe working load strictly complied with?

7

Is the carriage of passengers on goods only hoists clearly prohibited and this communicated by appropriate signs?

8

Are special precautions put in place when the load will overhang the cage or platform?

Operation Is it clearly understood that the hoist must not be operated from inside the hoist enclosure?

2

Are the hoist controls so arranged that the hoist can only be operated from one position at any one time?

3

Is the operator's position safe and adequately guarded with hand-rails and toe-boards?

4

Is the operator provided with a clear view of the platform at all times?

5

Are all operators trained, competent, and not under 18 years of age (unless under constant supervision of a competent person)?

6

Are all signals connected with the operation of the hoist clear and distinct?

7

Is adequate lighting provided at all loading places?

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Testing and thorough examination

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Hoist

All hoists should be tested and thoroughly examined before use and after any substantial alteration or repair.

2

All material (goods) hoists should have been subjected to a thorough examination within the preceding 12 months.

3

It is good safety practice for all hoists to be inspected weekly by a competent person.

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Winch

All material (goods) hoist winches must be thoroughly examined every 12 months, or in accordance with an examination scheme of lesser intervals.

2

All hoist winches should be inspected weekly by a competent person.

3

All wire ropes used in conjunction with a material hoist winch must be thoroughly inspected every 12 months, or in accordance with an examination scheme of lesser intervals.

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Major defects 1

Any report relating to a thorough examination of a hoist showing that there is a defect involving an existing or imminent risk of serious personal injury must be sent to the Qatar Enforcing Authority.

2

Any such report must also be given immediately to the Contractor. The hoist must not be used before the defect is rectified.

Recording requirements Tests and examinations 1

Tests and examinations must be recorded before first use, after re-erection, alteration or repair and following alteration in height of travel.

2

The results of thorough examinations carried out before first use must be recorded in

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whatever manner the company requires and that record must be available for inspection.

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It is good practice to ensure that a weekly inspection is carried out and recorded in whatever manner the company requires and kept available for inspection.

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Construction Site Safety 1.4.6

Plant and Work Equipment

1.4.6.1 Key points The term 'work equipment' is self-explanatory and very wide ranging; it refers to any item of equipment being 'used' to carry out work.

2

The word 'used' means any activity involving the work equipment, including: starting, stopping, repairing, modifying, maintaining, servicing or repairing.

3

Examples are an excavator, a hammer, a cement mixer and a hydraulic trench-support system.

4

Broadly speaking, the effort necessary to comply will depend upon the complexity of the equipment and its potential to cause harm; for example, a trowel will not require the same level of inspection as an electric goods hoist.

5

These Regulations also require anyone who uses an item of work equipment to be trained and competent to do so.

6

The effort and time needed to achieve the required level of competence will depend upon the complexity of the equipment and its potential to cause harm.

7

Work equipment must be inspected as necessary to ensure that it can continue to be used safely.

8

Certain work equipment must also be subjected to a schedule of thorough examinations.

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It is all referred to as 'work equipment' and includes all: toolbox tools, such as hammers and screwdrivers

(b)

powered tools, including electric and pneumatic (such as hand drills and circular saws)

(c)

testing and laboratory equipment, such as cube crushers

(d)

complex structures and machines made up of other components and equipment are also covered, such as scaffolds.

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1.4.6.2 Introduction

Some types of powered hand tools, such as engine-powered cutting-off machines and chainsaws, have the potential to cause severe personal injury unless they are used by trained and competent persons in appropriate circumstances.

3

Another type of equipment commonly used in the construction industry that has the potential to cause harm if not properly used is mechanical equipment that operates through the application of leverage or torque. This includes jacks, winches and various cutting and bending tools that incorporate manually operated mechanisms.

4

Tools and equipment operated by air also cause significant injuries upon failure of the tools or the connections to the compressor.

5

All items of plant are classified as work equipment, including static and mobile equipment, pedestrian-controlled equipment, ride-on equipment and remote-controlled equipment.

6

Plant used in construction operations on site includes static plant used in the actual construction work, such as mixers and pumps.

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1.4.6.3 Health and Safety at Work (Construction Sites) These Regulations place general duty on all Contractors to provide safe plant and machinery for use at work. The self-employed worker is given similar duties regarding plant and machinery that they provide for their own use.

2

Additionally, these Regulations place a duty on Contractors to provide the information, instruction, training and supervision necessary for persons to be able to operate the plant and machinery safely. Employees, in turn, are required to use the equipment safely, in accordance with the training which they have been given.

3

A general duty is placed on any person who manufactures, designs, imports or supplies any article, materials or substance for use at work to ensure, so far as is reasonably practicable, that articles and substances are, by design and construction, safe and without risks to health when being used, set, cleaned or maintained by persons at work.

4

In addition, duties are placed on employees not to recklessly interfere or misuse anything provided for health and safety purposes. This could include the act of removing a guard or defeating a safety cut out switch.

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1.4.6.4 The Management of Health and Safety at Work

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These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or other people might encounter as a result of the work being carried out.

2

Once those hazards have been identified, it is then the Contractor's duty to put control measures into place, to either eliminate the hazards or, where this is not possible, reduce the risk of injury or ill health resulting from those hazards, as far as is reasonably practicable.

3

The Contractor must, through the risk assessment process, establish any risks to the health and safety of any employee (or anyone else) arising out of the use of any item of work equipment. They must take the necessary steps to ensure that the equipment can be used safely.

4

This will involve:

providing employees with comprehensible and relevant information on any risks that exist with regard to the use of work equipment

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informing employees of any control measures that are in place to reduce those risks

(c)

taking into account the capabilities of employees who are required to use work equipment

(d)

providing adequate (health and safety) training in the use of potentially hazardous work equipment.

Employees, for their part, have a duty under these Regulations to tell their Contractor of any work situation that presents a risk to the health and safety of themselves or of any other person who may be affected.

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1.4.6.5 Provision and Use of Work Equipment 1

These Regulations are fundamental to the health and safety aspects of how work equipment is selected, used and maintained.

2

These Regulations place legal duties on Contractors with regard to work equipment that they provide to employees and the self-employed for their own use, and those who otherwise have control of work equipment, such as those who hire in equipment.

3

These duties are to: only provide work equipment that is suitable for the job

(b)

ensure that work equipment is maintained in an efficient state and kept in good working order by persons who are trained to do so

(c)

ensure that maintenance logs are kept up to date where they exist

(d)

ensure that where the safety of work equipment depends on the way it is installed, it is inspected as necessary and records of inspections made

(e)

ensure that equipment subject to deterioration through exposed conditions, which could give rise to a dangerous situation, is maintained and inspected at appropriate intervals to allow remedy, or after each exceptional circumstance

(f)

ensure that where the use of work equipment involves a specific risk to the health and safety of employees, the use, maintenance, repair, modification and service of the equipment is restricted to competent and specified workers

(g)

provide employees with information, instruction and training in the use of work equipment, where necessary for their health and safety, including abnormal situations

(h)

ensure that work equipment has been designed and constructed in compliance with any European Safety or International Safety Directives?

(i)

ensure that dangerous parts of machinery are adequately guarded, where practical, by fixed guards that cannot be defeated or removed

(j)

take measures to protect the health and safety of any person from exposure to:

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anything falling from or being ejected from any item of work equipment

(ii)

rupture or disintegration of any parts of work equipment

(iii)

work equipment overheating or catching fire

(iv)

the unintended discharge of any article, dust or gas which is produced by or stored in the work equipment

(v)

the unintended explosion of any item of work equipment or any article or substance produced, used or stored in it

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(k)

ensure that users of work equipment are adequately protected from any part of the work equipment that exposes them to very high or low temperatures

(l)

ensure that all work equipment has adequate controls, emergency controls and, where necessary, a control system to enable it to be used safely

(m)

ensure that where stop controls are fitted, they bring the machine to a safe condition. This may include bringing the machine to a complete stop and/or isolating it from energy sources

(n)

ensure that where stop controls are provided, they are easily accessible and activated

(o)

ensure that all controls for use are easily identifiable and that where reasonably practicable, the operator is in a position of safety when operating them

(p)

ensure that failure of any equipment leads to a safe situation and that the function of

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(r)

ensure that work equipment is stable in use, if necessary by clamping

(s)

ensure that suitable and sufficient levels of light are available for the safe operation of work equipment

(t)

ensure where reasonably practicable, that servicing, maintaining and cleaning of equipment is carried out whilst it is shut down or with appropriate measures in place to safeguard employees

(u)

ensure, where appropriate, that warnings are incorporated. These can range from signs and notices, to alarms and beacons.

Specific conditions apply to mobile and self-propelled work equipment that has the potential to cause injury to employees and third parties. These require the Contractor to:

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(q)

ensure that no one is carried on mobile equipment unless provision is made for carrying passengers and provisions for their safety are made

(b)

ensure where there is a risk of an operator being injured from plant turning over, that sufficient steps are taken to prevent the machine from overturning or the provision of a roll over protection system (ROPS) (see below for further detail)

(c)

ensure that equipment has facilities to prevent unauthorised start-up, has appropriate controls, anti-collision measures (rail-mounted equipment) and, if required, has suitable lighting and adequate fire-fighting facilities

(d)

ensure that the operator of such plant and equipment has suitable vision in all directions, with visibility aids if direct vision is blocked, so far as reasonably practicable

(e)

ensure that remote controlled equipment stops automatically upon leaving its control range and incorporates anti crush and impact devices that are appropriate

(f)

ensure that measures are taken to prevent drive shaft seizures and systems for safeguarding drive shafts.

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(a)

These Regulations apply to all lifting equipment and accessories, such as cranes, shackles, hoists and slings that are used to carry out mechanical lifting operations.

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1.4.6.6 Lifting Operations and Lifting Equipment

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1.4.6.7 General requirements applicable to all work equipment Suitability for purpose 1

All equipment that is used to carry out a work activity must be suitable for the work to be carried out.

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Improvisation is dangerous and can lead to serious accidents occurring. A hand-held circular saw being used instead of a router to cut grooves or rebates in timber, or a dumper being used to transport persons, both have the potential to create dangerous situations.

3

All work equipment must be regularly maintained in an efficient state, in efficient working order and in good repair (as described in the following section).

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To be able to work as safely as possible, it is essential that work equipment is regularly maintained, again by a competent person. In practice, maintenance is usually divided into three types of activity: (a)

daily basic maintenance can be as simple as regularly checking the oil and water levels of a petrol-driven cement mixer, and is sometimes referred to as 'pre-use checks'

(b)

periodic maintenance of equipment involves more detailed checks than carried out under 'daily maintenance' and is usually carried out by a fitter as part of a pre-planned programme of regular inspections, for example the replacement of engine oil or hydraulic oil filters

(c)

detailed inspection and servicing, which may involve a degree of dismantling of the equipment in a workshop and entail, for example, the measurement of wear of moving parts or the integrity of hydraulic hoses and connections. This type of inspection is carried out at specific intervals according to the manufacturer's instructions and is often based on the 'running hours' of the equipment.

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Maintenance

5

In conjunction with manufacturers' guidance, the competent person should draw up a programme of the frequency of maintenance to be applied to work equipment.

6

In drawing up the programme, there will be a need to take certain factors into consideration. (a)

The type, class and complexity of equipment.

(b)

Some types require weekly maintenance, others less frequent maintenance.

(c)

The frequency that a piece of work equipment is used.

(d)

Equipment in regular use will probably require more frequent maintenance than equipment used infrequently.

(e)

The equipment's potential to cause serious harm. Powered machinery with the potential to cause serious harm, for example a circular saw, will require more regular attention than a hammer.

(f)

The likely deterioration of work equipment when not in use.

(g)

The environment that the equipment is used in.

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Inspection

All work equipment must be inspected at suitable intervals and records of inspections made.

9

As with maintenance, a competent person must set up an inspection regime, in accordance with legal requirements and manufacturers' guidance. The frequency of inspection is not specified.

10

The level of inspection will depend on the complexity of the equipment and vary from a visual inspection to a comprehensive inspection that might include some dismantling and testing.

11

Usually inspection is undertaken as part of the maintenance activity as well, but inspection falls into two broad headings.

12

A visual check of low risk items before use will suffice for items such as hand tools, to check they are in good order. These inspections are not usually formally recorded inspections. In addition, equipment that poses a high risk, such as some plant, or is used in a high risk environment, such as a confined space, should undergo a visual check every time before use -usually an operator inspection, provided they are competent to do so.

13

More complex equipment and equipment used in higher risk areas should also undergo a formal inspection, after which the details of the inspection are recorded.

14

When deciding the frequency of inspections, the following points need to be considered:

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(a)

the type and class of the equipment

(b)

the frequency of use of the equipment

(c)

the potential of the equipment to cause serious harm if not maintained

(d)

the likely deterioration of the equipment whether in use or in store

(e)

the environment in which the equipment is being used.

15

Normal practice for most plant is to undergo a weekly formal inspection, in addition to the driver's daily inspection. The frequency of inspections may be adjusted after considering the above factors.

16

The following legislation also place duties on Contractors to ensure that specific work equipment and areas of work (which will also involve inspecting the associated work equipment) are inspected as highlighted below.

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Work at Height 17

These Regulations specifically require the inspection of work equipment used for working at height, such as scaffolds, and the recording of those inspections as detailed in these Regulations.

Construction (Design and Management) CDM 18

These Regulations require that: (a)

excavations which are supported are inspected at specific intervals

(b)

energy distribution systems are checked as necessary to prevent danger

both of which will involve the inspection of the associated work equipment.

20

Furthermore, these Regulations place duties on those people in charge of sites with regard to the safe use of vehicles on site.

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Records of inspection

These Regulations require that systems must be put in place for recording the results of inspections, Unlike in the past when prescribed registers had to be used, Contractors can produce their own records in paper form or electronically, providing that they can produce hard copy if requested.

22

Inspection records should include the following:

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information on the type and model of the equipment

(b)

any identification mark or number

(c)

its normal storage or use location

(d)

the date that the inspection was carried out

(e)

the name of the person who carried out the inspection

(f)

any faults found

(g)

any corrective action which was necessary

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to whom the faults were reported and details of the action taken the date when repairs or other necessary action were carried out and by whom.

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When hiring equipment, the records and results of the last inspection should be supplied, by the hire company, with the equipment.

24

There is no specified format for records of inspection, providing the necessary details are recorded.

Conformity with EU requirements or equivalent standards 25

Contractors should ensure that any work equipment that is in use or acquired, either new or second-hand, has a 'CE' or equivalent mark. This indicates that there is a relevant European product directive equipment and that it has been manufactured to known standards.

Training 26

Many accidents involving plant and equipment occur because the operator, through lack of training, is not competent. It is therefore essential that persons are adequately trained in the safe and correct use of the type of equipment they are required to operate.

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The level and complexity of the training required should be such that an operative can operate the plant or equipment safely, without risk to themselves or others who may be affected by their actions or omissions. In addition, adequate training should be given to supervisors and managers to allow them to understand the equipment and methods used.

Quick-hitches The operatives selected for training should be both physically and mentally able to cope with any situation the use of the item of plant or equipment demands. For example: (a)

a person with a fear of heights would not be suitable for training as a tower crane driver

(b)

a person who suffers from claustrophobia would be unsuitable as an operator of a tunnel-boring machine.

(c)

The intellect of the person to be trained should also be judged, to ensure that they can assimilate the information they will be expected to retain in order to carry out their tasks safely.

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1.4.6.8 Types of plant and equipment -specific requirements and risks

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Mobile work equipment

Mobile work equipment is any work equipment that carries out work while it is travelling, or which travels between different locations where it is used to carry out work. Mobile work equipment may be self-propelled, towed or remotely controlled, and may be fitted with attachments.

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Examples of the types of equipment falling within these definitions include:

(b)

diggers

(c)

loaders

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site transport

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remote controlled rollers etc.

(h)

trailers.

forklift trucks

compressors

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General considerations 3

The movement of mobile work equipment, whether over site roads or within specific areas, involves different and continually changing hazards. These have the potential to cause harm, such as: (a)

persons being struck or run over

(b)

persons being thrown from moving plant or equipment

(c)

persons being crushed by moving plant or equipment.

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Practical measures which should be considered to ensure that mobile plant and equipment can be used safely on site are: traffic routes should be planned in order to minimise congestion and risk of collision

(b)

these routes should be kept free of obstructions and properly maintained, with access points restricted and clearly marked

(c)

appropriate speed limits should be introduced

(d)

one-way traffic systems should be implemented if possible and appropriate parking places should be designated for delivery vehicles and those left temporarily on site

(e)

the operating area should be clear, as far as possible, on all sides

(f)

where excavation is taking place, operators must know the location of any overhead power lines, underground cables, sewers, ducts or services before digging operations commence

(g)

trenches and excavations should be fenced or otherwise guarded

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where equipment fitted with outriggers or stabilisers is used, the load-bearing capacity of the ground should be assessed so that the imposed loads do not exceed this capacity

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(i)

ground conditions should be stable and sufficiently level for the operations being carried out and the equipment used

(j)

where site vehicles are employed in tipping material into excavations, baulks of timber or other effective blocks should be provided to prevent the vehicle over-running the edge

(k)

excavations may have to be provided with extra support or shoring to prevent the weight of adjacent vehicles causing a collapse (surcharging).

5

Vehicles and plant designed for specific operations must only be used for those operations, and the design limitations and permitted modes of operation specified by the manufacturer must be complied with.

6

The overloading or overstressing of plant is particularly dangerous and must be prohibited. Manufacturers' and suppliers' instruction and information manuals should be made available for all who may need them.

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Forward-tipping dump trucks

(a)

overturning on slopes, rough ground and at the edges of excavations

(b)

travelling with a high-lift skip in the raised position

(c)

the driver failing to observe pedestrians who are then run over by the front wheels

(d)

the driver being thrown from the vehicle whilst travelling over rough ground

(e)

driver error due to lack of experience and training, including accidental operation of the controls.

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Efforts to reduce dumper accidents must focus on: effective site management and control of how dumpers are operated generally

(b)

selecting the correct machine for the job

(c)

ensuring that machines are routinely inspected, serviced and withdrawn from use if unsafe

(d)

ensuring that only trained, competent drivers are allowed to operate dumpers, which includes removing the key when not in use

(e)

ensuring that site roads are suitable and safe for the use of dumpers.

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Amongst mobile plant, forward-tipping site dumpers are worthy of special note because they are involved in a disproportionately high number of plant-related accidents. This applies to both rigid-frame and articulated dumpers. The common causes of these accidents are:

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Material unloading and loading

Materials that are unloaded or tipped from plant should be deposited in planned locations where they will not cause an obstruction or hazard.

10

A signaller should assist the driver during any tipping operation to ensure that it is safe to tip and that there are no other hazards to be encountered during the operation.

11

Operatives must not remain on vehicles that are being loaded unless the vehicle is equipped with a reinforced cab or falling object protection system (FOPS).

12

Operatives working with plant or vehicles, or on sites where there are regular vehicle movements, should be provided with the appropriate personal protective equipment which should include high visibility clothing.

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Roll-over protection systems (ROPS) 13

Where there is the risk of mobile work equipment rolling over, Contractors have a duty to ensure that protective measures, such as reinforced cabs or a roll-cage, are fitted to stop mobile equipment doing anything more than falling onto its side, thereby minimising the risk of a person being crushed. The cabs or roll-cages should give adequate clearance for operatives to escape if the equipment does completely overturn.

14

Where there is a risk of an operator being thrown then crushed by equipment rolling over, a suitable restraining system (such as a seat belt) should be fitted.

15

This requirement may also apply to equipment fitted with a fully enclosed cab if there is a risk that a person being thrown from their seat could be injured by coming into contact with the inside of the cab's structure.

16

Restraining systems must be fixed to a strong anchorage point on the main structure of the equipment.

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In areas of limited access, ROPS may be removed only if a suitable and sufficient risk assessment has been carried out and there is no risk of overturning.

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There is no requirement for forklift trucks fitted with a vertical mast to be provided with specific roll-over protection where the mast acts as an anti-roll device. There is, however, no exemption from forklifts having to be fitted with restraining systems.

Where there is the risk to persons operating mobile work equipment of being struck by falling material, overhead protection or reinforced cabs must be fitted which stop any falling material striking the operator.

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Falling object protection system (FOPS)

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Roll-over of forklift trucks

Prevention of unauthorised start-up 20

It must not be possible for self-propelled mobile work equipment to be started by unauthorised persons when the vehicle is parked. Additionally, it must be possible to isolate the drive mechanism. This can be achieved by the removal of ignition keys or starting handles.

Lighting and warnings 21

When self-propelled mobile work equipment is used in the dark or in reduced visibility, lights must be fitted and used to enable the work area to be adequately illuminated. In addition, amber flashing beacons that give warning of the presence of the vehicle should be fitted and used. It is required that some types of construction vehicles be fitted with audible reversing

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warning devices or similar devices, such as CCTV. Ride-on plant Ride-on plant refers to equipment that is operated or used with persons 'riding on' the piece of plant as opposed to riding in it. Some trucks, excavators and planers are among the types of equipment within this category.

23

Plant that is not designed to carry passengers should be provided with a notice clearly stating 'No Passengers'.

24

People can only be carried if the vehicle has been designed for such a purpose. Passengers and drivers must not be carried unless proper seating, strongly and correctly connected to the main structure of the vehicle, is provided.

25

Where passengers are permitted to be carried, additional restraining devices must be provided.

26

Where on-board work activities have to be carried out, seating should be provided, if possible, with work platforms fitted with suitable barriers or guard-rails to stop operatives falling from the equipment whilst it is in motion.

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All-round visibility

To ensure safe operation of plant, a standard is being accepted whereby the operator of the plant or vehicle has all-round vision from the operating position. It is generally accepted that the operator should be able to see, at all times, an object positioned 1 metre above ground level and 1 metre away from the plant through 360° visibility.

28

This can usually be achieved by the use of additional mirrors, convex mirrors or by CCTV.

29

Where this is not possible, consideration should be given to providing a competent, qualified signaller working exclusively with the plant operator.

30

Contractors meeting the above criteria would be seen to be doing what is reasonably practicable to provide a safe place of work and a safe system of work in respect of that item of plant.

31

Every Contractor must ensure that the work equipment is so constructed or adapted as to be suitable for the purpose for which it was provided.

32

In selecting the work equipment, every Contractor shall take account of the working conditions and to the risks to the health and safety of persons who are in the vicinity of where the work equipment is to be used.

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1.4.6.9 Pedestrian-controlled work equipment 1

This type of equipment relies heavily on the experience and competence of the operative for its safe operation. Small pedestrian-operated rollers, vibrating or 'whacker' plates and surface grinders are among the types of equipment within this category.

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Common accidents involving pedestrian-controlled equipment occur when operators of small vibrating rollers are crushed between the machine and adjacent obstructions. This is one reason why these Regulations require efficient stop controls to be fitted.

3

It is also essential that operators be provided with, and wear, strong protective footwear to prevent their feet from being injured.

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1.4.6.10 Static work equipment

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This type of small plant should be sited on firm, level ground with the brakes applied and wheel chocks in position, as necessary.

2

Cement or concrete mixers, compressors and pumps are examples of static equipment.

3

Plant should be sited clear of personnel with allowance for safe access by authorised persons.

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The correct procedures for starting, operating and shutting down should be correct and strictly complied with.

5

All gauges, valves, connections and guards should be checked for tightness and proper attachment as a matter of routine.

6

Other points to be considered are:

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appropriate personal protective equipment must be provided by Contractors and used by operatives

(b)

access to all dangerous or moving parts of the equipment must be provided with guards which are securely fixed and in position

(c)

adequate ventilation is essential when using equipment in confined places, with harmful fumes being extracted to the open air

(d)

any air lines, spray guns or blasting nozzles, used as an accessory to the equipment, must never be pointed towards other persons or at any part of the body

(e)

hoses, pipes or cables should be kept clear of traffic and pedestrian routes. Simple ramps and barriers can be used to protect cables etc., and to provide safe access

(f)

air hoses should be fitted with whip-checks at every connection to prevent the hose connections from blowing apart

(g)

electrical and mechanical plant and equipment, unless specifically designed to eliminate the risk, must be switched off or stopped before adjustments are made and before any accessories are connected or disconnected.

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1.4.6.11 Manually operated hand-held plant and mechanical equipment 1

Selection of the correct equipment for the job in hand is vitally important. Choosing modern equipment that reduces the risk of injury or ill health is fundamental to creating safer working environments.

2

The environment in which the equipment is used also has a bearing on the safety of the

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operative. It may be safe to use a hand saw from a pair of builders' steps, but to use the modern electric equivalent from them could have fatal results.

Hand-held power tools, whether powered electrically, by internal combustion engine, hydraulically, by cartridge or compressed air, are covered by the definition.

4

As the use of these types of tool has increased, so has the potential for serious injury. Old type hand-operated smoothing planes could cause nasty cuts if wrongly used, but those injuries bear no comparison with the injuries that could occur when wrongly using their modern electrical equivalent.

5

Cutting chases in a wall using an older type cutting disc produces unacceptable amounts of dust. Modern equipment that is fitted with a dust suppression mechanism is safer and much healthier.

6

Also included within this category is the type of equipment that requires human effort in its operation, such as jacks, bar-bending machines, pipe-threaders and other machines where the principles of leverage or torque are utilised.

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Many jobs, such as nailing tiling battens on a roof, that traditionally would have been achieved by using a hammer, are now carried out by using nail guns powered by gas canisters. Equipment of this type is open to abuse, which can result in horrific consequences. It is possible to propel a nail in free flight from a nail gun giving it the lethal potential of a firearm.

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Included in this category are hand tools, ladders scaffolding, etc. Also included are huts and other temporary structures used for welfare accommodation or fuel and materials stores.

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1.4.6.12 Non-mechanical plant and equipment

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Hand tools

Unfortunately, many persons working in the construction industry do not appreciate that simple hand tools have the potential to cause serious harm.

3

In many cases where hand tools are used, persons react when things go wrong, instead of proactively checking to ensure that things do not go wrong in the first place.

4

Cold chisels with burred-over mushroom heads can result in a person losing an eye when a burr breaks off during use. A hammer head becoming detached from its shaft can cause a serious injury and not necessarily to the user.

5

In both examples, the potential to cause harm can be drastically reduced if a system of regular inspection and maintenance, as required by these Regulations, is in place.

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1.4.6.13 Access equipment Scaffolds 1

Scaffolds, if incorrectly erected or exposed to misuse, can also be the cause of accidents.

2

Such equipment must: (a)

comprise suitable components that have been inspected prior to use

(b)

be regularly inspected every 7 days or after alteration, damage or high winds, the

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(c) 3

not be interfered with or altered by untrained individuals.

Many accidents have occurred due to installation of scaffold with damaged equipment such as split boards and bent tubes.

Ladders and other wooden access equipment Work equipment made from wood will not last for ever. It will deteriorate with age and use. Regular inspection of the equipment is essential for safety and will prolong its useful life, giving early indication of deterioration. It is commonplace for inspections of ladders and steps to be formally recorded, with each ladder or step being given a specific identifying number.

5

A key issue with wooden ladders and steps is that they must not be painted or treated with anything that would hide any faults or defects.

6

The regular inspection of wooden builders' steps must include the hinges that connect the support stays and the restraining rope that controls the opening of the steps as well as the condition of the timber.

7

Wooden extension ladders have ropes, pulley blocks, and clips that fit over rungs. These are vital to the safe use of these ladders and therefore must again be regularly inspected.

8

The simple wooden pole ladder must be checked to ensure that the wire ties beneath certain of the rungs are in place and tight. Rungs must be checked to ensure they are still firm and do not twist, and the stiles checked to ensure they are not split.

9

All work equipment has the potential to be the cause of accidents. Obviously, the potential and the consequences differ between types of equipment.

10

Management systems for the training and instruction of operators, and the inspection of equipment, must be in place and complied with.

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Construction Site Safety 1.4.6 Appendix 1 Plant and work equipment Safety checklist When was the plant or equipment last checked or tested?

2

Are statutory records being kept up to date?

3

Is the item of plant or work equipment the most suitable for the job in hand?

4

Is a risk assessment necessary to determine the most suitable item of plant or work equipment?

5

Have any faults developed through misuse or neglect?

6

Have faults or defects been correctly and promptly reported?

7

Are those faults reported being remedied promptly and effectively?

8

Does all plant or equipment comply with the relevant standards?

9

Are spot checks made on the condition of hand tools and other minor items of equipment?

10

Is there a procedure for the inspection of and repairing or replacing of such equipment and tools?

11

Are drivers and operators trained on specific plant or equipment aware of the hazards that are associated with its operation?

12

Is safety training included in any instruction which is given to operatives?

13

Is personal protective equipment available and issued to all who need it?

14

Have lists of authorised drivers and operators been kept up to date?

15

Is equipment issued to and used only by authorised persons?

16

What information is available in relation to specific items of plant? Where is it kept and by whom?

17

Do checks show that plant is being used safely?

18

Do operatives know the requirements of these Regulations and those which have a bearing on their activities, and are they aware of their own responsibilities?

19

Are rules observed by site vehicles?

20

Has any instance of overloading or over-stressing of plant come to light?

21

Are ROPS, FOPS and driver restraint systems fitted if appropriate?

22

Does the operator of mobile or self-propelled plant have adequate visibility in all directions and are all visibility aids in good order?

23

Are there any signs of the unplanned or dangerous location of any plant?

24

Are the locations of supply cables, pipes, services, etc. identified before any plant or other equipment is brought into the vicinity?

25

Where appropriate, are communications adequate between:

26

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(a)

the teams doing different work within the same area?

(b)

the different shifts using the same plant?

(c)

the workers engaged in a co-ordinated operation?

Has all work equipment been identified?

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27

Have inspection regimes appropriate to the equipment been instigated?

28

Are the records of the inspections and tests being kept up to date?

Construction Site Safety 1.4.7

Woodworking Machines

1.4.7.1 Key points Woodworking machines are classified as 'work equipment' and must therefore comply with certain legal requirements.

2

Many items of woodworking equipment, with their partially exposed blades or cutters, have the potential to cause serious personal injury if they are not properly used and maintained.

3

Users of woodworking machinery must be trained on each type of machine that they are required to operate and be judged as competent by their Contractor.

4

Hand-held, bench-mounted and free-standing woodworking machines can all be found on sites; all types present particular hazards to the operator and, in some cases, other people.

5

The use of woodworking machines also has the potential to cause occupational health problems if appropriate preventative measures are not taken.

6

Section 18 of the QCS covers carpentery, joinery and ironmongery.

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1.4.7.2 Introduction

Woodworking machine cutters can inflict very serious injuries and it is essential that these Regulations for guarding them are strictly observed. Neglect or ignorance of these Regulations governing the use of such machinery creates the conditions in which accidents occur.

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Furthermore:

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the use of woodworking machines

(b)

contact with some hardwoods used

(c)

contact with the dust produced

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All have the potential to cause occupational health problems.

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Within these Regulations, particular reference is made to circular saws and planing machines, since these are most commonly used on-site in the construction industry.

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1.4.7.3 The Management of Health and Safety at Work 1

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or other people might encounter as a result of the work being carried out.

2

When hazards are identified, it is then the Contractor's duty to either eliminate the hazard or to put control measures into place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

4

Compliance with these Regulations mainly involves Contractors pro-actively managing:

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(a)

personal injury risks resulting from contact with moving blades and cutters

(b)

personal injury risks resulting from the maintenance of the machines

(c)

occupational health risks resulting from the use and maintenance of the machines.

Employees, for their part, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or any other person who may be affected.

1.4.7.4 Provision and Use of Work Equipment These Regulations stipulate the requirements for the safe operation and maintenance of all 'work equipment', which includes woodworking machines.

2

In the context of this section, the parts of these Regulations that are particularly relevant cover such factors as: work equipment being suitable for the job, and kept in good working order by persons who are trained to do so

(b)

the guarding of dangerous parts of machines and provisions relating to working space, floors, lighting, noise and temperature. They apply to all places where woodworking machinery is used

(c)

the requirements relating to the instruction and training of persons operating work equipment, including those employed in 'taking-off' and maintenance, and specify the duties of operatives

(d)

work equipment being fitted with suitable controls, emergency controls and where necessary, a control system, to enable it to be used safely

(e)

ensuring that each item of work equipment can be effectively isolated from all sources of energy

(f)

the requirements for maintenance and inspection.

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The parts of these Regulations that are particularly appropriate to the use of woodworking machinery are expanded throughout.

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1.4.7.5 Personal Protective Equipment These Regulations place duties on Contractors and employees with regard to the provision, use and care of personal protective equipment (PPE). Where the risks to health and safety cannot be controlled by other means, PPE may be issued and used; as a method of controlling risk it is the last resort.

2

However, when using woodworking machinery on site, PPE will often be the only practical method of controlling risk, particularly health risks

3

These Regulations place legal duties on Contractors to:

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provide suitable PPE for their employees and make sure that it is used properly

(b)

make sure that items of PPE are compatible when more than one item is worn at the same time. For example, if wearing safety spectacles, it is possible that the side-arms would interfere with the seal of a half-face respirator

(c)

make an assessment of the most suitable PPE to protect against the identified risks

(d)

make sure that PPE is properly maintained where this is necessary

(e)

replace PPE that is damaged or lost

(f)

provide suitable accommodation where necessary for PPE that is not in use

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the risks that the PPE will avoid or limit

(ii)

why the PPE has to be worn and how it should be used

(iii)

how to maintain the PPE in efficient working order and good repair.

These Regulations place legal duties on employees to: (a)

use any PPE provided in accordance with the instruction and training provided

(b)

report to the Contractor the loss of or defect in any PPE provided.

1.4.7.6 Construction (Design and Management) CDM In the context of this section, the relevant requirements are that the Contractor or person in control of the site must ensure:

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the competence of everyone who has to use or supervise the use of a woodworking machine

(b)

a safe place of work with safe access and egress and sufficient working space is provided

(c)

the prevention of risks of fire or explosion

(d)

the provision of adequate fire detection methods and fire-fighting equipment

(e)

adequate levels of lighting, taking into account the nature of the work being carried out

(f)

an acceptable level of site tidiness and cleanliness

(g)

suitable information, instruction and training where necessary for work to be carried out safely and without a risk to health.

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(b)

Sanding machines

(c)

Bandsaws

Routing machines

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(e)

Planing/thicknessing machines

(f)

Chainsaws

(g)

Mortising machines

(h)

Tenoning machines

(i)

Vertical spindle moulding machines, including high-speed routing machines

(j)

Multi-cutter moulding machines having two or more cutter spindles

(k)

Trenching machines

(l)

Boring machines

(m)

Automatic and semi-automatic lathes.

1.4.7.8 Training 1

No person should be required to operate any type of woodworking machine unless they have

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been trained and instructed in its operation. They must either be competent or under the direct supervision of someone who is. 2

Training should include instruction on all machines the person is likely to operate and the types of work to be undertaken on the completion of training. Instruction on the provisions of these Regulations and the methods of using guards, devices and appliances required by these Regulations must be included. Training should emphasise the dangers connected with the use of such machines.

3

Contractors will need to make sure that they do not employ young people in work situations where: the work is beyond their physical or psychological capacity

(b)

it involves harmful exposure to hazardous substances

(c)

it involves a risk of accidents which the young person, by reason of a lack of experience etc., would not recognise

(d)

there is extreme heat, cold, noise or vibration.

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1.4.7.9 Duties of employees

Employees using woodworking machines must use and keep properly adjusted all guards and other safety devices, and use push sticks, spikes, push blocks, jigs, holders, backstops, and any other safety devices provided.

2

They must report to responsible persons any defects in machinery, guards, devices or appliances and any damage or defects in the surface or ground around the machine.

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1.4.7.10 Occupational health Hearing protection

Woodworking machines can be particularly noisy when in use and the noise generated will be a significant hazard to health unless adequately controlled.

2

Ideally, the level of noise will be controlled by means other than issuing personal protective equipment (PPE), although in practice this will often not be possible on construction sites.

3

Where work activities are liable to expose employees to certain levels, Contractors to carry out an assessment of the risk and implement the necessary control actions, which will often translate into:

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(a)

identifying suitable hearing protection (PPE)

(b)

issuing it to those persons who are at risk

(c)

ensuring that it is worn in certain circumstances

(d)

providing adequate information, instruction and training on the risk to health arising from noise and the correct use of hearing protection.

There are three action levels at which particular actions should be taken; (a)

The lower exposure action value (80 dB(A)), at which an employee may request the provision of hearing protection from the Contractor, should he or she so wish.

(b)

The upper exposure action value (85 dB(A)) at which the Contractor is required to provide hearing protection for employees and ensure that it is worn by all employees who are at risk.

(c)

The exposure limit value (87 dB(A)) above which no employee may be exposed.

In work areas where the noise is at or above the upper exposure action value, the Contractor

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is required to create hearing protection zones, designated by appropriate signs, within which everyone must wear the hearing protection provided.

1.4.7.11 Vibration protection 1

Contractors are required to control the level of vibration experienced by employees whilst at work.

2

In the context of using woodworking machines, the predominant problem is considered to be hand-arm vibration. Whilst several manufacturers have produced 'anti-vibration' gloves, laboratory testing has shown these to be largely ineffective against vibration at the most damaging frequencies. In some circumstances, the fact that such gloves will keep the hands warm may offer limited benefit against hand-arm vibration. The control of hand-arm vibration will have to be achieved by other means.

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1.4.7.12 Respiratory protection

Contractors must control substances hazardous to health and to control occupational health risks arising out of the use of hazardous substances.

2

As noted earlier, hardwood dust is known to be a cause of nasal cancer. Ideally, airborne dust will be controlled by the fitting of effective extraction systems or dust-collection bags to woodworking machines and hand-held tools that generate either softwood or hardwood dust.

3

However, if for any reason the control of dust is not possible in this way, operators must be provided with, and wear, suitable respiratory protective equipment.

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Depending on the machine being used and the nature of the work being carried out, it may be necessary for machine operators (and possibly anyone assisting them) to wear eye protection, such as goggles or a full-face shield of a suitable impact-resistant grade.

It may be necessary to provide operatives with suitable gloves to protect against skin damage whilst handling timber, particularly unplaned timber. Furthermore, the skin of a small number of persons is adversely affected by the natural oils that occur in some woods, notably cedar.

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1.4.7.14 Skin protection

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1.4.7.13 Eye protection

1.4.7.15 Working environment 1

Sufficient clear and unobstructed space must be provided around machines to allow persons to work without the risk of injury.

2

Floors should be level, in good condition, free of loose material (wood chips, wood shavings and sawdust) and must not be slippery.

3

Where woodworking machines are being used on site, the temperature of any indoor workplace must be reasonable, having regard to the purpose for which the place is being used.

4

Where a reasonable temperature cannot be achieved or maintained, effective means of providing warmth for operatives should be introduced. If it is not a construction site, then a temperature of 16°C should be maintained but, where work is of a physically demanding nature, a temperature of 13°C is appropriate.

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Adequate natural or artificial lighting must be provided so that the work being carried out on each machine can be done safely. Artificial light must be positioned or shaded to prevent any glare affecting the operator.

1.4.7.16 Maintenance 1

Saw blades must not be cleaned while they are in motion or with the power supply to the machine switched on.

2

All machines must be of good construction, manufactured with sound material and properly maintained. Unless a machine is hand-held, it must be level, and fixed securely to a substantial structure which ensures its stability.

1.4.7.17 Controls

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1.4.7.18 Braking

An essential safety feature of most woodworking machinery is the provision of an automatic brake.

2

This is to ensure that, if there is a risk of an employee coming into contact with tooling during the rundown period, the machine stops within 10 seconds or less, as defined by European Committee for Standardization (CEN) standards.

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1.4.7.19 Retrofitting of brakes

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All work equipment should be provided with the necessary controls which bring the equipment to a safe condition in a safe manner. To achieve this, a risk assessment should be carried out to determine whether the rundown time should be reduced and the retrofitting of brakes to a machine is necessary.

2

If the risk assessment shows that there would be no added safety benefit, then braking does not have to be provided.

3

Examples include machines fitted with interlocking guards that enclose the cutters and cannot be opened until the cutters have come to rest. Some machines might be totally enclosed by a noise hood, but the same interlocking requirements will apply.

4

In these situations, the machine rundown time is immaterial since an acceptable standard of safety has been achieved by guarding alone and subsequently there is no risk of contact in the rundown period.

5

Another example is where the blade, tool or cutter returns automatically to a safe position, such as a cross-cut saw fitted with a spring return which retracts the blade into a protective housing at the end of the cutting operation. However, if a risk assessment shows that the machine has a long rundown period and is in regular use by more than one person, consideration should be given to fitting a brake. This is because the machine could still be running down after use by one person when a second person pulls the saw carriage out of the protective housing, unaware that the blade is still rotating.

6

As well as enhanced safety, braking can improve productivity since more rapid stopping will allow quicker setting, adjustment and unjamming of a machine.

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1.4.7.20 Guarding cutters - general 'Cutters' include saw blades, chain cutters, knives, boring tools, detachable cutters and solid cutters. Cutters must be guarded to the greatest practicable extent, having regard to the work being done.

2

Guards must be of substantial construction, properly secured and adjusted, and maintained constantly in position while cutters are in motion.

3

Adjustments must not be made to any guard whilst the cutters are in motion, unless safe means (i.e. mechanical adjusters) are provided for those adjustments to be made.

4

The shape and size of guards may change as technology develops alternative safeguards, if these are at least as effective as before.

5

Every dangerous part of any woodworking machine must be securely fenced, unless it is in such a position or of such construction that it is as safe to every person on the site as it would be if it were fenced.

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1.4.7.21 Portable electrically-powered saws

Portable electrically-powered saws should always be disconnected from the electrical supply before any adjustments, repairs, cleaning or any type of maintenance is carried out.

2

Whenever possible, to reduce the risk from electric shock, all portable electric tools should operate from a 110 volt supply and be earthed or double insulated. The mains input to the 110 volt transformer should be protected by a residual current device (RCD), commonly known as a 'power breaker'.

3

Portable electrically-powered saws must never be carried by their supply cable. Furthermore:

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when operating, the supply cable must always be kept clear of the saw blade

(b)

the power plug must be examined each time, prior to use, for damage and security of the cable

(c)

all electrically-powered saws should be examined regularly by a competent electrician.

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Care should be taken to ensure that the spring-loaded, lower blade guard returns to cover the blade after every cut. This guard, also known as the swivel guard, is designed to uncover the saw teeth when material is being cut then automatically covers the saw teeth when the saw is withdrawn. This guard must never be wired in the open position.

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1.4.7.22 Riving knife (also called splitter or spreader) 1

The riving knife must be securely fixed below the table level, be of the correct radius, behind and in line with the saw blade.

2

It must be strong, rigid, smooth and easily adjustable.

3

The radius of the knife must not exceed the radius of the largest saw blade for which the machine has been designed.

4

It must be adjusted as close as practicable to the saw blade. Any gap between the riving knife and the blade must not exceed 8 mm at table level.

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5

In the case of a parallel plate saw blade, the knife must be thicker (usually about 10%) than the parallel plate of the saw blade to form a wedge in the saw cut, thereby preventing the timber 'ripping' the saw blade.

6

Where the diameter of the saw blade is less than 600 mm, the top of the knife should not be more than 25 mm below the top of the blade.

7

Where the diameter of the blade is 600 mm or more, the knife must extend at least 225 mm above the machine table.

1.4.7.23 Top guard (crown guard) The guard must be strong and easily adjustable.

2

It must be adjusted to extend from the top of the riving knife to a point as close as practicable to the surface of the material being cut; or to a point not more than 8 mm above the material being cut where squared stock is being hand fed.

3

The guard should have flanges on either side of the blade and be adjusted so that these extend beyond the roots of saw blade teeth. Where the guard has an adjustable front extension piece, it must be flanged on the side remote from the fence, and adjusted to extend beyond the roots of saw blade teeth above the saw table.

4

Note: Some saws have adjustable extensions to the front of the guard.

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The part of the blade below the table must be guarded to the greatest extent practicable.

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1.4.7.24 Bottom Guard

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1.4.7.25 Size of saw blade

Saw benches with a one-speed spindle must not use a saw blade less than 60% of the diameter of the largest saw blade which the bench is designed to use. In the case of saw benches with more than one spindle speed, the blade must not be less than 60% of the diameter of the largest blade which the machine is designed to use at the fastest spindle speed.

2

A notice should be displayed on the machine specifying the smallest diameter saw blade that may be used.

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1.4.7.26 Limitations on use 1

No circular saw may be used for cutting rebates, tenons, mouldings or grooves unless the cutter above the table is effectively guarded.

2

The saw blade teeth must project right through the upper surface of the timber at all times in any ripping operation.

3

A circular saw must not be used for crosscutting logs unless the material is firmly held by a gripping device, secured to a travelling table.

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1.4.7.27 Push sticks 1

Push sticks must be available for use on every table-mounted circular saw, and used to: (a)

keep hands away from the saw blade

(b)

feed material throughout any cut of 300 mm or less

(c)

feed material during the last 300 mm of any cut more than 300 mm in length

(d)

remove cut material from between the saw blade and the fence.

1.4.7.28 Removal of material Assistants employed to 'take-off' cut material may only stand at the delivery end of the machine.

2

Where this operation must be performed, the delivery end of the machine table must extend (over its whole width) at least 1.2 m from the up-running part of the saw blade.

3

This requirement is not applicable to machines which have a roller table, or a travelling table, or to portable machines with a maximum blade diameter of less than 450 mm.

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a suitable top guard, riving knife and ripping fence to be fitted

(b)

that the fixed guards should be of adequate strength and construction to withstand normal operational use

(c)

the fitting of a suitable switch attachment to enable the operator to control the saw at the bench.

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Mounting a hand-held circular saw onto a support for use as a bench circular saw, requires:

Note: Some manufacturers have designed a saw bench complete with a top guard, riving knife assembly and fence for use with their hand-held circular saws.

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1.4.7.29 Bench-mounted portable hand circular saws

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1.4.7.30 Narrow bandsaw

A narrow bandsaw is defined as a machine with a blade not exceeding 50 mm in width, running vertically.

2

The saw wheels and the whole of the blade, except the part which runs downward, between the top wheel and the machine table must be enclosed by guards.

3

The part of the blade between the top wheel and the friction disc or roller must be guarded by a front plate, as close as practicable to the blade, and having a flange at right angles to the plate extending behind the saw blade.

4

The friction disc or rollers must be adjusted as close to the surface of the machine table as practicable.

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1.4.7.31 Planing machines 1

(See illustration in Appendix 3)

1.4.7.32 Limitations on use A planing machine must not be used for cutting any rebate recess, tenon or mould unless the cutter is effectively guarded.

2

If the machine is not mechanically fed and is used for surfacing work, it must be fitted with a cylindrical cutter block.

3

Table gap

4

If the planer is hand fed, the gap between the cutter block and the front edge of the infeed or delivery table must not exceed 6 mm, measured radially from the centre of the cutter block.

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1.4.7.33 Bridge guard

Planing machines not mechanically fed must have a bridge guard over the cutter block, mounted approximately centrally and not liable to accidental displacement.

2

The guard must be strong, rigid and easily adjustable, vertically and horizontally, to allow work to be carried out without the risk of injury.

3

The guard must cover the full length and diameter of the cutter block, be mounted centrally over it and be securely fixed.

4

When 'flatting' squared stock:

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the gap between the end of the guard and the fence should not exceed 10 mm

(b)

the gap between the upper surface of the wood and the underside of the guard should not exceed 10 mm.

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When 'edging' (i.e. planing the narrow surface of a squared stock):

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(d)

the gap between the end of the guard and the surface of the wood should not exceed 10 mm

(e)

the gap between the underside of the guard and the surface of the feed table should not exceed 10 mm.

5

When 'flatting' and 'edging' are carried out successively, the clearances between the bridge guard and the material for each operation must be no greater than 10 mm.

6

When the planing of adjacent surfaces of stock of square cross-section is carried out as successive operations, the bridge guard must be adjusted so that the clearance between the material and the guard, or the fence and the guard, never exceeds 10 mm.

7

Where the above adjustment of the bridge guard is not practicable because of the shortness of the material, a suitable push block with handholds must be provided and used.

1.4.7.34 Cutter block guards 1

In addition to the bridge guard, hand-fed overhand planers must be provided with an

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effective, easily adjustable guard over the part of the cutter block which is behind the fence.

1.4.7.35 Combined machines used for thicknessing 1

The part of the cutter block exposed in the table gap must be effectively guarded.

1.4.7.36 General safety procedures The following general procedures should be observed to ensure the safety of operators and anyone else who may be affected by wood machining activities: knives, saws and cutters should be properly sharpened and correctly set

(b)

circular saw blades should be checked for cracks, particularly near the gullet at the root of the teeth. Defective items should not be used

(c)

before a machine is started, a check should be made to see that the cutters, saws or knives are of the correct type and are securely fixed; and that guards are properly adjusted and secure

(d)

the area around the machine should be cleared of waste material and there should be sufficient space to stack work safely before and after machining

(e)

the floor must be clean and free from oil, grease or anything else which might cause the operator to slip or trip

(f)

multi-speed machines must be started at their lowest speed

(g)

guards should be set to give the minimum clearance necessary for the material being worked. They must always be in position

(h)

the operator should not wear loose clothing, and should wear goggles, masks or ear protectors, if necessary

(i)

workplaces should have adequate heating and be well lit

(j)

adjustments must never be made to a machine while it is in motion, unless safe provision is made to do so

(k)

push sticks and jigs should be available and in use whenever necessary

(l)

offcuts, chips and sawdust should not be removed from the machine table with the hands while machine is in motion

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material should not be forced through the machine any fault should be promptly reported to responsible persons. If a fault develops, the machine must be switched off immediately

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machines must be switched off when left, even for a short period. They should also be switched off when the operator is speaking to somebody

(p)

operators should never allow their attention to be distracted while operating a machine, neither should anybody seek to distract them

(q)

at the end of a work operation, the machine must be switched off and isolated.

1.4.7.37 Operational safety - circular saws 1

Low peripheral speeds result in inefficient cutting as do dull, badly set or badly ground saw teeth. The extra effort applied to feed the wood increases the accident risk.

2

Deposits of sap, gum or resin on the blade tend to cause the saw to jam, or stall, or the timber to stick. Such deposits must never be cleaned whilst the blade is moving or with the power supply to the machine switched on. The saw should be stopped, electrically isolated and the proper tool used.

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1.4.7.38 Chainsaws Due to their high potential to cause injury, the use of chainsaws on building and construction sites is not generally recommended.

2

Where chainsaws are used on site, they must be used only by operatives who are fully competent, have received specific and nationally approved training, and who are certificated to carry out the intended operation.

3

A specific risk assessment should be carried out for the operation and a written method statement produced covering the operation, including the need for full personal protective equipment, safe working at heights and, if necessary, a workplace safely away from other workers,

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Construction Site Safety 1.4.7 Appendix 1 Safety checklist - general Operatives Is a list kept of operatives who are authorised and competent to operate woodworking machines?

8

Are operators only required to operate machines on which they have been trained and are competent?

9

Are operatives properly supervised, particularly those under 18?

10

Is adequate training given on the types of machine to be used and the kinds of work to be done?

11

Are operatives provided with all necessary personal protective equipment, including goggles, ear protectors, face masks and other protective equipment, where required?

12

Is the wearing of loose-fitting clothing prohibited at those machines where entanglement could be a problem?

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Is a programme of planned preventative maintenance in place for all woodworking machines?

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Machines and surrounding area

Are the start and stop controls so situated that they can be easily reached and operated?

15

Are all cutters guarded to the greatest extent practicable?

16

Are all machines level and securely fixed to ensure their stability?

17

Are all machines of sound construction and properly maintained?

18

Is sufficient space provided around a machine for safe working?

19

Are floors level, in good repair, free of loose material and not slippery?

20

Is adequate natural or artificial light provided in the workplace without glare being caused?

21

Is the temperature of the workplace satisfactory?

22

Is respiratory protection required?

23

Are noise levels reduced as far as practicable?

24

Is ear protection available where required?

25

Is eye protection required?

26

Is skin protection required?

27

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Is extraction equipment provided for chips and particles as is required on specified machines?

28

Has provision for the extraction of fumes been made where necessary?

29

Are fire extinguishers of the correct type immediately available?

30

Are suitable personnel fully trained in the use of fire-fighting equipment?

31

Do machines, as far as possible, run off a 110 volt supply with mains-powered equipment protected by a residual current device (RCD)?

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Construction Site Safety 1.4.7 Appendix 2 Circular Saw

Safety checklist Riving knife

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Is the riving knife secure, in a sound condition, and easily adjustable?

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Is the radius correct and in line with the saw blade?

3

Is the gap between the riving knife and the saw blade correct?

4

Is the riving knife of the correct thickness?

5

Is the height of the riving knife correct for the saw blade fitted?

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Saw blade

Is the saw blade in good condition -sharp with no cracks, and not less than the smallest diameter permitted?

7

Is a notice fixed to machines, specifying the smallest permitted blade diameter?

8

Does the saw blade project through the upper surface of the timber when ripping?

9

Is the saw blade above the table effectively guarded, when the machine is rebating, tenoning, moulding or grooving?

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Fence

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Is the fence correctly adjusted and secured?

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Top guard

Is the top guard sound and easily adjustable?

12

Is it adjusted correctly for the work being done?

13

Do the flanges at either side of the blade extend below the roots of the saw teeth?

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Front extension guard 14

Is the front extension guard adjusted to give maximum protection, and does it cover the saw teeth?

Bottom guard 15

Is the blade guarded below the table (open frame machines)?

Feeding work 16

Is a gripping device in use when cross-cutting?

17

Is there a push stick or are push blocks available and in use?

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Taking off 18

Does the delivery table extend at least 1.2 m from the up-running part of the saw blade?

19

Is the assistant, if present, correctly positioned?

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Table

Is the gap between the table and the cutter not more than 6 mm?

2

Is the table gap as small as possible?

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Bridge guard

Is the bridge guard rigid, strong, securely fixed and easily adjustable?

4

Is the bridge guard centrally mounted over the cutter block?

5

Does the bridge guard cover the full length and diameter of the cutter block?

6

Is the bridge guard adjusted to exclude the risk of injury, as far as is practicable?

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Cutter block 7

Is the cutter block guarded, on the side of the fence, remote from the bridge guard?

Limitations on use 8

Is the cutter effectively guarded when rebating, recessing, tenoning and moulding are taking place?

9

Is the machine fitted with a cylindrical cutter block if it is being used for surfacing?

10

Is the bridge guard correctly adjusted when 'flatting' or 'edging' is taking place?

11

Are push sticks available and in use?

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Combined machine used for thicknessing Is the cutter block exposed in the table gap effectively guarded?

13

When thicknessing, is an anti-kickback device fitted, or notice displayed specifying one piece only?

14

Is an extraction system provided to remove and collect any wood chips?

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Are saw wheels and saw blades guarded correctly?

16

Is the saw blade between the top wheel and disc or roller guarded by a frontal plate as closely as possible, and does the flange extend behind the saw blade?

17

Are rollers or discs correctly adjusted?

18

Is the saw blade tension correct?

19

Is the saw blade in good condition and sharp?

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Construction Site Safety 1.4.7 Appendix 5

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Safety checklist Operative

Is the operative suitably trained in the correct use of the machine?

2

Does the operative understand that there should be no loose clothing, ties or scarves, etc.?

3

Is the operative aware of the relevant Regulations?

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Prior to use

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Ensure the electrical power plug is removed from the supply socket before carrying out priorto-use checks. Are the machine and plug compatible with the electrical supply?

5

Are all leads, plugs and switches undamaged?

6

Does the on/off trigger and safety interlock operate freely?

7

Is the correct type of saw blade fitted for the work which is to be carried out?

8

Is the saw blade in good condition, sharp and not cracked?

9

Is the saw blade effectively guarded, above and below the soleplate?

10

Is the condition and the function of the spring-loaded bottom guard checked before use?

11

Does the spring-loaded bottom guard return to cover the saw blade after every cut?

12

Is the saw blade securely fitted to rotate in the correct direction? (Teeth should point upwards at the front end of the saw towards the soleplate.)

13

Has the fence (if used) been adjusted to the correct dimension?

14

Has the saw been adjusted to the correct depth and angle before use, with the teeth projecting just through the underside of the material?

15

Are all locking nuts and securing devices properly tightened and fastened?

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In use 16

Is the saw being held correctly with two hands using the main and front hand grips?

17

Is the material being cut adequately supported?

18

Is the fence or a straight edge being used as a guide as necessary?

19

Has a check been made to ensure that the clamps do not impede any movements of the saw? Is there sufficient free cable on the saw?

21

Is the correct stance being taken behind and in line with the saw?

22

Is the work area clear and free of obstructions?

23

Is the correct protective equipment in use?

24

Do all other personnel on site know that the operator must not be distracted whilst he or she is operating a saw?

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Construction Site Safety 1.4.7 Appendix 6

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Operative

Is the operative competent, adequately and properly trained and supervised?

2

Is the operative familiar with the type of machine they are using and with the manufacturer's operating instructions?

3

Is the correct personal protective equipment being worn?

4

Is the operative aware that whilst using a chainsaw there must be no loose clothing, ties, belts, etc.?

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Prior to use 5

Is the ignition switched off?

6

Are new chains soaked in oil prior to use?

7

Is the chain sharp and in good condition?

8

Is the guide bar excessively worn? If so, it should be changed.

9

Does the chain brake function correctly?

10

Is the tension of the chain correct?

11

Is the lubrication reservoir functioning?

12

Are all handles and guards firm and secure?

13

Are all switches and controls effective?

14

Are wood or plastic wedges available to free the saw if it jams?

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In use Is the correct starting procedure (i.e. on the ground) undertaken?

16

Is the stance of the operator correct?

17

Does the operator keep both hands on the machine when it is in use?

18

Is there a safe system of work in place for cutting, avoiding kickback?

19

Is the chainsaw correctly adjusted so that the chain does not rotate when the engine is idling with the chain brake released?

20

Is the operator aware that the nose of the guide bar should not be used to cut?

21

Are all bystanders kept well clear of any cutting operations?

22

Do all other personnel on site know that the operator must not be distracted whilst he or she is operating a saw?

23

Is the work area kept clear and free from obstruction?

Are all parts checked for damage and soundness?

25

Are the cutting components protected from damage?

26

Are any defects found reported to the supervisor?

27

Is the chainsaw stored safely?

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After use

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15

Refueling

Is the correct type and grade of fuel used, from a properly marked, leak-proof, securely capped container?

29

Is all refueling carried out in a well-ventilated area outdoors?

30

Is there any leakage of fuel or spillage during refueling?

31

Are fuel and lubrication systems leak-free and functioning correctly?

32

Are fuel and lubrication system fluid levels correct?

33

Has clothing (which may have been contaminated during refueling) been changed prior to the saw being operated?

34

Is any spilt fuel removed from the saw or work area prior to saw operation?

35

Is the saw always started at least 3 metres away from the refueling area?

36

Is care taken to ensure that refueling is never carried out near to fires, sparks or other sources of ignition?

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Transportation 37

Is the chainsaw switched off when being transported, even if it is only a few paces?

38

Is the chainsaw always carried by the front handle?

39

Is the chainsaw always carried with the engine muffler away from the body, to prevent burns?

40

Has the chain guard (scabbard) been fitted?

41

If the chainsaw is being transported in a vehicle, has it been secured to prevent overturning and damage?

END OF DOCUMENT

QCS 2014

Section 11: Health and Safety Page 1 Part 1.05: Other hazardous Activities (Regulatory Document)

REGULATORY DOCUMENT .......................................................................... 1

1.5

OTHER HAZARDOUS ACTIVITIES ................................................................ 1

1.5.1

Working With or Near to Buried Services ...................................................... 4

1.5.2

Lone Working .............................................................................................. 19

1.5.3

Electrical Safety on Site............................................................................... 25

1.5.4

Working In and Around Excavations............................................................ 56

1.5.5

Working in Confined Spaces ....................................................................... 75

1.5.6

Safety in Demolition..................................................................................... 95

1.5.7

Safety in Piling ........................................................................................... 115

1.5.8

Safety in Formwork/Falsework .................................................................. 124

1.5.9

Explosives ................................................................................................. 126

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Section 11: Health and Safety Page 2 Part 1.05: Other hazardous Activities (Regulatory Document)

FORWARD

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This Section of the Regulatory Document (RD) was produced as a project deliverable under Ministry of Municipality and Urban Planning Contract Number P2009/3, entitled “Consultancy Services for the Preparation of Codes and Standards for Safety and Accident Prevention on Construction Sites”. During the latter stages of the project, the Committee responsible for the administration of the project decided that the RD and the associated Safety and Accident Prevention Management/Administration Systems (SAMAS) would be best delivered to stakeholders via the portal provided by the Qatar Construction Standards (QCS). The QCS includes references and certain sections which address occupational health and safety. To ensure that that users of the RD/SAMAS are fully aware of the where occupational health and safety issues are addressed in the QCS, the following table summarises where potential overlaps may occur. For consistency, it is recommended that in matters relating to occupational health and safety reference is made first to the RD/SAMAS. For the purpose of clarity, however, references are made in the relevant section of the RD/SAMAS to their comparable sections in the QCS and vice versa.

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Sr. No

QCS 2014 Section No.

Part No.

Part Name

1

1

7

Submittals

8

7.5.2

Health and Safety Organization Chart

2

1

7

Submittals

9

7.6.1

Health and Safety Plan

3

1

10

Health and Safety

All

All

All

4

1

11

Engineer's Site Facilities

10

11.4.6

Safety Equipment and Clothing

5

1

14

Temporary Works and Equipment

3

14.4

Test Certificates for Cranes and Lifting Tackle

6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1

General Requirements for Piling Work

7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

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Item Name

.

Page No. Item No.

Safety and Management

4.9.1.13 Protection of Testing Equipment 1.6

Temporary Fencing

15

7.8.13

Safety Requirements

Works in Relation to Services

4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

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8

1

17

8

8

Painting and Protective Coatings

6

8.1.9

Safety

18

8

9

Trenchless Pipeline Construction

7

9.2.5

Safety Requirements

19

8

10

Pipeline Cleaning and Inspection Survey

4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

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Sewer Rehabilitation

9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16

Noise Levels and Vibration

1

23

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11

19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1

General Provisions for electrical Installation

7&8

1.1.11

Fire and Safety Precautions

25

21

1

General Provisions for electrical Installation

14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5

Fire Resistance Period

28

29

3

Geotechnical Specifications

4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4

Safety Measures and Systems

32

29

7

Concrete Structures

6

7.1.10

Safety Railing

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Construction Site Safety 1.5.1

Working With or Near to Buried Services

1.5.1.1 Key points Many injuries and deaths have occurred because the location and exposure of buried services were not carried out in a safe manner.

2

Cable plans and charts cannot be depended upon to accurately identify the exact route of a buried service.

3

Safe digging procedures are essential; final exposure of buried services by hand-digging will be necessary.

4

Prior consultation with utility companies will be necessary in most circumstances.

5

There are now devices available for locating all types of underground service; operators must be trained and competent in their use, including the interpretation of survey results.

6

The exposure of buried marker tape or tiles whilst digging will indicate the presence of buried services below.

7

It should always be assumed that buried services are 'live' unless proved otherwise.

8

On certain sites old and abandoned metallic services or other metallic items can pick up signals from known services and distort survey results.

9

Accidental damage to any buried service must be reported immediately to the relevant authority.

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Buried services are, to a great extent, out of sight and out of mind until, perhaps, there is a fault or another reason to excavate. Every year people are injured and some killed due to accidental contacts with buried services, such as electricity cables and gas pipes. In every case, the damage and injury could have been avoided if the proper procedures had been followed.

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1.5.1.3 Legislative requirements The Management of Health and Safety 1

All work, including any work in relation to the location and exposure of buried services, must have been subject to a risk assessment.

2

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

3

Once those hazards have been identified, it is then the Contractor’s duty to put control measures into place to either eliminate the hazard or, where this is not possible, reduce the risk of injury as far as is reasonably practicable.

4

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and of any control measures that have been put in place to reduce those risks.

5

In the context of this module, some of the factors that the risk assessment must take into

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Section 11: Health and Safety Page 5 Part 1.05: Other hazardous Activities (Regulatory Document)

account are:

6

(a)

the equipment and work methods employed to safely identify, locate, expose and, if necessary, work on the services

(b)

the potential hazards posed by

(c)

accidental damage to the buried services

(d)

the competence of the persons who are to plan, supervise and carry out the work

(e)

satisfactory reinstatement of the disturbed ground.

Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or of any other person who may be affected.

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The Provision and Use of Work Equipment All equipment used in conjunction with excavations or buried services is 'work equipment".

8

These Regulations require that a Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

9

It is essential that any work equipment used to locate buried services:

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is suitable and sufficient, for example, a cable avoidance tool that works by detecting electromagnetic fields will not detect a plastic gas pipe

(b)

is fully serviceable and calibrated where appropriate

(c)

is used by a trained and competent operator who has the knowledge and experience to interpret the results.

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Construction (Design and Management) CDM Under these Regulations, the client must provide the project-specific information needed to identify hazards which can be obtained by making sensible enquiries. This includes information from utility companies on the location of underground services.

11

By providing this information to the designer, the client creates an opportunity for hazards to be avoided by design.

12

Information on new services installed should be passed to the Engineer for inclusion in the health and safety file.

13

Contractors are required that energy distribution installations are located, checked and clearly marked to prevent danger.

14

Suitable and sufficient steps must be taken, so far as is reasonably practicable, to prevent risks to health and safety from construction work likely to damage or disturb underground services

15

Furthermore, under these Regulations the following requirements are particularly relevant to working with or near to buried services:

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(a)

no duty-holder may arrange for any person to carry out design or construction work unless they are competent to carry out the work they are required to do, or are under the supervision of a competent person

(b)

all duty-holders must co-operate with each other to ensure that each can fulfil their duties under these Regulations

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Section 11: Health and Safety Page 6 Part 1.05: Other hazardous Activities (Regulatory Document)

(c)

every person working on a project under the control of another person is required to report to that person anything which is likely to pose a risk to health or safety of any persons

(d)

duty-holders must co-ordinate their work activities to ensure, so far as is reasonably practicable, the health and safety of those people carrying out the construction work and any other person who might be affected by it

1.5.1.4 Types of buried services The most obvious examples of buried services are those used to carry gas, electricity, water and telecommunications. These may be found almost anywhere. However, drains and sewers are also buried services, the location of which must be identified before excavation starts.

2

There are many other types of buried services, the presence of which may not be known or detected unless a thorough investigation is carried out. They include services associated with cable television, hydraulics, process fluids, pneumatics, railway signalling, petroleum and fuel oils (large bore, deep pipelines linking major installations), private telecommunications, highway authorities, street lighting, civil aviation and military authorities.

3

Work in the vicinity of gas transmission pipelines, normally operating at above 7 bar (100 psi), often requires special measures to be taken and the local gas distribution company will be able to supply details of appropriate procedures.

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1.5.1.5 Risks and cost of damage

A significant risk of injury results from accidental contact with electricity cables. Buried electrical cables often carry high voltages, and accidental damage and contact has resulted in death or major burns. Most injuries are caused to people using pneumatic drills or jackhammers and involve 415 volt cables which were located within 0.5 metres of the surface.

2

Damage to gas pipes can cause a leak resulting in fire and an explosion.

3

In the event of a gas leak, suspected gas leaks or any other emergency relating to gas, immediately ring:

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Gas Emergency Service Number: 4

The consequences of damaging water pipes and telephone cables may be less immediately evident but are nonetheless serious, both in terms of disruption and cost. The interruption of services can create serious problems for places critically dependent upon them - for example, hospitals - and many people are likely to be put at risk or inconvenienced.

5

The cost of damage can be considerable. Fibre optic telecommunication cables are very expensive and a simple break may mean the replacement of a 2 kilometre length, at a cost measured in thousands of Riyals. Indirect costs, in some cases resulting from loss of production and disruption of business activities, will be borne by all affected, including those whose negligence caused the incident.

1.5.1.6 Checking for buried services 1

Before any digging takes place, a check must be made with all public and private utilities, such as gas, electricity, telecommunication and cable TV companies, and the owner or occupier of the land for the existence of services in the proposed work area.

2

The routes of known buried services should be clearly marked on the site plans

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Section 11: Health and Safety Page 7 Part 1.05: Other hazardous Activities (Regulatory Document)

When looking at plans, it should be borne in mind that reference points may have been moved, surfaces may have been regraded, services moved without authority or consent, and that not all service connections or private services are shown. Plans must be interpreted with care; the route shown may only be approximate. There may be other services present not shown on the plans.

4

It is not unknown on certain sites for old and abandoned services or other buried metallic items, such as tram lines or cast iron pipes, to pick up the electro-magnetic signals from known cables and distort the survey results.

5

Where appropriate, the route, when established, should be identified with paint, tape or markers but not steel spikes which might penetrate a cable or pipe.

6

A line on a plan does not necessarily mean a pipe or cable is located exactly in the position marked. It only indicates that it is roughly in that location. The exact position will only be known when the buried service is uncovered.

7

In many cases, there is no indication above the ground that a buried service exists. They may be found almost anywhere and at any depth from immediately beneath the surface to 1.5 metres or more below.

8

Indications that buried services do exist include the presence of lighting columns, illuminated traffic signs, telephone boxes, concrete or steel manhole covers, and hydrant and valve pit covers.

9

A change in the colour of the surface material may indicate the line of a trench where services have previously been installed.

10

Indicator posts, usually on the verge, or plaques on walls, are a clear sign that buried services are present. Indicator posts belonging to water and gas suppliers often give the size of the pipe and its distance from the post. The absence of posts or covers must not be taken as evidence that there are no buried services. Access covers can be as much as 1.5 km apart.

11

Cables or pipes may be laid loose in the ground, run in earthenware, concrete, metal, asbestos or plastic ducts, or be buried in cement-bound sand, loose sand, fine backfill or material dissimilar from the surrounding ground. Plastic marker tape, tracer wire, boards, tiles or slabs may have been laid above the service to indicate that there is something below. These may, however, have been removed or damaged in the past; they are also liable to be laterally displaced by ground water or movement and thus no longer indicate the true location of the service.

12

It is common practice for brightly coloured polythene tape (150 mm wide) or expanded plastic mesh, sometimes incorporating metallic tracer wire, to be placed in the backfill about 300 mm above the pipe or service. A text on the tape identifies the type of service below. When uncovered, these tapes indicate the presence of a pipe or cable before any damage is done. The absence of a tape should not be taken as evidence that there are no pipes or

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Section 11: Health and Safety Page 8 Part 1.05: Other hazardous Activities (Regulatory Document)

cables at the location; it may simply mean that no marker tape was used. Caution Never assume that services have been installed at the recommended depth, they are often shallower.

14

Never assume that when you have located a service that it is the only one, there may be others adjacent to, above or underneath it.

15

Beware of services encased in concrete bases, structures or in the concrete backing to kerbs.

16

Beware of services rising over obstructions, culverts, bridges etc. They are often much shallower in these locations.

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1.5.1.7 Use of cable and pipe locators

A wide range of instruments are available for the detection of buried services. Often they are just referred to as CATs (Cable Avoidance Tools). Several different principles may be applied in the task of detection and an instrument may incorporate more than one of these.

2

Note: Both CAT and Generator must be used together to give an effective search for services. Using the CAT alone will only give part of the picture.

3

Power detection. Virtually all electricity cables give off or radiate a magnetic field while current is actually flowing through them. This magnetic field or 'hum' is usually easy to detect by a CAT.

4

However, it should be noted that CATs may not be able to detect live cables:

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when there is no current flow because the cable has been disconnected from its load. (An example of this is a live pot-ended cable)

(b)

when the loading on a three-phase supply is evenly distributed across the three phases

(c)

when the current flow is so small that it is beyond the detection capability of the detection tool

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QCS 2014

Used in the power detection mode, CATs will occasionally detect metal, gas and water pipes, and telephone cables in proximity to electricity cables.

6

Radio frequency. Metal pipes and cables can act like radio aerials and re-broadcast low and very low frequency radio signals which can be detected. There are limitations due to geography and initial broadcast signal strength. If this method is used, other metallic objects may also radiate the signal, but it is a useful method and can sometimes detect electricity cables that have not been found by power detection. Not all CATs have this function.

7

Transmitter and receiver (inductive or conductive). This method is used when the service is not carrying electricity or there is no current flow in the service to be located.

8

A small portable transmitter or signal generator (Genny) is connected to an exposed part of the cable or pipe, or placed very close to it, so that the signal is fed into or induced in the pipe or cable. This signal is then detectable by a CAT. In order to use this method, the location of at least one section of the cable or pipe must be accessible, so that the transmitter can be positioned or attached.

9

It is important to continue to use the locator as the excavation progresses.

10

Metal detectors. Conventional metal detectors will usually locate flat metal covers, joint boxes, etc., but may well miss round cables or pipes. The deeper the object, the less the chance of detection. Reinforcing bars, metal deposits in the ground and discarded metal objects will usually also be registered by a signal. Some cable locators have a metal detector function.

11

Developments in 'moles', 'pigs', 'mouses' and 'sondes', which are detection devices put into pipes and services to trace their routes, mean that previously undetectable pipes and services can be followed and, in some instances, blockages and joints can be located.

12

Ground-penetrating radar. A portable radar transmitter is used to 'sweep' the area of land under which the buried services run. A display on the transmitter indicates variations in the density of the materials below the surface and can show where the land has previously been disturbed.

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The display will also show solid objects such as cables or pipes filled with air, gas or liquids, and indicate the depth at which they are buried. By marking all the spots on the ground where an underground service has been located, its route can be traced. Ideally, this method should be supported by existing service plans.

14

The proper training of operatives is essential. Interpretation of the radar display can be difficult for the untrained. A skilled and trained operative with the correct instrument can detect the majority of underground services.

15

In unskilled hands, the average locator will not reveal exactly what has been found, or exactly where and how deep it is.

16

One problem that can arise in the use of ground-penetrating radar is the detection of individual buried services where more than one service follows the same route. The majority of detectors cannot distinguish between cables or pipes running close together. Consequently, the uncovering of one cable or pipe does not mean there is not another close by.

17

Some of the detectors or detection modes are not omni-directional and it is therefore essential to cover or sweep the area twice to ensure a good chance of detecting a buried service. This is especially true in the case of electricity cables. The sweep must be made up and down, then from side to side.

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It is important that those using any type of cable locating equipment are given sufficient training and experience to be competent.

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Recording location of services 19

A record of the nature, co-ordinates, line and level of newly installed services as well as those exposed on site should be kept and passed to the Client. This will enable those in the future to locate underground services more accurately.

1.5.1.8 Colour-coding of buried services 1

A national agreement exists between the utilities groups for the colour-coding of buried services.

2

The colours used for ducts, pipes, cables and marker/warning tapes are listed in Appendix 1 of this module. The listing has been reproduced from the publication NJUG Guidelines on the Positioning and Colour Coding of Underground Utilities Apparatus (December 2007).

3

These colour-coded buried services should not be confused with the colour system contained in BS 1710 Specification for identification of pipelines and services, which

QCS 2014

Section 11: Health and Safety Page 11 Part 1.05: Other hazardous Activities (Regulatory Document)

generally applies to all above-ground building and process services. 4

It should be noted that both green and black plastic-covered cables have been laid for private telecommunications and television, some of these in earthenware ducts or previously used metal pipes.

5

Identification of colours in conditions of poor light or artificial lighting may be difficult.

6

The colour-codings in Appendix 1 apply to services being laid now. With the great variety of pipes and services laid over a period of years, there is a wide mixture of materials and colours. The principal ones, excluding cement, plastic, metallic or earthenware ducts, are summarised in the table below. This table also highlights the different services that may have similarly coloured pipes or cables. Service(s)

Cast iron

Gas, water

Steel

Gas, water

Braided steel

Electricity

Yellow steel

Gas

Copper

Water

Lead or lead covered

Electricity, water

Asbestos

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Red PVC

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Blue PVC Grey PVC

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Hessian wrapped

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Pipe or cable

Electricity Electricity, water, telecoms Water Water, telecoms Electricity Gas

Natural PVC

Telecoms

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Yellow PVC

The following points should be noted:

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All plastic, polythene and polyvinylchloride pipes are shown above as PVC.

(a)

black PVC must always be assumed to be live electricity until proved otherwise

(b)

all cast iron and steel must be assumed to be carrying gas until proved otherwise

(c)

ducts may well contain any one of the services, irrespective of type or colour of the duct.

1.5.1.9 Digging - mechanical or manual 1

Once the approximate location of a service has been identified using all available information (including plans, marker posts and other indicators and detectors), trial holes should be dug carefully by hand to establish the exact location and depth of the service.

2

Where two holes are dug at intervals, it should not be assumed that the service runs in a straight line between them, or that it runs at a consistent depth.

3

Mechanical excavators and power tools should not be used within 0.5 metres in any direction of the indicated line of a service, unless prior agreement on a safe system of work has been reached with the service owner. Power tools may be used to break paved surfaces, but great

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Section 11: Health and Safety Page 12 Part 1.05: Other hazardous Activities (Regulatory Document)

care must be taken to avoid over penetration, since a service may have been laid at an unusually shallow depth, especially in the vicinity of buildings or other services. Power tools must never be used directly over the indicated line of a cable unless it has been made dead or steps have been taken to prevent damage. 4

Buried services that cross the route of an excavation must be supported as necessary. It is also necessary to ensure that the method used to support the sides of an excavation allow for the protrusion of buried services through the excavation's sides.

5

Before and during excavation work: Check with all utilities and landowners before starting work.

(b)

Assume the presence of services when digging, even though nothing is shown on plans.

(c)

Use detection devices and keep a close watch for signs of buried services, such as marker tape or tiles.

(d)

Although there are recommended minimum depths for all services, they may be closer to the surface than normal, especially in the vicinity of works, structures, or other services.

(e)

Markers such as plastic tape, tiles, slabs or battens may have been displaced and will not indicate the exact location of the buried service.

(f)

Some electric cables and water pipes look alike, as do some gas pipes and water pipes. Ensure each pipe is properly identified before starting work on them.

(g)

Services could be easily damaged by a fork or a pickaxe forced into the ground, but careful use of spades and shovels enables services to be safely uncovered.

(h)

Carefully lever out rocks, stones and boulders.

(i)

Overpenetration of the ground or surface with hand-held power tools is a common cause of accidents.

(j)

If an excavator or digger is being used near any service, take extra care to prevent accidental damage. Where possible, no one should be near the digger bucket while it is digging.

(k)

Ensure the excavator operator and others excavating are informed of the presence of suspected services.

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If the service is embedded in concrete or paving material, the owner should deenergise it, otherwise make it safe or approve a safe system of work before it is broken out.

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(a)

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Always assume closed, capped, sealed, loose or pot-ended services are live or charged, not dead or abandoned, until proved otherwise.

(n)

Follow the guidelines and advice issued by the electricity, gas, water and telecommunication industries.

1.5.1.10 Piling and drilling, etc. 1

Piling and drilling, thrust boring, bore holing and augering must not start until all the necessary steps and precautions have been taken and a safe system of work has been devised and implemented.

2

Services shown or thought to be nearby should be exposed by hand digging to establish their precise location.

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1.5.1.11 Exposure and protection 1

When a service is exposed in the bottom of a trench or excavation, it should be protected with suitable timber or other material to prevent it becoming damaged.

2

Services across a trench or along a trench above the bottom should be supported by slings or props, to avoid unnecessary stresses. In case of doubt, advice should be sought from the utilities or the owner.

3

Cables and services must never be used as jacking or anchorage points, or as footholds or climbing points. If a service pipe or cable needs to be moved to allow work to progress, the owner should be consulted and advice sought.

1.5.1.12 Reporting damage

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Any damage to buried services must be reported to the owners. Minor damage to the sheath of a cable or to a coating on a pipe can result in moisture penetration, corrosion and subsequent failure. A cable pulled and stretched may result in a conductor or core being broken, and a broken earthenware or concrete duct may prevent a service being routed through it.

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1

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If a gas pipe is fractured or starts leaking: evacuate all personnel from the area

3

enforce a ban on smoking and naked lights

4

prevent any approach by members of the public or vehicles

5

inform the gas company immediately.

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If an electricity cable is damaged: avoid all contact with it

7

do not attempt to disentangle it from digger buckets, etc.

8

do not attempt to leave your cab. Stay put until you are told the cable has been made safe

9

inform the electricity company

10

keep everyone clear.

11

Note: Some cables are automatically re-energised by the local sub-station after a short time following the supply tripping out due to damage. Do not assume that a damaged cable will remain dead.

12

Beware of old pot-ended cables and pot joints; these are easily damaged if moved. Always consult the service provider before touching such apparatus.

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If any other service pipe or cable is broken: 13

leave well alone

14

inform the owner.

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Section 11: Health and Safety Page 14 Part 1.05: Other hazardous Activities (Regulatory Document)

Backfilling 15

Surplus concrete, hard core, rock, rubble and flint must never be tipped onto a service while backfilling a trench or hole, since it may result in damage.

16

Selected backfill material should be adequately settled and compacted, with care being taken to avoid mechanical shocks to the service pipe or cable. Warning tapes, tiles, etc. should be placed above the service at about 300 mm. When gas service pipes have been exposed, advice on backfill should be sought from the gas company.

Emergency works Emergency works and excavations usually mean that there is no time for planning or contacting each of the utilities.

18

However, work can be carried out safely if:

(b)

detectors are used correctly

(c)

trial holes are dug by hand

(d)

the practice of safe digging is followed.

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the area is marked out carefully

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(a)

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17

Permit to Work and Permit to Dig

Where it is appropriate, a formal Permit to Work system should be employed, with a Permit to Dig being issued, duly signed by a competent person. Those engaged on the work can then see exactly what has been done, what is expected of them and what precautions they must take. The permit also allows the person in control of the works to authorise excavation to proceed only when they are satisfied that the conditions of the permit have been met.

20

An example of a Permit to Dig is given in Appendix 2.

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Conclusion

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PLAN... LOCATE... DIG...

Plan the work to be done, including the risk assessment, using all available sources of information. Contact the utility companies and owners of services for information and advice on procedures and continue to liaise with them.

22

Locate the buried service before digging or excavation starts. Use all available information; look for indicators or markers and other signs; use detectors and locators, and dig trial holes.

23

Dig using a safe method of work (Permit to Work systems whenever possible); observe the rules in respect of the use of mechanical diggers and power tools. Ensure that all services are identified positively. Do not make assumptions about the number, type or exact location of services.

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Construction Site Safety 1.5.1 Appendix 1 Colours of ducts, pipes, cables and marker/warning tapes 1

These guidelines, reflect utility practice in the UK. However, operators must not assume that any mains or services encountered will conform to the recommendations for positioning or colour coding detailed in this appendix.

Pipe/Duct Identification Issue 4, dated 8 January 2009 The pipe or duct may have the owning utility's name stamped upon it.

Duct

Pipe

Cable

Electricity HV (High Voltage)

Black or red tile

N/A

Black or red

Yellow with black legend

Electricity LV (Low Voltage)

Black or red

N/A

Black or red

Yellow with black legend

Gas

Yellow

Yellow or yellow with N/A brown stripes that is removable to reveal white or black pipe

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Yellow with black legend

Water non potable & Grey water

N/A

Black with green stripes

N/A

N/A

Water -Firefighting

N/A

Black with red stripes or bands

N/A

N/A

Oil / fuel pipelines

N/A

Black

N/A

Various surface markersMarker tape or tiles above red concrete

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Black

No distinguishing N/A colour/ material (e.g. Ductile Iron may be red; PVC may be brown)

N/A

Grey White Green Black Purple

N/A

Various

Water

Blue or grey

Blue polymer or blue N/A uncoated Iron / GRP. Blue polymer with brown stripe (removable skin revealing white or black pipe)

Blue or Blue/black

Water pipes for special purposes (e.g. contaminated ground)

N/A

Blue polymer with brown stripes (nonremovable skin)

Blue or blue/black

Telecoms

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Colour of Marker/ Warning Tape Where Used

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Colour of Duct/Pipe/Cable Buried in Ground

Black or light grey

N/A

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Section 11: Health and Safety Page 16 Part 1.05: Other hazardous Activities (Regulatory Document)

Duct

Pipe

Cable

Tape

Street lighting England and Black or orange Wales (consult the electricity company first)

N/A

Black

Yellow withblack legend

Street lighting Scotland

Purple

N/A

Purple

Yellow with purpleblacklegend or

Street lighting Northern Ireland

Orange

N/A

Black or orange

Various

Traffic control

Orange

N/A

Orange

Yellow withblacklegend

Street furniture

Black

N/A

Black

Yellow withblacklegend

Telecoms

Purple/orange

N/A

Black

Communications

Purple

N/A

Grey

Communications power

Purple

N/A

Black

Road lighting

Orange

N/A

Black

Communications

Black or grey

N/A

Road lighting

Purple

N/A

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Highway Authority Services

Yellow withblacklegend Yellow withblacklegend Yellow withblacklegend

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Various

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Black

Yellow withblacklegend

Purple

Yellow withblacklegend

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Construction Site Safety 1.5.1 Appendix 2 Example of a Permit to Dig Work must not start until Sections A, B & C of this permit have been completed and signed by authorised persons. Section A. Project details To be completed by project manager Company: .................................................................. Job/Contract ref: .............................................................. Contractor: .................................................................Location of works:...............................................................

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Start date: ..................................................................Completion date:.................................................................

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Brief description of works

Section B. Preliminary work

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To be completed by the Supervisor in change of the works

Yes

No

Comments

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Essential procedures

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1. Have contract drawings and details been issued by the client or otherwise obtained?

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2. Do drawings show the location, type and status of buried services?

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3. Have live services been made dead as far as it is possible or necessary to do so?

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4. Has the work area been surveyed by a competent person, using appropriate detection equipment to confirm the exact location of buried services?

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5. Has a method statement been written and submitted for comment and approval? 6. Has the method statement been explained to the operatives carrying out the work? 7. Is the person in charge of the excavation fully conversant with the principles of safe digging and/or avoidance of buried services? 8. Are all operatives familiar with safe excavation practices? 9. If plant is being used, is the operator competent and familiar with safe digging practices? I declare that the above safety precautions will be put into place before work commences or that an explanation given as to why some or all are not necessary:

Name:..................................

Signature:..................................

.Date:.....................

Time:....................

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Section 11: Health and Safety Page 18 Part 1.05: Other hazardous Activities (Regulatory Document)

Section C. Certification To be completed by the supervisor in charge of the works

I am satisfied that the precautions identified on the previous page are satisfactory to enable the excavation to be undertaken safely* I am NOT satisfied that the precautions identified on the previous page are satisfactory to enable the excavation to be undertaken safely and require the additional precautions / work outlined below to be undertaken before excavation work commences*

.

*Delete as appropriate

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Name:............................Signature:...................................Date:.....................Time:.................... Additional precautions / work necessary prior to commencement:

Section D. Completion of work

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To be completed by the supervisor in charge of the works I am satisfied that the precautions identified on the previous page are satisfactory to enable the excavation to be undertaken safely*

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*Delete as appropriate

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I am NOT satisfied that the precautions identified on the previous page are satisfactory to enable the excavation to be undertaken safely and require the additional precautions / work outlined below to be undertaken before excavation work commences*

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Name:............................Signature:...................................Date:.....................Time:.................... Additional work that is necessary to enable this permit to be cancelled:

Section E. Cancellation of permit To be completed by the supervisor in charge of the works I am satisfied that all work has been completed and this permit is now cancelled.

Name:............................Signature:...................................Date:.....................Time:....................

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Construction Site Safety 1.5.2

Lone Working

1.5.2.1 Key points The implications of lone working must be thoroughly investigated, via a risk assessment, before anyone is allowed to work alone.

2

Lone working must be avoided whenever it may put the health or safety of any person at an unacceptable level of risk.

3

Anyone working alone, for example a single person working in a lift shaft, is a lone worker even if there are other people on site.

4

The suitability of the job and the person who will undertake the work must both be taken into account to establish whether lone working is advisable.

5

A suitable and effective system of checks to confirm the continued wellbeing of the lone worker must be put in place.

6

The risk assessment might indicate the need for a rescue plan.

7

Resist the urge to carry out unplanned lone working, for example the two members of a maintenance team separating so that one of them can fix an unexpected fault, unless it is proved safe to do so.

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1.5.2.2 Introduction

Before lone working is permitted, the risks of a single worker carrying out the task must be assessed. The findings of the risk assessment must demonstrate that the person would not be at a greater level of risk than if accompanied.

2

Contractors have responsibilities for the health and safety of their employees and other people who might be affected by the Contractor’s work activities. Whilst legal duties are also placed upon employees, the Contractor still retains the legal duty to ensure the wellbeing of the employees.

3

Lone workers are people who work by themselves without any close or direct supervision.

4

As far as construction industry activities are concerned, they are likely to be people who:

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(a)

work on their own in a part of the site that is otherwise occupied by other people

(b)

have to work alone on the site outside of normal working hours

(c)

work alone in premises which are remote from the site, such as company offices or a builder's yard

(d)

work alone in domestic premises whilst the householder is not present.

1.5.2.3 Legislative requirements Duties of Contractors 1

A general duty on every Contractor is to ensure, so far as is reasonably practicable, the health, safety and welfare at work of all their employees.

2

All of the requirements listed below could have implications when considering the need or advisability for someone to work alone.

3

So far as is reasonably practicable, Contractors must:

QCS 2014

protect the health, safety and welfare at work of all their employees

(b)

provide and maintain plant and systems of work that are safe and without risk to health

(c)

ensure safety and absence of risks in the use, handling, storage and transport of articles and substances

(d)

provide any necessary information, including information on legal requirements, to ensure the health and safety of their employees

(e)

provide adequate supervision and training, as is necessary, to ensure the health and safety of their employees

(f)

provide and maintain a safe and healthy place of work, with safe access and egress

(g)

provide and maintain a working environment that is safe and without risks to health and is adequate with regard to welfare facilities and arrangements for welfare at work.

.

(a)

Certain additional duties have been placed on the Contractor including:

to ensure, as far as is reasonably practicable, that the conduct of their activities does not endanger persons not in their employment who may be affected by operations under their control, for example, all contractors or the public.

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Section 11: Health and Safety Page 20 Part 1.05: Other hazardous Activities (Regulatory Document)

General duties on employees:

to exercise reasonable care for the health and safety of themselves or others who may be affected by their acts or omissions at work

(b)

to co-operate with the Contractor, as far as may be necessary, to enable them (the Contractor) to carry out their legal duties in health and safety matters.

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Duties of employees

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The Management of Health and Safety at Work

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

7

Once those hazards have been identified, it is then the Contractor’s duty to put control measures into place in order either to eliminate the hazard or, where this is not possible, to reduce the risks of injury or ill health arising from the hazards, as far as is reasonably practicable.

8

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

9

Employees, in turn, have a duty to tell their Contractor of any work situation which they believe presents a risk to themselves or to others, or of any matter which affects the health and safety of themselves or other persons.

10

Also of importance with regard to lone working are the requirements on the Contractor to:

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(a)

establish contacts with external services, for example the emergency services

(b)

provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks

(c)

assess employees' capabilities when allocating work to individuals

(d)

provide adequate training for anyone involved in any aspect of lone working (including

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Section 11: Health and Safety Page 21 Part 1.05: Other hazardous Activities (Regulatory Document) rescue).

11

Arising out of the risk assessment for lone working the Contractor may decide that there is a need to: (a)

develop a method statement for each job

(b)

implement a Permit to Work system, encompassing or supplemented by a Permit to Enter.

1.5.2.4 Practical considerations 1

Before the job starts, the following factors must be considered as part of assessing the risks of carrying out lone working.

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Job factors that must be taken into account when considering whether the risks of lone working are acceptable include the following: Does the place of work and the job to be carried out present more unacceptable risks to the health and safety of a lone worker than it would for, say, a gang of two workers?

(b)

Can the lone worker enter and exit from the place of work safely, including exiting quickly and safely in an emergency?

(c)

Can all equipment, plant and substances used be safely handled by one person?

(d)

Are there barriers to effective communication with the lone worker?

(e)

If something goes wrong, is a prompt and effective rescue a realistic possibility?

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The job

There may be circumstances in which unplanned lone working takes place when, for example, one person decides to separate from workmates to investigate a fault or sort out a problem. Depending on the working environment, these situations have the potential to put the health or safety of the 'lone worker' at significant risk. The findings of the risk assessment should indicate the potential risks arising from one member of a team becoming separated from workmates.

4

If such a situation could arise, managers and supervisors must ensure that clear instructions are given about the need for 'team members to stick together'.

5

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The suitability of the person who will undertake the work has to be considered when deciding whether lone working is safe. Questions to be asked and satisfactorily answered as part of the risk assessment include the following. (a)

Given that there will be no direct supervision, has the person who will carry out the job received adequate training and instruction to do it safely?

(b)

Does the person have sufficient experience to be able to recognise an unsafe situation developing which necessitates leaving the place of work?

(c)

Does the person know how to inform others, and who to inform if an unsafe situation develops?

(d)

Considering both routine work and a possible emergency situation, does the person have a medical condition that might make them unsuitable for lone working?

(e)

Does the person require and possess a particular level of physical fitness to carry out the work?

(f)

Is a young female or non-English speaking worker at a greater level of risk?

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Section 11: Health and Safety Page 22 Part 1.05: Other hazardous Activities (Regulatory Document)

The risks 6

A wide range of work activities can be classified as lone working, not all of which present unacceptable risks. For example, it could be argued that a lone worker travelling to an otherwise unoccupied part of a highway construction site, in a serviceable and suitable vehicle, is at far less risk than a lone worker entering an underground chamber after normal working hours.

7

The findings of a thorough assessment of the risks arising out of proposed lone working will indicate whether it is safe to proceed.

8

An assessment of the risks arising from carrying out work which involves the following common construction activities might indicate that lone working is not acceptable: working at height

(b)

working in any area which could become a confined space

(c)

working in narrow, deep excavations, whether classified as a confined space or not

(d)

working with, or close to, exposed live electrical cables or fittings

(e)

working with, or close to, other sources of other potentially hazardous energy

(f)

using any substance that could deplete the level of oxygen or otherwise result in reduced awareness or loss of consciousness

(g)

any hot-works

(h)

disturbance of sludge in any underground chamber, pipe etc.

(i)

entering ductwork

(j)

working over or near to water or other fluids in which a person could drown

(k)

the operation of any equipment such as power saws, misuse of which could lead to severe bleeding

(l)

the operation of any engine-driven equipment that emits toxic exhaust fumes

(m)

the operation of construction plant.

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Note: The above list is not exhaustive.

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Control measures 9

The health and safety of anyone who is working alone should not be put at a higher level of risk than if working with other people.

10

This may require that extra risk-control measures are taken, for example: (a)

ensuring that the lone worker is competent to carry out the work

(b)

supplementing the risk assessment with: (i)

a permit to work which clearly defines the limits of the work allowed and the time within which it must be completed, and/or

(ii)

a method statement

(c)

providing the lone worker with a means of communication

(d)

implementing a 'check-in' system whereby either: (i)

the lone worker contacts another person at prearranged intervals, the frequency of checking-in depending upon the urgency of response if the lone worker fails to 'check-in'; or

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Section 11: Health and Safety Page 23 Part 1.05: Other hazardous Activities (Regulatory Document) (ii)

the reverse of the above system in which someone such as a supervisor periodically contacts the lone worker

(e)

supplying the lone worker with a manual alarm system or one which operates automatically by the absence of activity (see below)

(f)

providing the lone worker with a 'travelling' first-aid kit and possibly (if indicated by the findings of the risk assessment) first-aid training

(g)

establishing a trained rescue person or team and practising the rescue procedure.

Alarm systems Automatic alarms, also known as 'man down' alarms, have been in use in hazardous industries such as petrochemicals for some time. This equipment also has its uses for lone workers in the construction industry. Although the alarm can be triggered manually by a lone worker who is in distress or danger, depending on the type, they can be automatically triggered by: a lack of motion for a pre-set period of time

(b)

a tilt switch which typically operates after a short delay if the unit is tilted beyond 45° from the vertical.

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(a)

Of course, if such a system is in use, it is essential that:

the 'base station' where the alarm system is received is staffed continually whilst lone working is taking place

(b)

the exact location of the lone worker is known

(c)

a prompt rescue can be initiated by a trained rescue person or team, depending upon the circumstances.

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Construction Site Safety 1.5.2 Appendix Lone working checklist 1

Have the risks of lone working been assessed?

2

Do the findings of the risk assessment show: (a)

that there are any particularly hazardous aspects of the job that might make it unsafe for lone working?

(b)

that lone working significantly increases the risks to the person doing the job?

(c)

that particular skills, knowledge, training or instruction are necessary?

Will the lone worker be able to cope with all the physical aspects of the Job without assistance?

4

Do the physical characteristics of the place of work make it suitable for lone working and emergency evacuation?

5

Are the levels of risk acceptable?

6

Is a permit to work necessary?

7

Is a method statement necessary?

8

Can the person selected for lone working follow a method statement when unsupervised?

9

Is the lone worker competent to work without direct supervision?

10

Will the lone worker be able to recognise an unsafe situation developing?

11

If so, will they know what to do?

12

Is a rescue plan necessary?

13

Has sufficient instruction and training been provided?

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(a)

Will an effective method of communication between the lone worker and a supervisor/manager be established?

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Is an automatic 'man down' alarm system necessary and if so: (a)

where will the base station be located? who will staff it whilst lone working is in progress?

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Is it necessary to establish a rescue plan and team?

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Is a 'check-in' system required?

17

Does the lone worker have a medical condition that might increase the risks to their health or safety?

18

Does the lone worker require a 'travelling' first-aid kit and first-aid training?

19

Is there a need to isolate electrical supplies or other sources of energy?

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Section 11: Health and Safety Page 25 Part 1.05: Other hazardous Activities (Regulatory Document)

Construction Site Safety 1.5.3

Electrical Safety on Site

1.5.3.1 Key points Electricity can be a killer; you cannot see it and may not know that an item of equipment is live until you touch it.

2

Buried cables, and those inside partition walls or other 'hidden places', are just waiting for the unwary to accidentally damage the cable and cause themselves serious injury or even death.

3

The electrical distribution systems found on site tend to operate in a harsh environment and must be treated with care and respect.

4

No-one other than a qualified electrician must alter the site distribution system.

5

Ideally, apart from mains-powered equipment in site offices, all other powered equipment such as electrical hand tools will run off a 110 volt supply.

6

The safest electrically powered tools and equipment are those that run off batteries.

7

Working on or near to live, exposed conductors poses obvious dangers. Competence is required and such work is usually carried out under a Permit to Work.

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Note:

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1.5.3.2 Introduction

Unlike most other hazards which can be seen, felt or heard there is no advance warning of danger from electricity; and electricity can kill.

2

Electricity and electrical installations on construction sites must always be treated with the utmost care and be under the control and supervision of experienced competent persons. Hazards arise through faulty installations, lack of maintenance and abuse of equipment.

3

Electric shock is a major hazard. The severity of the shock will depend on the level of electric current, and the duration of the contact.

4

At low levels of current, about 1 milliamp, the effect may be only an unpleasant tingle but enough to cause loss of balance or a fall. An electrical current of about 10 milliamps can cause muscular spasm and loss of control. Higher levels of electric current of 50 milliamps or above, for a period of about one second, can cause fibrillation of the heart which can be lethal.

5

Electric shock also causes burning of the skin at the points of contact.

6

1 milliamp is a one thousandth part of an amp.

7

Fuses cannot be regarded as adequate protection against electric shock. A fuse is intended only to protect equipment from damage. They are commonly rated at 3, 5, 10 or 13 amps for domestic and normal business use.

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1.5.3.3 Causes of electric shock 1

Contact between a live conductor and earth.

2

Contact between phase and neutral conductors (as the body is likely to have less electrical

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Section 11: Health and Safety Page 26 Part 1.05: Other hazardous Activities (Regulatory Document)

resistance than any load). 3

The majority of electrical accidents happen because people are working on or close to equipment which is either: (a)

assumed to be dead but is, in fact, live

(b)

known to be live, but workers have not received adequate training, lack adequate equipment or have not taken adequate precautions.

It cannot be emphasised too strongly that the installation, maintenance and repair of electrical services must only be carried out by a competent, qualified electrician.

5

Electric shock is not the only hazard. The very high temperature that results from electric arcing can produce severe and deep-seated burns. An electric arc also produces intense ultraviolet radiation which can damage the eyes (arc eye).

6

An electrical short circuit or the use of unstable or badly maintained equipment can ignite flammable materials, resulting in a fire or explosion.

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1.5.3.4 Legislative requirements

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The Management of Health and Safety at Work

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2

Once those hazards have been identified, it is - then the Contractor’s duty to put control measures into place, to either eliminate the hazards or, where this is not possible, reduce the risk of injury or ill health resulting from those hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and of any control measures that are in place to reduce those risks.

4

Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or to any other person who may be affected.

5

In the context of this module, the risk assessment should include consideration of:

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(a)

the possibility of anyone coming into contact with live electrical equipment at a dangerous voltage

(b)

the control measures that must be put in place to ensure that no one is injured by coming into contact with live electrical equipment at a dangerous voltage, for example a Permit to Work system

(c)

the training and competence of any person who may have to work in the vicinity of live electrical supplies.

The Provision and Use of Work Equipment 6

These Regulations require that a Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

7

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to competent and specified workers.

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Furthermore, these Regulations require that: all work equipment has adequate controls, emergency controls and where necessary, a control system, to enable it to be used safely

(b)

each item of work equipment can be effectively isolated from all sources of energy

(c)

the Contractor provides employees with adequate information, instruction, training and supervision to be able to carry out any work task safely and without risk to their health.

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Section 11: Health and Safety Page 27 Part 1.05: Other hazardous Activities (Regulatory Document)

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Section 11: Health and Safety Page 28 Part 1.05: Other hazardous Activities (Regulatory Document)

Construction (Design and Management) CDM The hazard of exposure to live electrical conductors can in many cases be eliminated, or the residual risks reduced, by careful attention to design and planning aspects before construction work starts. Any residual risks must be controlled by good management and safe working practices during construction.

10

These Regulations place health and safety responsibilities on the client, designers, contractor and provide a framework for the management of risks, including electrical risks.

11

The client must ensure that all designers and all contractors appointed by the client, or likely to be, are promptly provided with all relevant information that the client has in relation to the health and safety risks arising from the project.

12

In the context of this section, this information could cover, for example, the existence of buried electrical services or live electrical circuits in a building that is about to undergo renovation.

13

The client must ensure that the Engineer promptly supplies the relevant information to the contractor and all designers.

14

Given the hazardous nature of electricity, it is difficult to see how identifying the location of live electrical services could be anything other than relevant.

15

These Regulations require that where there is a danger from electrical power cables they must be:

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suitably located (positioned) to prevent danger, periodically checked and clearly indicated by signs

(b)

directed away from the area of risk, or

(c)

made dead and where necessary earthed, or

(d)

where neither of the above two options are 'reasonably practicable', erect suitable warning notices and:

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barriers suitable to exclude work equipment which is not needed, or

(ii)

suspended protection if vehicles need to pass below the cable, or

(iii)

in either case other equally effective measures

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(i)

construction work that is liable to create a risk to health or safety from underground services must not commence unless all reasonably practicable steps have been taken to avoid damaging or disturbing them.

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(a)

Electricity at Work 16

These Regulations apply to all situations involving electricity, at any place of work, and place legal obligations on both Contractors and employees.

17

The main points of these Regulations are, briefly, as follows. (a)

All systems shall be of such a construction so as to prevent, so far as is reasonably practicable, any danger.

(b)

All work activity on or near a system, including operation, use or maintenance, shall be carried out, so far as it is reasonably practicable, so as not to give rise to any danger.

(c)

Any equipment provided to protect people while they are at work on, or near, any electrical equipment shall be suitable for use and properly maintained.

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Section 11: Health and Safety Page 29 Part 1.05: Other hazardous Activities (Regulatory Document) Notes: (i)

(i) 'System' includes every part of the system or installation, all conductors and electrical equipment, whether the system is electrically alive or dead.

(ii)

(ii) 'Electrical equipment' includes everything from overhead to underground cables with thousands of volts, right down to 6 volt circuits and even batterypowered hand lamps. The spark from the switch on a hand lamp could be a source of danger in an explosive atmosphere.

(iii)

(iii) 'Danger' is the risk of injury to any person.

(iv)

(iv) 'Injury' means death or any injury caused by electricity. This covers electric shock, electric burns, fires, arcing or explosions caused by electricity.

The strength and capability of electrical equipment must not be exceeded in such a way as may give rise to any danger.

19

All electrical equipment which may be exposed to the following must be constructed, or protected to prevent, so far as reasonably practicable, any danger arising from: mechanical damage

(b)

the effects of weather, temperature and so on

(c)

wet, dirty or corrosive conditions

(d)

flammable or explosive dusts or gases.

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Note: 'Technical knowledge and experience' means that the person must be competent to do their job. To be considered competent a person needs: adequate knowledge of electricity

(f)

good experience of electrical work

(g)

an understanding of the system being worked on

(h)

practical experience of that type of system

(i)

knowledge of the hazards that might arise and the precautions that need to be taken

(j)

the ability to immediately recognise unsafe situations.

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(e)

Electricity supply

The supply of electricity on construction sites will normally be provided by one or both of the following:

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(a)

A public supply from the local electricity company.

(b)

A site generator, where public supply is not practicable or is uneconomic.

Public supply 21

A public supply of electricity being provided depends on the following: (a)

written application being made to the local electricity company, as soon as possible at the planning stage

(b)

the name, address, and telephone number of the main contractor and developer, giving the full site address and a location plan

(c)

details of the maximum demand load (in kilowatts) which is likely to be required during construction

(d)

details of the maximum final demand load (in kilowatts) which will be required when the job is complete

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Section 11: Health and Safety Page 30 Part 1.05: Other hazardous Activities (Regulatory Document)

(e)

dates when the supply is needed

(f)

a discussion with electricity company staff to determine the necessary precautions to avoid damage or hazards from any existing overhead or underground cables

(g)

the establishment of supply points (where incoming cables will terminate), switch gear, metering equipment and requirements for earthing.

Generators Generators (even if for stand-by purposes) may be required, and will be powered by petrol or diesel engines. Attention should be given to the siting of such equipment in order to minimise pollution caused by noise and fumes.

23

Any private generating plant must be installed in accordance with BS 7375. You are advised to seek advice from the local electricity company.

24

If the generator will produce over 55 volts AC, it must be effectively earthed. A competent person should test the effectiveness of the earth.

25

The principle of low voltages and their advantages should be considered further where portable generators are used on site.

26

Not all portable generators available for use on site have the 110 voltage output centre tapped to earth. This is particularly true of generators which have dual voltage selectable. This is important as the whole concept of using 110 volts on site is that by centre tapping to earth, the maximum voltage to which anyone is exposed is only 55 volts. Most people can survive a shock of 55 volts. If the supply is not centre tapped to earth, anyone receiving a shock will be exposed to the full 110 volts.

27

The metal framing of the generating set should be bonded to the metalwork of the site distribution system, where there is one.

28

The use of generators in excess of 10 kVA may require advice from a specialist electrical contractor.

29

Overhead power lines

30

Generally, electricity supplies above 33,000 volts are routed overhead. Supplies below this voltage may be either overhead or underground.

31

Overhead lines are normally uninsulated and can be lethal if contact, or near contact, is made. Electric arcs may jump a considerable distance. Care should be taken when dumping, tipping waste, regrading, landscaping, or when in planned or unplanned storage areas, not to reduce these minimum clearances.

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Working near overhead power lines 32

The local electricity company must be consulted before any work starts and a safe system of work must be devised and implemented.

33

Other suppliers may also need to be consulted, for example, Qatar General Electricity & Water Corporation and other electricity companies.

34

For some jobs, it may be necessary for the electricity supplier to isolate or re-route overhead cables to enable the work to proceed.

35

Practical steps that can be taken to prevent danger from any live electrical cable or apparatus include the placing of substantial and highly visible barriers.

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36

If access is only required from one side of a power line, then a barrier, on that side only, will suffice. If the overhead line crosses the site, barriers will be required on both sides of it. If there is a danger to people carrying metal scaffold poles, ladders or other conducting objects, the barrier should exclude both people and mobile plant.

37

Any ground level barriers should consist of either: a stout post and rail fence, or

(b)

a tension wire fence, earthed at both ends, with flags on the wire. The fence is earthed in consultation with the electricity company, or

(c)

large steel drums (for example 200-litre oil drums) filled with rubble or concrete, and placed at frequent intervals, or

(d)

an earth bank, not less than 1 m high and marked by posts to stop vehicles, or

(e)

substantial timber baulks, to act as wheel stops.

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(a)

Fences, posts and oil drums should be made as distinctive as possible by being painted with red and white stripes. As an alternative, red and white plastic warning flags or hazard bunting should be used on wire fences.

39

There should be a general rule prohibiting the storage of materials in the area between the overhead lines and the ground-level barriers. Precautions are necessary even though work in the vicinity of the line may be of short duration.

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38

Before doing any work on site, consult the local electricity company. They will normally arrange a site meeting and advise on heights, distances and other precautions.

(b)

It must be assumed that all overhead lines and cables are live unless advised otherwise by the electricity company.

(c)

All work should be carried out under the direct supervision of a responsible supervisor, appointed by the Contractor, who is familiar with the hazards likely to be encountered.

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If mobile cranes or excavators are used, the minimum distance from the ground level barrier to the line should be 9 m if on wood or metal poles, 15 m if on pylons PLUS the length of the jib or boom.

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Working near overhead power lines

Section 11: Health and Safety Page 32 Part 1.05: Other hazardous Activities (Regulatory Document)

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Ensure that safety precautions are developed and observed.

(b)

All plant, cranes and excavators may be modified with suitable physical restraints to limit their operations, where applicable.

(c)

Additional care may be needed as work proceeds because of reduced clearances.

(d)

Electronic proximity warning devices may be fitted on crane jibs.

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(a)

Where it is necessary to work beneath live overhead lines, additional precautions will be required to prevent the upward movement of ladders, scaffold poles, crane jibs or excavator buckets.

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Note: If any work takes place after dark, notices and crossbars should be illuminated. The height will be specified by the electricity company.

Working in proximity of underground cables 42

Damage to live underground cables during excavation work is the cause of a number of accidents resulting in injuries and disruption of supplies. There have been occasions when such accidents have been fatal. The electricity company should be consulted before the commencement of any work that may result in the exposure of or damage to, underground electricity cables.

43

Technology such as ground penetrating radar has improved cable identification significantly and there is now very little excuse for hitting underground cables.

44

It is essential that all those involved, particularly machine operators, are aware of the hazards.

45

Before any excavation work starts: (a)

ensure that employees have proper and safe work procedures and are working under

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Section 11: Health and Safety Page 33 Part 1.05: Other hazardous Activities (Regulatory Document) adequate supervision

(c)

obtain advice on the location and ownership of any underground electricity cables

(d)

check plans to establish cable routes, as well as their depth and voltage

(e)

use cable location devices where necessary and mark cable routes

(f)

users need to be trained to use cable avoidance tools (CAT) effectively

(g)

CAT will usually only locate energised cables and so a signal generator may have to be used in conjunction with the CAT to find the cable (CAT and genny as it is known).

During excavation: regard all buried cables as live. Do not assume that pot-ended cables are dead or disused

(b)

dig by hand when nearing the assumed line of the cable

(c)

do not use excavators and power tools within 0.5 m of the indicated line of the cable

(d)

if hand digging is not an option, the service must be isolated

(e)

ensure exposed cables are supported and protected against damage. They should not be used as hand and footholds

(f)

consult the local electricity company (Qatar General Electricity & Water Corporation) in all cases of doubt.

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(a)

Many incidents occur where people are asked to hand dig through concrete, tarmac and other compressed surfaces, and have to resort to using bars and picks. Consequently, cables are hit and penetrated. Alternatively, they persuade the excavator driver to dig a bit closer to the cable to reduce the amount of hand digging that they have to do. It is important to understand and be aware of situations where these so called 'human factors' may make an incident more likely.

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check with the electricity company that it is safe to start work

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(b)

Site distribution 48

As a first general guide, all wiring should conform to BS 7671: Requirements for Electrical

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Installation, even though much of it will be temporary. Makeshift arrangements cause accidents and must be prohibited. 49

All switch gear should be freely accessible and capable of being locked in the 'off position.

50

Wherever possible a reduced voltage system should be used.

51

Site offices and other accommodation should be a standard installation to the current BS 7671: Requirements for Electrical Installation.

Distribution equipment Electrical equipment must be manufactured to a standard which prevents, for example, the ingress of fingers, tools, dust or moisture as appropriate, depending upon the nature of the hazard. This is particularly important where electrical distribution equipment is to be sited outdoors, where the ingress of water and to a lesser extent, dust could be a problem.

53

Internationally, such equipment is assigned an IP (ingress protection) number. For example, equipment manufactured to:

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IP 32 - is protected against the ingress of solid objects over 2.5 mm, for example tools, and against the ingress of direct sprays of water up to 15° from the vertical

(b)

IP 54 - is protected against the ingress of dust (no harmful deposits) and low pressure jets of water (limited ingress).

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(a)

Electrical distribution equipment obtained from reputable suppliers or hire companies will conform to the necessary British or International standards.

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Site accommodation

Site offices and welfare facilities are the only locations where electrical equipment that runs off a 230 volt supply should be in use. The electrical supply panel for such facilities must incorporate a residual current device (RCD) in each circuit.

56

The correct operation of each RCD must be confirmed weekly by operating the 'TEST' button.

57

The incoming electrical supply to site accommodation must be properly designed and be installed and commissioned by competent electrical contractors.

58

All portable electrical equipment must be electrical safety (PAT tested) at appropriate intervals as decided by a competent person. This includes:

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(a)

common types of office equipment, such as fax machines and photocopiers

(b)

'kitchen-type equipment', such as kettles, microwave ovens, and so on.

(c)

small items, such as chargers for site radios and battery-powered tools.

59

All units for site use should comply with BS 4363 and installations with BS 7375. Plugs, sockets and couplers must conform to BS EN 60309-2.

60

BS 4363 recommends use of the following units:

Supply incoming unit (SIU) 61

Ratings up to 300 amps per phase. These units include main switch gear and metering equipment.

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Mains distribution unit (MDU) For the control and distribution of electricity on site. 415 volt three-phase, 230 volt singlephase AC.

63

A combined supply incoming and distribution unit (SIDU) may be used in some installations.

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Transformer units (TU)

TU 1 single-phase 230 volts - 110 volts TU 3 three-phase 415 volts - 110 volts

65

Transformer units are available with different outlet ratings, i.e. 16, 32 or 60 amps. Some units have socket outlets switched through miniature circuit-breakers for added protection.

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Such transformer units can be used for portable tools and plant, and general floor lighting.

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(b)

16 or 32 amp

Outlet units (OU)

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110 volt socket outlet units

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Such outlet units can be used for portable tools, floodlighting and extension outlets. They are not usually protected by circuit-breakers.

Extension outlet units (EOU)

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(a)

110 volt socket outlet

(b)

16 amp

Such units can be used for portable tools, local lighting and hand lamps. They are not usually protected by circuit-breakers.

Markings 69

All supply, distribution and transformer units should be marked with the warning sign shown below from BS 5378 Safety signs and colours.

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Section 11: Health and Safety Page 36 Part 1.05: Other hazardous Activities (Regulatory Document)

Earthing

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All metal parts of the distribution systems and fixed appliances not carrying a current must be effectively earthed in accordance with BS 7430 Code of Practice for Earthing, to either: (a)

the metallic sheath and armouring of the incoming supply cable

(b)

the earthed terminal supplied by the supply authority

(c)

a separate earth electrode system.

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Periodic maintenance, inspection and testing is essential.

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Earthing via water pipes or gas pipes is not permitted.

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Monitored earthing systems are recommended for all transportable plant operating at any voltage above 110 volts and supplied with flexible cables. In these systems, a very low voltage current circulates continuously in the earthing circuit. If this circuit is broken or interrupted, the supply to the plant is automatically cut off until the earth path is made effective.

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Plugs, socket outlets and couplers Only components to BS EN 60309-2 should be used. This covers both single and threephase supplies and is intended to prevent plugs designed for one voltage being connected to sockets of another. This is achieved by different positions of the key-way in plug and socket.

Examples

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Accessories should be marked with the maximum rated operating voltage and current.

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Colour coding may sometimes be used. Colour Operating voltage (AC) at 50/60 Hz Violet White Yellow Blue Red Black

25 50 110-130 220-230 318-415 500-750

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In all site offices, workshops, huts and similar premises, wiring, which is of permanent nature, should comply with BS 7671: Requirements for Electrical Installation.

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1.5.3.5 Cables

Changes to electrical wiring colours

In order to bring about a complete standardisation Internationally, changes to cable core colours were introduced and have been effective since 1 April 2004. These changes were introduced by an amendment to BS 7671: Requirements for Electrical Installation and will affect all single-and three-phase circuit cables.

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The new core colours are:

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Neutral Blue (previously black) Earth will remain Green/Yellow Phase 1 Brown (previously red) Phase 2 Black (previously yellow) Phase 3 Grey (previously blue)

Many cables and flexes in the new colours are already in use, but this recent change further emphasises the need to use competent electricians for all cabling and wiring work, if electrical accidents are to be avoided.

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More information on the changes can be found in a promotional leaflet that can be accessed at www.iee.org/publish/wireregs/cablecol.cfm

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Cables used for site distribution

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(a)

Cables that carry more than 65 volts (with respect to earth) should have a continuous armour or sheath, which is effectively earthed. (This requirement does not apply to arc welding processes.)

(b)

Where trailing cables are used, sheathing must be earthed in addition to the normal earth conductor.

All cables should have an overall protective sheathing. The three most common types in use are: (a)

tough rubber sheathing (TRS), resistant to wear and abrasion. Not used near solvents or oils

(b)

polyvinyl chloride (PVC). For site office and permanent work. Not suitable for outside work at low temperature

(c)

polychloroprene (PCP). This is the best all round type.

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Buried cables 7

All buried cables should be: (a)

at least 0.5 m below ground

(b)

protected with tiles or covers or placed in a duct

(c)

in a trench marked to indicate their route.

Cables on the ground The use of cables laid on the ground is dependent on the nature of work being carried out, and should be: (a)

only permitted for short periods

(b)

provided with additional protection, such as a reinforced sleeve

(c)

clearly marked, so as not to constitute a tripping hazard.

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Suspended cables are permissible on condition that: there is no tension or strain on connections

(b)

they are adequately marked for protection

(c)

they are supported on proper hooks, not nails

(d)

spans over 3 m are supported by catenary wires on poles

(e)

they are at a minimum height of 5.2 m above ground.

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Suspended cables

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1.5.3.6 Installations

Installations should be in accordance with plans drawn up by a competent person.

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Any work or alterations to the installation may only be undertaken by a competent person.

3

The installation should conform with BS 7671: Requirements for Electrical Installation, and BS 7375 Code of Practice for the distribution of electricity on construction and building sites.

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All installations should comply with these Regulations as for permanent installations, with good workmanship and the use of correct materials.

Testing 5

Every installation should be tested in accordance with BS 7671: Requirements for Electrical Installation, before use on site, at three-monthly intervals or shorter periods if necessary. (a)

The record of any testing and inspections should be made by a responsible person on the appropriate certificates.

(b)

Testing and inspections must include: (i)

a visual inspection

(ii)

the continuity of final circuit conductors

(iii)

the continuity of protective conductors

(iv)

the earth electrode resistance

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Section 11: Health and Safety Page 39 Part 1.05: Other hazardous Activities (Regulatory Document) (v)

the insulation resistance

(vi)

polarity

(vii)

the earth fault loop impedance

(viii)

the correct operation of residual current devices and fault voltage operated protective devices.

6

Weekly inspections should be made of the whole system, including all portable electric tools. Records should also be kept of all these inspections.

7

Annual portable appliance testing of electrical equipment used in offices is recommended especially for items with heavy usage, for example, kettles, microwaves, photocopiers.

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Power requirements The calculation for power requirements should be left to an experienced person or to the electricity supply company.

9

To enable the total site requirements to be established, a site demand table listing items of plant, equipment and general site requirements should be completed. (See Appendix 4. This appendix also contains a guide to voltages required for typical plant.)

10

When calculating the demand, it is permissible to allow a diversity factor (assuming not all appliances will be in use at the same time), and a figure of not more than 50% is generally acceptable. Care should be taken to ensure that items such as lighting and heating remain at their full rated value, because heaters used in huts and drying rooms, or for water and cooking apparatus, tend to be left on.

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Work on site

The activities of contractors and others installing electrical equipment, lifts, heating, ventilation, and so on, must be carefully monitored to ensure that they do not jeopardise electrical safety or leave an installation in a dangerous condition.

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Particular care is needed in respect of any alterations and extensions to existing installations, especially in the identification of circuits.

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Use of mains powered equipment 13

Wherever possible, battery-powered or 110 volt powered equipment should be used for reasons of electrical safety. However, on rare occasions, it may be necessary to use mains (230 volt) operated equipment on site, possibly because 110 volt variants are not available. Electrical equipment used in site offices will invariably be mains operated. As previously stated, the use of low voltage equipment is preferred due to the potentially deadly nature of 230 volt equipment in the event of a fault.

14

Where the use of mains powered equipment is inevitable, additional safety precautions must be taken. The supply must be protected by the use of a residual current device (RCD).

Residual current devices 15

Under fault conditions, these devices detect an imbalance in the current in the circuit and disconnect the supply before the person at risk can receive a potentially fatal electric shock.

16

There are two types of RCD: (a)

Those that are fitted as part of an electrical distribution system and, for example, are found within the supply panel for a site office. This type of RCD can only be installed

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(b)

Plug-in RCDs (commonly known as 'power-breakers') that are plugged into a mains supply socket and which have an in-built socket into which an individual mains powered electrical tool or other appliance is plugged.

17

Both types of RCD have a test button that simulates a fault and operates the device. The correct operation of the test button should be checked daily.

18

It should be noted that:

(b)

RCDs are delicate devices and should be treated with care. Advice on suitable RCDs for construction sites should be sought from manufacturers or suppliers

(c)

the use of a RCD does not give a 100% guarantee of safety

(d)

the device does not have a fail-safe feature and will not give an indication if it is faulty.

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RCDs do not reduce current flow or the voltage, only the time that the current flows (about 30 milliseconds), and thereby the severity of the shock

It cannot be stressed strongly enough that every attempt should be made to use battery powered tools or 110 volt powered tools where practical and possible. The use of mains powered equipment, apart from situations like site offices, should be avoided wherever possible.

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(a)

Portable and hand-held electric tools

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All portable and hand-held electric tools should be selected according to the principles of risk control. For example, where there is a very high risk of electric shock due to site conditions, the use of pneumatic equipment will eliminate the risk.

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A reduced low voltage system, i.e. virtually safe, which is recommended as the safest type of system for building and construction sites, is one where the phase to earth voltage does not exceed:

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Reduced voltage systems for use with portable and hand-held electric tools

55 volts to earth in the case of a single-phase centre tapped to earth supply

(b)

63.5 volts to earth in the case of a three-phase neutral point earthed supply.

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(a)

The maximum recommended voltage to earth for a reduced low voltage system is stated as 65 volts. Both of these systems will offer a phase to phase voltage of 110 volts for supplying power tools on site.

23

A reduced low voltage system will eliminate the risk of death from a phase to earth shock in the majority of situations. Other safer systems, for example, compressed air or battery power, should be considered when working in confined spaces or damp conditions.

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Outputs of 230 volts or 110 volts 24

110 volt systems that are not centre tapped or neutral point earthed can be just as lethal as a 230 volt system in phase to earth faults. In certain situations, even reduced low voltages are not safe.

25

The maximum voltage for portable and hand-held electric tools should be 110 volt centre tapped to earth. Flexible cables should be kept as short as possible, frequently checked for damage and properly repaired as necessary.

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1.5.3.7 Maintenance and testing 1

An appropriate maintenance schedule should be established for all portable electrical equipment and should include user checks, regular visual inspections, and combined inspection and electrical testing as necessary. It is recommended that 110 volt portable and hand-held tools should have the following inspection and testing facilities: (a)

User check Weekly

(b)

Visual inspection Monthly

(c)

Combined inspection and test before first use and thereafter three-monthly.

Insulating tape by itself is neither a legal nor satisfactory repair, either on conductors or the cable sheath.

3

Long leads which trail over the ground or floor and so create a tripping hazard must be avoided. Care must be taken in the use of cable drums or reels, as internal cable terminations may become loose. They can overheat and cause a fire. Drums and reels should be inspected regularly for signs of damage or wear.

4

All insulated or double-insulated tools manufactured in accordance with BS 2754, and with the recognised symbol attached, give extra protection against the danger of electric shock.

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1.5.3.8 Fuses

Fuses can blow through ageing as the internal fuse wire sags and eventually breaks. However, fuses usually blow for other reasons; usually due to a fault in a piece of equipment. The reason should be investigated and rectified before a fuse is replaced. If a second fuse blows immediately the power is switched on, the equipment is defective and no further attempt should be made to use it.

2

The equipment should be quarantined if it is repairable or otherwise safely disposed of and replaced.

3

Nails, screws, wire or silver paper must never be used to replace fuses.

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1.5.3.9 Lighting 1

Lighting is needed for safety, productivity and security.

2

The colour and nature of any artificial lighting must not adversely affect, or change the perception of the colour of any safety sign.

3

Where the failure of the primary artificial lighting would create a risk to health or safety of the person(s) at work, secondary lighting must be provided.

4

There are many different types of lighting, each with its own most suitable application. Advice should be sought in order to obtain the best light for a particular place, considering such factors as colour rendition, humidity, flammable or explosive atmosphere.

Handlamps 5

Handlamps must never be run from a 230 volt supply. They should be used on 110 volts or lower, and preferably from a safety extra low voltage (SELV) supply.

6

Lamps should all be insulated or double-insulated to BS EN 60598.

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7

The use of extra low voltage handlamps, even down to 12 volts, does not give any protection against fire or explosion in flammable or potentially explosive atmospheres if the bulb is broken. In such hazardous areas, only lamps to BS EN 60079-14 should be used.

8

Special care is needed in sumps and pits, where petrol, LPG fumes or other flammable gas might collect. All electrical equipment should be BASEEFA approved.

9

In confined spaces, boilers, tunnels, cramped locations or other hostile damp or humid atmospheres, lamps supplied should work at 25 volts.

Levels of illumination Illumination is measured in units of lumens or lux, which is the amount of light falling on one square metre.

11

Light meters are used to check levels of illumination. Illumination should be measured at the workplace, not at the light fitting.

12

There are certain factors which can affect the efficiency of lighting, such as:

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the amount of daylight available

(b)

the cleanliness and maintenance of light fittings and reflectors

(c)

reflection from walls and ceilings

(d)

the distance of the light source from the workplace

(e)

shadows thrown by equipment, materials, and so on.

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When considering the level of illumination required at a workplace, it should be remembered that if the distance from the light source to the workplace is doubled, the illumination level will be reduced to one quarter (inverse square law). For recommended levels for site lighting, see Appendix 2.

(a)

securely mounted at a height that will avoid damage to the lights whilst giving the required level of illumination positioned so as to prevent glare, dazzle or reflection

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Lighting should be:

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The mounting of lights

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(c)

able to change position as work proceeds

(d)

adaptable, remembering that 50 to 100% more light is required for people over 40 years of age

(e)

increased if necessary, because more light will be required in hazardous situations and when goggles are worn

(f)

so positioned that it can be screened or shielded from reflective surfaces, on traffic routes, etc.

(g)

treated as a heat source, with the possibility of burns or fire hazards, particularly with halogen lighting units.

Site lighting 15

For area lighting with floor lights or beam floodlights: (a)

all areas should receive light from at least two directions

(b)

fittings should be mounted on poles; towers and high masts must be securely stayed

QCS 2014

(c)

fittings should usually be spaced at not more than two or three times the mounting height

(d)

230 volts is generally accepted for fixed floodlighting, mounted well above ground

(e)

installations must be to BS 7375, equipment to BS 4363

(f)

additional lighting should be provided in hazardous areas.

Dust and dirt on lights can absorb up to 20% of their output and cleaning is often costeffective in maintaining adequate levels of lighting for both working and safety. However, there may be access issues to overcome.

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This is usually of the tungsten filament type. It is used to supplement the general area lighting scheme.

(b)

Small sources of light tend to produce shadows; they should be used with a diffuser or be hung in rows.

(c)

Pendant fittings should be supported so as not to tension the supply cable. They should be of the festoon type only, with moulded-on lamp holders and protective guards.

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Local (task) lighting

(d)

The common type of lighting used by operatives should be 110 volts reduced voltage.

(e)

Care should be taken not to dazzle or cause a nuisance to anyone, including people outside the site boundary. For a guide to the characteristics and types of electric lamp, see Appendix 3.

Dispersive lighting 18

This is used over working areas, walkways, ladder access and stairs.

19

Types include dispersive, cargo cluster, fluorescent trough, wall glass unit, bulkhead unit

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tungsten or fluorescent. Fittings should be similar to the industrial indoor type but waterproof.

(b)

They should be mounted centrally, overhead where possible.

(c)

They should usually be spaced at one-and-a-half times mounted height, but the manufacturer's recommendations should be followed.

(d)

They should be mounted as high as possible to give an even spread of light.

(e)

Mains voltage (230 volts) should only be used where the installation is well protected and of a permanent nature. Reduced voltages should be used for regular sire work.

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1.5.3.10 Permit to Work

Permit to Work systems are essential to ensure safe working where high-voltage electrical supplies, cables and equipment exist, particularly in installation, maintenance or construction work.

2

A Permit to Work system should form part of that 'safe system'. In the case of construction sites, Permits to Work are more commonly used whilst the site electrical distribution system is itself being worked on.

3

Permits to Work must only be issued by an appointed authorised person, using duplicate and numbered printed forms as the example shown (see Appendix 5). They must be signed by an authorised person and by the competent person who is to carry out (or be responsible for) the work described on the permit.

4

Most systems contain provisions for the physical locking off of switches, and the retention or display of keys or permits.

5

One copy of the permit must be retained for the duration of the work by the person to whom it is issued. Before apparatus is made live again, the permit must be returned for cancellation. At cancellation, it must be countersigned by both the holder and the authorised person.

6

The authorised person should keep a record in the job file of the issued permits and their cancellation.

7

Before work starts, the authorised person should ensure that the Permit to Work will cover the making safe from all possible sources of supply.

8

If the work is handed over from one competent person to another, the permit is to be

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endorsed by the authorised person and transferred to the second operative.

1.5.3.11 Dealing with electric shock emergencies 1

On a construction site, a plan should be prepared for potential emergencies, including electric shock.

2

The plan should include: posting notices in appropriate and prominent places publicising the emergency procedures

(b)

training sufficient workers in the procedures to follow when treating an electric shock casualty, including first aid action

(c)

instructing workers in the action to take in the event of someone receiving an electric shock. For example, switching off the electrical supply and calling the emergency services.

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(a)

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Construction Site Safety 1.5.3 Appendix 1 Safety checklist Permit to Work Are the instructions clear about who can grant permits and the time when a permit comes into operation or expires?

2

Who is the manager responsible for overseeing Permit to Work systems?

3

What is the procedure for co-ordinating the activities of different trades working on the same job?

4

What is the procedure for informing all contractors that a Permit to Work system exists?

5

Have all operatives been instructed and trained in safety procedures, such as Permit to Work systems, locking off and treatment for electric shock?

6

Have Permit to Work documents and procedures been checked and agreed by the Contractor and employee representatives to ensure all necessary safeguards have been provided?

7

Is the Permit to Work procedure regularly reviewed and updated?

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Cables

Have all necessary precautions been taken where overhead lines exist close to the site?

9

Are distribution cables so positioned that they do not cause a hazard at openings, passages, ladders, stairs, and so on?

10

Have precautions been taken to ensure that cables lying on the ground have been protected from physical damage or wet conditions?

11

Have the necessary precautions been taken to ensure that cables do not hang directly from nails, which may cause insulation damage?

12

Are cables protected from the edges of sharp objects?

13

Have all possible precautions been taken to ensure that suspended cables do not carry any weight? Are they supported by rods or catenary wires?

14

Are all cables visible, with, if necessary, yellow and black or red and white plastic bunting strips attached?

15

Is there an adequate supply of extension cable for use on the site?

16

Are all junctions and repairs properly carried out by a qualified electrician?

17

Are electrical circuits used for the correct purpose (for example, lighting circuits must not be used for power tools, especially where lighting festoons are fitted with trailing leads)?

18

Are buried cables correctly protected by a 450 mm cover and cover tiles? Is the line of the cable also clearly marked?

19

Are cables capable of carrying the load required and are they adequate for their purpose?

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Plugs 20

Are all industrial plugs to BS EN 60309-2, in good condition, not cracked or otherwise damaged?

21

Are splash-proof covers being used as necessary?

22

Are the correct plugs properly fitted to equipment?

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23

Are all plugs being used suitable for the site conditions prevailing?

24

Have any plugs been forced into the wrong sockets (for example, by the removal of keys)?

25

When plugs have been fitted, have the correct connections been made, with the wire being correctly colour coded in line with British and International Standards.

26

Are cable grips being used and is the earth cable fitted with some slack, so that it is the last to be pulled out?

27

Have all possible steps been taken to ensure that there are no improvised junctions, nails, matches or silver paper, being used in place of the correct equipment?

28

Is the correct type of fuse with the proper rating fitted?

29

Have all made-up leads or extension cables been correctly assembled by a competent electrician?

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Site accommodation

Has the incoming supply been installed by competent electrical contractors?

31

Is an RCD incorporated into each electrical circuit?

32

Is each RCD checked for correct operation on a weekly basis?

33

Is the use of 230 volt equipment restricted to office accommodation and welfare facilities?

34

Is a programme of PAT testing carried out on all portable 230 volt equipment?

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Power tools

Are all power tools used manufactured to BS EN 50144-1 or double-insulated to (BS 2754) and CE marked?

36

Is the plug undamaged?

37

Are cable clamps secure?

38

Have checks been made to ensure that trailing leads are not cut or frayed?

39

Is the cable protected from excessive flexing by a rubber sleeve where the cable enters the tool?

40

Are all screws in place and secure?

41

Have the tools or machines been checked to ensure that there are no cracks or missing pieces?

42

Have checks been made to ensure that the nameplate is secure with details of:

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Type

Serial number

Voltage

Volts AC/DC

Frequency

(normally 50 HZ)

Current

Amps

Speed

RPM

Checklist for operatives 43

Are all machines and hand tools disconnected before any adjustment or work is carried out on them?

44

Are all machines disconnected when not in use?

45

Is the tool fitted with the correct type and size of plug?

46

Have checks been carried out to ensure that any colour codings are correct?

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47

Are cables of an adequate rating for the tool that is being used?

48

Are checks carried out to ensure that no unofficial cables are being used?

49

Have instructions been issued to ensure that no makeshift repairs or maintenance are carried out?

50

Are all defects reported immediately to a competent person?

51

Is the machine kept clean and free from damp?

52

Are all connections correctly made, including waterproofing?

53

Are all operatives aware that they should never carry any tool or machine by its cable?

54

Have instructions been issued to ensure that no machine is started or stopped under load?

55

Do all portable tools have a current PAT test sticker?

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until the electricity company is consulted for advice

(b)

within 9 m of overhead power lines on wood, concrete or steel poles, or

(c)

within 15 m of overhead power lines on steel towers?

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(a)

Are all personnel working close to overhead power lines aware that the distances mentioned above are measured horizontally at ground level from directly below the outermost conductor?

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Is everyone working on site aware that no work should take place:

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Working near overhead power lines

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Note: Electricity companies have different rules for the lateral swing of conductors in high winds and the distance of barriers may vary between companies.

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Precautions near live overhead power lines

Has an essential ongoing system of liaison between Contractor or contractor and the electricity company been established?

59

Where overhead power lines have not been diverted or made dead and therefore remain live, have all practicable steps been taken to provide adequate barriers.

60

Have adequate arrangements been made for the passage of tall plant at specific times where overhead power lines have been made dead?

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Work beneath overhead power lines 61

On sites where work will take place below overhead power lines, have additional precautions, as necessary, been taken, as well as the provision of barriers with passageways?

62

Is all work carried out under the direct supervision of a responsible person, familiar with the hazards, after consultation with the local electricity company?

Passage beneath overhead power lines 63

If there is no work or passage of plant under overhead power lines, have barriers been positioned so as to prevent any close approach of any plant, equipment or personnel to within at least 9 m from the overhead power lines?

64

Does all plant passing under overhead lines use a defined passageway, protected by barriers?

Alterations to buildings 65

Have all electrical circuits been identified before any work is allowed to start?

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Section 11: Health and Safety Page 49 Part 1.05: Other hazardous Activities (Regulatory Document)

Is there a plan to remove old wiring and equipment which is no longer required, as early as possible?

Commissioning new parts of the electrical installation Has the Contractor prepared an agreed plant commissioning programme?

68

Are all the relevant contractors aware of this programme?

69

Is the programme regularly monitored?

70

Is each part of the installation that is being worked on securely isolated (lock, tag and try)?

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Construction Site Safety 1.5.3 Appendix 2 Recommended levels for site lighting

Applies to both indoor and outdoor activities and relates to the value on the ground, floor or horizontal working plane. They may require adjustment according to district brightness. Governing factors

Design value lux

Security

Depending on the degree of risk

5-30

Movement and handling

Movement of people, machines and vehicles, handling of materials, walkways and access routes

Stores and stockyards

For stored goods

Site entrances

General access, vehicle and pedestrian

General work area

General rough work, site clearance

Craft work

Reinforcing concreting, shuttering erection, bricklaying, scaffolding

100

Fine craft work

Joinery, all work with power tools and circular saws, plastering, painting, electrical, plumbing, shopfitting, brickwork

300

Special work

Retouching paint, French polishing

500

Site huts

Rest rooms, locker rooms, toilets

20

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Site offices

.

Purpose

30

30 50

150

On desks and reference tables, general lighting of drawing 500 office

Drawing offices on site

On drawing boards

750

Emergency lighting

For escape and standby purposes

5-70

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Construction Site Safety 1.5.3 Appendix 3

Tungsten halogen (T-H)

Mercury vapour (MBF)

Fluorescent tubular (MCF)

Sodium Sodium vapour vapour low high pressure pressure (SON) (SOX)

Wattage range

40/1500

300/2000

50/2000

6/85

35/180

250/1000

Voltage range

25/250

110/250

200/250

110/250

200/250

220/250

* Efficacy (Lumens Watt)

10-18

17-22

35-55

41-68

80-100

Colour rendering

Good

Good

Fair

Good

Resistance to vibration

Poor

Fair

Good

Normal life (hours)

1000

2000

Restrictions on use or on position

None

Horizontal 4 degrees

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124-175

Good

Good

Good

Good

5000/7500

6000

6000

None

None

For road lighting only

None

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Poor

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Brief lamp characteristics

.

Tungsten filament (GLS)

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Guide to the characteristics and types of electric lamp

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* The efficacy is the measure of effectiveness in converting electrical energy into usable light.

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Construction Site Safety 1.5.3 Appendix 4 Electrical demand for construction sites

Plant 415 V3 phase

Type

Portable tools 110V 1/3 Site lighting 110V1 Temp accommodation phase phase 230 V 1 phase

kW No Total

Type

RW No

Total

Location

Type

kW

Requirement

Tower crane

Chasers

Lighting

Hoist

Hammers

Heating

Platform

Saw drills

Water heating Drying

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hoist

kW

Cooking

Pump 'A'

Vibrators

Pump 'B'

Air blowers

Saw bench

Dehumidifiers

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Sanders

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Compressor

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Batching plant

Power

Printing Fixed Floodlighting

Total load

Total load

Total load

Diversity factor

Diversity factor

Diversity factor

Diversity factor

Demand load

Demand load

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Total load

Demand load

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Demand load

For calculation purposes, check that only the formula: i x V = W is used i = current in amps

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where

V = voltage

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W = wattage

Volts

Phase 3

230

Derived from

Special provision

Application

Supply undertaking

Fixed and transportable equipment above 5 hp, e.g. crane, hoist, compressor, concrete mixer, and large scale personnel amenities

1

Supply undertaking

110

3

415V ' transformer Secondary winding phase to earth 64 V

Site offices, personnel amenities and fixed floodlighting Transportable equipment up to 5 hp, e.g. vibrators, pumps, site lighting other than fixed floodlighting, and hand tools

110

1

230V transformer

Secondary winding outers to earth 55 V

All portable and transportable tools up to 2.5 hp and site lighting

50

1

Transformer

Secondary winding outers to earth 25 V

Dangerous situations, tunnelling work, inside boilers, confined spaces

25

1

Transformer

Secondary winding outers to earth 12.5V

Dangerous situations, tunnelling work, inside boilers, confined spaces

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Typical electrical supplies used on construction sites

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Construction Site Safety 1.5.3 Appendix 5 Permit to Work on high voltage equipment

No. Issued to ........................................................................ Job ...............................................................................

.

I hereby declare that it is safe to work on the following H.V. apparatus which is dead, isolated from all live conductors and is connected to earth:

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……………………………………………………………………………………………………………………… ………… All other apparatus is dangerous

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SWITCHING AND ISOLATING. The apparatus is disconnected from all live conductors by the following operations:

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……………………………………………………………………………………………………………………… …………

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EARTHING. The equipment is earthed at the following points:

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……………………………………………………………………………………………………………………… …………

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DANGER NOTICES are posted at.....................................................................................................

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AUTOMATIC FIRE EXTINGUISHING CONTROL has been rendered inoperative at.................................... OTHER PRECAUTIONS..................................................................................................................

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Signed .................................................................. Date ........................................... Time ................................. (Authorised person) I hereby declare that I accept responsibility for carrying out work on the apparatus detailed on this permit and that no attempt will be made by me, nor by any person under my control, to carry out work on any other apparatus: Signed .................................................................. Date ........................................... Time ................................. Note: After signature for work to proceed, this receipt must be signed by, and the Permit to Work retained by, the person in charge of the work until work is suspended or completed and the clearance section has been signed. This is to certify that the work authorised above has been completed or stopped and that all workers under my charge have been withdrawn and warned that it is no longer safe to work on the apparatus specified on this Permit to Work and that gear, tools and additional earthing connections are all cleared. Automatic fire extinguishing control has been restored.

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Permit to Work is hereby cancelled

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Signed .................................................................. Date ........................................... Time ................................. (Authorised person)

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Construction Site Safety 1.5.3 Appendix 6 High voltage safety Identity of site................................................................................................................. THIS IS TO CERTIFY THAT ............................................................................................................... is the person responsible on this site for ensuring that the rules for the safe operation of H.V. systems and the Permit to Work system are complied with in every respect.

.

Signed .............................................................................. Date ..........................................................

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Status .............................................................................. Company...................................................

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The authorised person(s) for H.V. switching, isolation, testing and earthing is (are):

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………………………………………………………………………………………………………………………

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……………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………………

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Construction Site Safety 1.5.4

Working In and Around Excavations

1.5.4.1 Key points Many deaths and serious injuries have resulted from the collapse of unsupported excavations.

2

These accidents could have all been prevented if the sides had been supported.

3

The type of support system must be selected or designed by a competent person.

4

There is no minimum depth at which an excavation must be supported; it depends on the soil/sand.

5

The installation, modification and removal of any support system must be carried out:

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by persons who have been trained and are competent to do so

(b)

without putting the safety of these people at risk.

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(a)

Generally, the longer that an unsupported excavation is open the more chance there is of it collapsing; ground that was previously stable can become waterlogged or dry out.

7

In some cases it will be possible to detect at an early stage that the sides of an excavation are becoming unstable, for example during the inspections carried out by a competent person.

8

There are other hazards associated with working in excavations, for example the presence of underground services, contaminated land, etc.

9

Excavations can become confined spaces under certain circumstances, necessitating the management of additional health and safety hazards.

1.5.4.2 Introduction

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Section 2 of the QCS covers ground investigation and Section 12 covers earthworks.

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Note:

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Almost all construction work involves some form of excavation, for foundations, drains, sewers, etc. These can vary greatly in depth and may be only a few centimetres deep or be very deep and very dangerous.

2

A relatively small collapse might involve about a cubic metre of soil, but a cubic metre of soil weighs over a tonne. A person at the bottom of a trench who is buried under this volume of material would be unable to breathe, due to the pressure on the chest, and could quickly suffocate and die.

3

Deep trenches look dangerous; however, trenches less than 2.5 metres deep are where most related deaths occur, in fact, most accidents occur in ground conditions with no visible defects; the trench sides seem clean and self-supporting.

4

Despite appearances, however, the removal of material causes pressure relief and introduces the conditions which lead to failure. Rainwater or hot, dry weather increase the chances of such failure. Surcharging the sides of an excavation also increases the likelihood of collapse.

5

Neither the shallowness of an excavation nor the appearance of the ground should be automatically taken as indications of safety.

6

An excavation may also be a 'confined space' and additional precautions will need to be taken.

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1.5.4.3 Legislative requirements The Management of Health and Safety at Work Before carrying out any work, including excavation work, a risk assessment of the work to be done is required under these Regulations.

2

These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard that employees or any other person might encounter as a result of the work being carried out. This includes other contractors and the public.

3

Once those hazards have been identified, it is then the Contractor’s duty to put control measures into place in order either to eliminate the hazard or, where this is not possible, to reduce the risks of injury or ill health arising from the hazards, as far as is reasonably practicable.

4

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

5

Employees, in turn, have a duty to tell their Contractor of any work situation which presents a risk to themselves or to others, or of any matter which affects the health and safety of themselves or other persons.

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With regard to excavations, these Regulations require that: all places of work are safe, with safe means of access and egress

(b)

steps are taken to ensure any structure that has become unstable due to any construction work, including excavation, does not collapse

(c)

steps are taken to prevent anyone being buried by a collapse of material

(d)

the sides of excavations are supported or battered back where necessary to prevent collapse or dislodgement and fall of material

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steps are taken to prevent people, materials, spoil, vehicles, equipment or plant falling into, or causing the collapse of, an excavation

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Construction (Design and Management) CDM

(f)

steps are taken to prevent danger from damage to underground and overhead services

(g)

excavations are inspected by a competent person and inspection reports prepared as specified

(h)

each excavation has sufficient fresh air

(i)

there is suitable lighting at places of work

(j)

anyone who has to carry out excavation work or work in an excavation is provided with appropriate training and is competent

Risk assessments 7

Before carrying out any work, including excavation work, a risk assessment of the work to be done is required.

8

The risk assessment must consider the potential for the sides of an excavation to collapse, the potential for someone to be injured and the possible need for a support system. The

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person assessing the risk of collapse must be competent to assess the soil stability. 9

The risk assessments should seek to eliminate or control the risk at source, for example by specifying trenchless techniques or ensuring the sides are 'battered' or 'stepped' (sometimes known as 'benched)' thus making a collapse impossible.

10

The risk assessment must include consideration of the following hazards: collapse of the sides

(b)

underground services

(c)

contaminated ground

(d)

fall of materials, persons, plant or equipment into the excavation

(e)

confined spaces - poisonous or explosive atmospheres or lack of oxygen

(f)

flooding

(g)

overhead services

(h)

moving plant - injury to persons

(i)

lifting operations

(j)

undermining adjacent structures or services

(k)

surcharging the sides of an excavation. Control measures should include:

(l)

protection of person(s) who are installing the support system

(m)

safe exposure and, if necessary, support of underground services

(n)

safe access and egress from the excavation

(o)

adequate ventilation of the workspace

(p)

dewatering the trench if necessary

(q)

the need for inspections of the excavation by a competent person

(r)

the stability of adjacent structures or land

(s)

guarding and lighting where necessary.

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Soil stability

.

(a)

Excavation involves the removal of soil and rock, in lesser or greater quantities. Water is almost always present, even if only as moisture in the soil. This presents an additional hazard that must be considered.

12

Soil varies in its nature. Some soil, like fine sand, flows easily. Other soils, like stiff clay, are more cohesive. No soil, whatever its structure, can be relied upon to support its own weight and, if a trench or excavation cannot be made safe by battering or stepping the sides, some form of support will be required. Loose and fractured rock will also need some support.

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Firm or stiff clay type ground Trenchless techniques 13

This module highlights the potential dangers associated with any form of excavation. Readers should also be aware of the work techniques available to eliminate, or at least partially eliminate, the need for excavations and thus their associated hazards.

14

Thrust boring, directional drilling and pipe jacking are examples of such techniques. Some of the trenchless methods that have been developed still require the excavation of pits at either end of the 'trenchless run' in order to launch and retrieve the boring equipment.

If battering the sides of an excavation, the angle at which the sides are cut will depend upon: the nature of the soil, which may be a mixture of materials

(b)

the water content of the soil, including any increase or decrease whilst the excavation is open.

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Battering or stepping excavations

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Refer to Appendix 4 - Angles of repose

1.5.4.4 Trench supports General requirements 1

The need for adequate support will depend on: (a)

the type of excavation

(b)

the nature of the ground

(c)

ground water conditions

(d)

surcharge of sides of excavation.

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Close boarded excavation

Generally speaking, timbering or shoring is not required for trenches or excavations where there is no danger whatsoever of any material falling or collapsing or where excavations are so shallow that such a fall would not result in any injury.

3

For all other excavations or trenches, a survey of the type of soil or other materials that will be excavated must be carried out by a trained and experienced person prior to excavation. This will usually provide sufficient information for a suitable method of excavation and support to be determined.

4

Where large, complex or extensive excavations are concerned, a specialist engineer should decide how to proceed.

5

An adequate supply of support materials must be available on site ready for use before the excavation commences.

6

They must be sound, free from defects, of adequate strength, of good construction and properly maintained. Supports must be fixed securely to prevent displacement.

7

All supports should be erected, altered and dismantled under the supervision of a competent person.

8

It is essential that work is organised so that the person(s) installing any type of support system can do so without their safety being put at risk.

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Types of support systems 9

All practical steps should be taken where necessary to prevent danger to any person from collapse of an excavation and from accidental fall or dislodgement of material from the side or roof or adjacent to any excavation.

10

Conventional timber shuttering or steel trench sheets and adjustable props should be used. The props may be mechanical (jacks or acrows) or hydraulic.

11

A temporary framework of supports, or a protective box or cage, may be needed to protect workers while they put in permanent timbering. A box or cage can be moved forward as timbering progresses.

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In addition to the traditional systems of supporting excavations, several proprietary support systems are available. These include shields (also known as drag boxes), trench-boxes and plate lining systems.

Shields 13

A shield consists of two vertical plates which are permanently braced apart to provide a safe working area between them. Shields are designed for providing temporary protection for workers in a trench, rather than for providing permanent support for the trench sides. Shields are designed to be dragged along the trench as work progresses, therefore only localised protection from falling materials is provided.

Trench-boxes The trench-box support system is modular and involves either lowering strutted, metal box sections into a pre-dug trench, or progressively digging the boxes in to provide continuous support as the depth of the trench increases.

15

The box sections are built up vertically and laterally to form a permanent support for the trench sides.

16

Boxes of this type can generally be extended in width and height to cater for various excavation dimensions.

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The principle of a plate lining system is that metal plates are slid into position between vertical soldier posts, which have been installed previously at pre-set intervals. The soldier posts are strutted apart to counteract inward pressure from the trench sides.

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Avoiding buried services

The use of any of these proprietary support methods can present problems when existing buried services cross the line of the trench being excavated.

19

A further method of supporting the sides of excavations, which combines proprietary and traditional technology, is the use of hydraulic waling frames. This system incorporates the lowering of a hydraulic frame into an excavation in which trench sheets have already been installed. The hydraulic frame is then jacked apart to provide support for the trench sheets. Each hydraulic frame, when in position, is disconnected from the hydraulic supply and left in the pressurised state. This method of support is better able than the other proprietary systems to cope with buried services that cross the trench because it leaves gaps between the trench sheets. Hydraulic frames that can be expanded in both length and width are available to cope with the excavation of manholes and pits.

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Inspection and maintenance of support systems 20

All excavation work requires careful monitoring, particularly when trenches are first opened and sides are unsupported. Even when support work has been installed, constant vigilance is essential.

21

Small movements of earth, resulting in movements in the supports or timbering of no more than 6-12 mm, are usually the only sign of the progressive weakening in cohesive soils.

22

Such movements can easily pass unnoticed but they are signs that something is wrong.

23

Movements can be detected from slight distortion in the timbering, bowing of poling boards and walings, or signs of local crushing.

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All timber must be regularly checked. Where timber remains in position for any length of time, it may dry out, shrink or rot.

25

The ground also may dry out and shrink, which loosens the timbering. Alternatively, it may absorb additional moisture, swell and displace the timbering. Soil may even leak into the excavation from behind the timbering, loosening it.

26

In close-boarded excavations, the support-work members must be kept tight against each other and against the soil face; wedges or telescopic struts holding them must always be kept tight. Raking, or angle, struts should all be regularly examined for signs of having been damaged or dislodged.

27

When loads are being moved into or out of the excavation by skip or bucket, care should be taken to avoid damage to struts or walls. Vertical boards, commonly known as rubbing boards, should be provided to avoid such damage.

28

During bad weather, spoil heaps tend to slump, and loose boulders or masonry may fall into the excavation. As a general rule, the distance between the edge of the trench and the bottom of the spoil heap must not be less than the depth of the trench.

29

Heavy vehicles should not be allowed near the edge of excavations unless the support work has been specially designed to permit it.

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Care must be taken to see that excavation work does not jeopardise the stability of any adjacent structure. Precautions to protect workers and others must be taken before and during any excavation work.

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1.5.4.5 Access

Safe means of getting into and out of an excavation must be provided. If a risk assessment identifies that ladders are a reasonable means of access or egress from an excavation, they must be suitable and of sufficient strength for the purpose.

2

They must be on a firm level base, sufficiently secured so as to prevent slipping and must, unless a suitable alternative handhold is provided, extend to a height above the landing place of at least 1 metre (about 5 rungs), so as to provide a safe handhold. Climbing into or out of an excavation using the walings, buried services and struts must be prohibited and specifically covered in the safe system of work and, if there is one, the method statement.

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Open sheeting using steel sheets and jacks

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1.5.4.6 Guarding excavations

Where necessary, suitable steps must be taken to prevent any person, vehicle, plant or equipment, or any accumulation of earth or other materials from falling into an excavation.

2

Barriers should also serve to keep materials, plant and equipment away from the edges of an excavation. Barriers may be removed to permit access of personnel, plant and equipment, but should be replaced as soon as possible.

3

During darkness, the edges of an excavation should be marked with lights, especially where they are close to public thoroughfares. Battery-operated traffic lamps placed at suitable intervals are usually sufficient.

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1.5.4.7 Vehicles and plant 1

Ideally, all vehicles and plant (except those which must approach an excavation, for example, for tipping or lifting activities) should be kept away from excavations. Traffic routes should be planned and set out accordingly.

2

When heavy loads (such as items of construction plant) are positioned close to excavations, additional pressure - known as surcharging - is placed on the excavation sides and on any form of support system that is in use. Where this cannot be avoided, it must be allowed for in

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the design of the excavation support system. Where vehicles are used for tipping materials into an excavation, safety measures, such as well anchored stop blocks, should be used to prevent the vehicle overrunning the edge. These must be placed at a sufficient distance from the edge of the excavation to avoid the danger of the edge breaking away under the weight of vehicles.

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1.5.4.8 Site lighting

There must be suitable and sufficient lighting at every workplace, the approaches to the workplace and on traffic routes. As far as possible, this should be natural lighting.

2

It is also good practice to ensure that attention is paid to the adequate lighting of access points, openings and lifting operations.

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1.5.4.9 Ventilation

Excavations must be kept clear of suffocating, toxic or explosive gases. These may be natural gases like hydrogen sulphide, methane and sulphur dioxide, exhaust gases from nearby plant, or leaks from nearby pipes or installations. These can seep through the soil and can accumulate at the bottom of an excavation, below ground level.

2

Leakage of propane and butane from LPG cylinders is potentially very dangerous; the gases will sink to the lowest point and form an explosive concentration that cannot disperse naturally. In a similar way, leaking oxygen in an excavation can lead to oxygen enrichment which can lead to fire or explosion. Gases which are heavier than air can leak into an excavation causing air to be displaced, leading to asphyxiation.

3

For the purpose of dealing with these hazards, the bottom of a deep excavation should be regarded as a confined space.

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Confined spaces 4

When an excavation is classified as a confined space, tests for toxic gas or oxygen depletion must be carried out before work starts, and continuously as work progresses. It is also recommended that the work should be subject to the issue of a Permit to Work certificate.

5

To ensure that every workplace or approach is safe and without risks to health, there must be a sufficient supply of purified air. The most common method of ventilation is to blow clean air into the excavation in sufficient volume to dissipate any gas and provide adequate breathable air.

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1.5.4.10 Underground cables and services 1

No excavation work should be carried out unless steps have been taken to identify and prevent any risk of injury arising from underground cables or other underground services.

1.5.4.11 Inspection and reports All excavations used to carry out construction work must be inspected by a competent person: (a)

at the start of every shift in which the work is to be carried out

(b)

after any event likely to have affected the strength or stability of the excavation or any part of it

(c)

after any accidental fall or dislodgement of any material.

.

1

The person who carried out the inspection must be satisfied that the work can be carried out safely and without risk to workers.

3

A report must be prepared by the person carrying out the inspection, giving the following information:

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the name and address of the person on whose behalf the inspection was carried out

(b)

the location of the place of work inspected

(c)

a description of the place of work or part of that place of work inspected, including plant and equipment or materials, if any

(d)

the date and time of the inspection

(e)

details of any matter identified that could give rise to a risk to the health or safety of any person

(f)

details of any action taken as a result of any matter identified above

(g)

details of any further action considered necessary

(h)

the name and position of the person making the report.

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(a)

The person who prepares the written report must write it before the end of the shift in which the inspection was carried out and provide a copy of the report within 24 hours to the person on whose behalf the inspection was carried out.

5

The report or a copy of it must be kept on the site until the work is completed and for a period of three months from the date of completion.

6

Not more than one written report in any period of seven days is required in respect of the inspection at the start of any shift. However, it is advised that a daily record of the inspection is kept, possibly in the site diary.

7

An example of an inspection report, which may be reproduced, can be found in Appendix 3 of this module.

8

Steps must be taken to protect workers from the fall of any material or object.

9

No material or object may be thrown or tipped from a height where injury may result. This includes scaffolding materials which should be lowered under control.

10

No timber or other materials are to be left with projecting nails.

11

Every workplace on a construction site must be kept in a reasonable state of tidiness and

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cleanliness. 12

Materials and equipment must be properly and securely stacked and stored.

13

Work equipment must be constructed or adapted so as to be suitable for the purpose for which it is used or provided. This includes any tools or items of equipment, for example, a shovel, podger or pile driving rig.

14

Contractors must avoid the need for employees to undertake any manual handling operations at work that will involve the risk of them being injured. Every client must ensure that the engineer and designer for any project carried out for the client is provided with any relevant information which the client holds, or could find out by making reasonable enquiries. For example, the client must provide details of underground services, ground conditions, etc, which could be found from making reasonable enquiries.

(b)

The designer has a duty to eliminate or reduce hazards by design. This might mean locating structures to avoid underground services, or specifying techniques that minimise deep excavations.

(c)

A health and safety plan must be prepared for every project and should include details of health and safety risks to any person carrying out construction work. This would include the risks from any excavation project.

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1.5.4.12 Excavators used as cranes

Excavators, loaders and combined excavator loaders may be used as cranes in connection with work directly associated with an excavation, and any other application where this type of equipment can be used.

2

All work is subject to a suitable and sufficient risk assessment, subsequent control measures and capabilities of the work equipment.

3

The risk assessment should take account of the fact that when a machine is in the object handling mode (being used as a crane), it will be necessary for the slinger to approach the machine to hook the load on and off. This person will be in what is regarded as a hazardous area and much hearer to the machine than anyone would be in normal circumstances. The slinger is at risk of being struck by the load, bucket or excavator arm if the excavator moves or slews rapidly.

4

Excavator operators and slingers must be made aware of these dangers; effective communication and constant vigilance are essential.

5

The risk assessment must also establish " whether the machine is suitable for the proposed task. The weight of the bucket (if still fitted) plus the quick hitch must be added to the weight of the load to establish if the machine will be working within its safe working load.

6

Ideally, unless there are good reasons for not doing so, the bucket will be removed to improve the machine operator's visibility.

7

The risk assessment must also address:

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(a)

the need for the lifting operation to be ideally segregated from other work activities taking place in the vicinity, particularly where it is necessary for the machine to travel with a raised load

(b)

the ground conditions, particularly where a tracked excavator will carry out the lifting operation. Such machines have no means of levelling themselves and are therefore dependent upon the ground being sufficiently level to track across it and carry out the lifting operation safely.

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8

The safe working load must be clearly marked on the machine and any lifting accessories, such as a quick hitch. A rated object handling capacity table, must be available in the cab.

9

If the rated lifting capacity for an excavator (or the backhoe of a backhoe-loader) is greater than 1 tonne (or the overturning moment is greater than 40,000 Nm), the machine must be fitted with: (a)

a boom lowering control device on the raising boom cylinder(s) (a safety check valve), which meets the requirements of ISO 8643, and

(b)

an acoustic or visual warning device, which indicates to the operator when the object handling capacity or corresponding load moment is reached.

Chains or slings for lifting must not be placed around or on the teeth of the bucket. Accessories for lifting may only be attached to a purpose-made point on the machine.

11

Whilst BS 7121 may not specifically refer to excavators used as cranes, compliance would assist in the provision of safe systems of work.

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Construction Site Safety 1.5.4 Appendix 1 Excavations Safety checklist Before starting excavation work Check that a site-specific risk assessment has been carried out.

2

For purposes of excavation, no ground should be considered good or safe until it has been investigated.

3

Prevent all access to the excavation by unauthorised persons, especially children. Backfill as soon as possible to reduce risks.

4

Check the soil types and decide which type of support work is required in consultation with a competent engineer or supervisor.

5

Check whether the excavation will affect adjoining roads, buildings or other structures, such as scaffolds.

6

Determine the positions of all public services, especially buried services, and ensure that they are adequately marked, supported or disconnected as necessary.

7

Always seek advice before excavating below existing foundations of adjacent or adjoining buildings. It may be necessary to provide shoring, i.e. raking or flying or both.

8

Provide an adequate supply of material for support work, along with barriers and correct traffic notices, before work starts.

9

Make provision for any side support system to stand proud of the existing ground levels. This prevents any loose material from falling into the excavation.

10

Check the need for, and provision of, adequate lighting.

11

Check that adequate and sufficient ladders have been provided for safe access to the excavation and that sufficient ropes for securing these items are to hand.

12

Determine the positions of bridges, temporary roads and spoil heaps.

13

Determine the methods of excavating before starting work, and the method by which it is intended to install and remove any support work.

14

Plan traffic routes to keep heavy plant and vehicles away from excavations, as far as is possible, except where they must approach the excavation for tipping and lifting activities.

15

Plan the safe backfilling of the excavation, using suitable materials.

16

Check that the excavator operator is competent.

17

Check that the excavator and equipment is in good repair and has been inspected.

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Construction Site Safety 1.5.4 Appendix 2 Excavations Safety checklist Whilst digging, working in, or reinstating an excavation Ensure that only sound support material is being used.

2

Ensure that approved and safe methods are adopted for the installation of support work in excavations. A competent person should be in attendance at all times.

3

Ensure that all working surfaces are safe.

4

Install supports as soon as the excavation sides are trimmed. This should be done from a work cage, from ground level, or from inside existing supports.

5

Ensure that all support work is secure and that props and wedges are tight and properly maintained.

6

Check for signs of overstress in support work, any damage that may have been caused by plant and, when timber is used, make long-term checks for disease and defects, i.e. dry rot, shakes, etc.

7

Check for any water or soil which may be seeping through support work.

8

Check for signs of the earth peeling or cracking at unsupported faces.

9

Check that there are adequate ladders, that they are maintained, secured and used correctly.

10

When pumping, ensure that there are adequate sumps and that soil is not being drawn from behind support work.

11

Check for hazardous atmospheres.

12

Ensure that spoil heaps and other materials are kept back from the edges of the excavation.

13

Ensure that there are adequate barriers, notices and warning lights.

14

Check that the edges of excavations are provided with top and mid guard-rails at all places where there is a danger of persons falling a distance likely to cause personal injury.

15

Check that any bridges and gangways are fitted with guard-rails and toe-boards.

16

Ensure that stops for dumpers, and tipping lorries are well anchored.

17

Ensure that all passing traffic is kept well back from the edge of the excavation.

18

Ensure that the correct method of withdrawing support work is used; if for any reason it is considered unsafe to remove it, leave it in.

19

Ensure there is adequate separation between working plant and people.

20

Dumper drivers should dismount while the dumper is being loaded.

21

Ensure that appropriate protective clothing and protective equipment are being used.

22

Ensure that persons are wearing suitable ear defenders when piling or other noisy activities are taking place.

23

Ensure that machine operators have the best possible vision of the work which is in progress.

24

Ensure that services are marked, protected and adequately supported when exposed in excavations.

25

Ensure that any backfilling is carried out correctly and in a planned sequence, and maintained.

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Ensure that each excavation is inspected by a competent person: (a)

before it is first entered

(b)

at the start of each shift

(c)

after any accidental fall of rock, earth or other material

(d)

after any event likely to have affected the strength or stability of the excavation.

Ensure that a proper record of all inspections is made and signed by a competent person.

28

Remember that records of inspections may be kept on computer or in another electronic form, so long as it is possible to immediately produce a hard copy on request.

29

Ensure that the written report, or a copy, is provided to the person on whose behalf the inspection was made within 24 hours.

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Report of inspection on *excavations, *cofferdams and caissons (*Delete as appropriate) Inspection carried out on behalf of (name and address)...................................................................................................................................................

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Inspection carried out by (name) ...................................................(position) ....................................................................................................................

Description of place of work, or part inspected

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Location inspected

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Address of site ................................................................................................................................................................................................................... Details of any matter identified giving rise to a risk to the health and safety of any person

Details of any action taken Details of any further action as a result of any matter considered necessary identified

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Construction Site Safety 1.5.4 Appendix 4 Angles of repose for different soil types The graph below shows the angle of repose at which various types of soil will slide if unsupported. They represent the maximum safe angle of batter.

2

This illustration shows typical maximum safe 'battering' or 'stepping' angles for certain types of soil. A competent person must be consulted on the safe angle for battering or stepping excavations. If in doubt, consult a geotechnical engineer.

3

Users of the above graph should be aware that:

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(a)

in many cases soil is a mixture of material and the above diagram must be interpreted with caution

(b)

an increase in water content will affect the ability of some types of soil to be selfsupporting. Bad weather, vibrations and other pressure could cause early failure

(c)

Slip planes can form in seemingly solid materials, even some types of rock.

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Construction Site Safety 1.5.4 Appendix 5 Requirements for excavators used as cranes Requirements on manufacturer at time of supply When object handling with When object handling with a rated lift capacity of more a rated lift capacity of less than 1 tonne than 1 tonne EC or Equivalent Certificate Yes Yes of Conformity Hose burst check valve on Yes Not required boom lift ram

Yes

Lift point with SWL marked

Yes

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Fixed safe working load (SWL) marked on the machine or displayed in the cab Acoustic or visual warning device

Not required

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Yes

When not object handling Yes Not required Not required

Yes

Not required

Not required

Not required

Yes

Not required

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Rated object handling capacity table in cab

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Requirement

Machine maintenance required by owner Yes

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Not required

Yes

Yes

Not required

Yes

Yes

Yes

Yes

Yes

Yes

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Four-yearly test and thorough examination Twelve-monthly thorough examination

Yes

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Six-monthly thorough examination of lifting gear

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Records may be kept as a paper copy or by electronic means providing a hard copy is always easily accessible.

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Construction Site Safety 1.5.5

Working in Confined Spaces

1.5.5.1 Key points Working in confined spaces has the potential to be very hazardous unless the appropriate controls are put in place.

2

Many people have died as a result of work in confined spaces not being adequately planned or organised, or safely carried out; many of them were would-be rescuers.

3

Ideally it will be possible to carry out the work without anyone having to enter a confined space.

4

Confined spaces are not just sewers and ducts; under these Regulations many other work areas could also be classified as confined spaces with issues including difficulty of access and egress, heat stress, etc. having to be considered.

5

A risk assessment must be carried out for all work in a confined space.

6

Where the findings of the risk assessment reveal there to be significant risks to health or safety, it may result in a method statement being written.

7

Any plan of the work must consider the method of rescuing the people in the confined space should the situation become unsafe.

8

Entry to a confined space should be controlled by a Permit to Work and, where considered necessary, a separate Permit to Enter.

9

Any training may need to be specific for the type of confined space - a sewer entry course may not be appropriate for someone who has to work in a hot roof space.

10

The use of respiratory protective equipment is common in confined space work and users must be face-fit tested and trained in its use, general care and maintenance.

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1.5.5.2 Introduction

Every entry into a confined space is potentially hazardous.

2

Accidents are caused by a combination of factors arising from a lack of safety awareness, inadequate supervision and a lack of training. The situation is often made worse by heroic but ill-conceived rescue attempts, founded on insufficient planning and knowledge, which may lead to multiple fatalities. It is essential therefore, to be able to identify confined spaces and the hazards associated with entering and working in them.

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1.5.5.3 Meaning of 'confined space' 1

A "confined space' can be either: (a)

a place which is substantially, though not always entirely, enclosed or

(b)

a place where there is a reasonably foreseeable risk of serious injury from hazardous substances or conditions within the space or nearby.

2

Some confined spaces are easy to identify, such as closed tanks, vessels and sewers. Others are less obvious but may be equally dangerous, such as basement-level boiler rooms or toilets, as well as open-topped tanks, vats, silos or other structures that become confined spaces during their manufacture.

3

Some places may become a confined space only occasionally, perhaps due to the type of work to be undertaken, such as a room during paint spraying. A confined space may not necessarily be enclosed on all sides; some confined spaces (such as vats, silos or deep

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excavations) may have open tops. Places not usually considered to be confined spaces may become confined spaces because of a change in the condition inside or a change in the degree of enclosure or confinement. 4

The expression 'confined space' could also refer to the following examples: ducts, vessels, boreholes, building voids, and enclosures for the purpose of asbestos removal.

1.5.5.4 Legislative requirements The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2

Once those hazards have been identified, it is then the Contractor’s duty to put control measures into place in order either to eliminate the hazard or, where this is not possible, to reduce the risks of injury or ill health arising from the hazards, as far as is reasonably practicable.

3

The Contractor must provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks.

4

Employees, in turn, have a duty to tell their Contractor of any work situation which presents a risk to themselves or to others, or of any matter which affects the health and safety of themselves or other persons.

5

Also of importance with regard to confined space working are the requirements on the Contractor to:

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provide health surveillance for at-risk employees

(b)

establish contacts with external services, for example the emergency services (rescue and medical services)

(c)

provide employees with comprehensible and relevant information on any risks that exist in the workplace and on any control measures that are in place to reduce those risks assess employees' capabilities when allocating work to individuals

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(a)

(e)

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provide adequate training for anyone involved in any aspect of confined space working (including rescue).

Arising out of the risk assessment for confined space working will usually be a need for the Contractor to: (a)

develop a method statement for each job

(b)

implement a Permit to Work system, encompassing or supplemented by a Permit to Enter.

Confined Spaces 7

These Regulations require Contractors to plan work so that entry to confined spaces is avoided so far as is reasonably practicable, for example, by doing the work from outside. They also require a safe system of work to be developed and implemented if entry to a confined space is unavoidable, and adequate emergency arrangements, which will also safeguard rescuers, to be put in place before work starts.

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Duties to comply with these Regulations are placed on: (a)

Contractors in respect of work carried out by their own employees and work carried out by any person (for example, a contractor) insofar as that work is to any extent under the Contractor’s control.

9

The key duty is a complete prohibition of any person entering a confined space to carry out any work for any purpose whatsoever, where it is reasonably practicable to carry out the work by any other means.

10

If entry into a confined space is necessary then a risk assessment by a competent person must be undertaken. The outcome of the risk assessment will then provide the basis for the development of a full and effective safe system of work, including rescue arrangements.

Construction (Design and Management) CDM These Regulations place a legal duty on designers, when preparing their designs, to carry out design risk assessments and 'design out risk' so far as it is reasonably practicable to do so.

12

In the context of this section, designers should carry out their design work so that no-one has to enter a confined space during construction work, maintenance or cleaning of the structure or during its demolition.

13

Also, within the context of this section these Regulations place legal duties on contractors, including Contractors, with regard to:

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safe places of work

(b)

excavations

(c)

prevention of drowning

(d)

prevention of risk from fire, explosion, flooding and asphyxiation

(e)

emergency procedures

(f)

fresh air.

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The Provision and Use of Work Equipment These Regulations require that a Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

15

Where the use of the equipment involves a specific risk to the health and safety of employees, the use of the equipment must be restricted to specified workers.

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Personal Protective Equipment 16

These Regulations require that where a risk has been identified by a risk assessment and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment (PPE) is used by employees.

17

In essence, PPE may only be used as a last resort after all other means of eliminating or controlling the risk have been considered and are found to be not reasonably practicable to implement. In practice, however, unless it is possible to carry out the work without entry into the confined space, the wearing of PPE will usually be necessary.

18

In deciding which type to issue, the Contractor must take into account the risk that the PPE

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is being used to protect against, and ensure that the PPE will fit the wearer and allow them to work safely. Where the use of RPE is necessary, face-fit testing to establish the suitability of the RPE for the wearer, would be required. If more than one item of PPE is being used, the Contractor must make sure that individual items of PPE are compatible and suitable for the task that is to be undertaken. Whenever PPE is to be issued, the Contractor must ensure that employees have been given adequate and appropriate information, instruction and training to enable them to understand the risks being protected against, the purpose of the PPE and manner in which it is to be used.

20

Whilst the Contractor must ensure that personal protective equipment is supplied and used, the employee has a duty to properly use the equipment provided, follow the information, instruction and training that they have been given, and know the procedures for reporting loss or defect to their Contractor.

21

In addition to the more commonly used PPE, confined space working will often require the use of appropriate respiratory protective equipment (RPE) and rescue equipment such as a safety harness and line.

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1.5.5.5 Lifting Operations and Lifting Equipment

Access to and egress from many confined spaces is made by lowering or raising a person vertically through the entry/exit point, including during practice or actual rescues.

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In these circumstances:

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safety harnesses and rescue lines must be regarded as lifting accessories

(b)

the tripod hoist or other type of winch must be regarded as lifting equipment used for lifting persons

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All such require inspection on a six monthly basis.

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1.5.5.6 Dangers in confined spaces

The air that we breathe contains around 21% oxygen and, at that level, people can work without difficulty. A falling level of oxygen will create an increasingly serious situation if breathing apparatus is not worn, or the level of oxygen otherwise restored. Generally, the following symptoms are experienced at the corresponding level of oxygen depletion:

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Oxygen deprivation and suffocation

(a)

19% tiredness (normal acceptable minimum level for working)

(b)

17% judgement (decision making) is affected

(c)

12% respiration is affected, fatigue experienced, flames are extinguished

(d)

10% light-headedness, increasingly difficult respiration

(e)

8% nausea, possible collapse

(f)

6% respiration stops, death in minutes.

Oxygen deprivation may be the result of: 2

the displacement of oxygen by gas leaking in from elsewhere, or the deliberate introduction of purge gas

3

the displacement of oxygen by a naturally occurring gas, such as methane

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4

oxidisation, rusting or bacterial growth using up the oxygen in air

5

oxygen being consumed by people working and breathing, or by any process of combustion

6

welding and other 'hot works'

7

the prior discharge of a fire extinguisher containing carbon dioxide or other asphyxiating gas.

Toxic atmospheres 8

However much oxygen is present in the atmosphere, if there is also a toxic gas present in sufficient quantity it will create a hazard.

9

Some of the many toxic gases which may be encountered include: hydrogen sulphide, usually from sewage or decaying vegetation

(b)

carbon monoxide from internal combustion engines, or any incomplete combustion, especially of liquefied petroleum gases (LPG)

(c)

carbon dioxide from any fermentation or being naturally evolved in soil and rocks, or coming from the combustion of LPG

(d)

fumes and vapours from chemicals such as ammonia, chlorine, sodium, and from petrol and solvents.

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(a)

Whenever a toxic gas (or any gas, fume or vapour that may be hazardous to health) is thought to be (or known to be) present, then an assessment of the risk to health must be made. Appropriate control measures must be put into place to eliminate the hazard or control the risks.

11

Petrol and diesel engines create carbon monoxide, which is an extremely toxic gas.

12

Liquid petroleum gas-powered engines create an excess of carbon dioxide, which is a suffocating hazard. The use of any form of internal combustion engine within a confined space must be prohibited, unless a specifically dedicated exhaust extraction system is operative.

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Some gases need only be present in very small quantities to create a hazard. A few of the major sources of explosive and flammable hazards are:

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Flammable atmospheres

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(a)

petrol or liquefied petroleum gas, propane, butane and acetylene. These are explosive in the range of 2% in air upwards. The hazard is normally created by a spillage or leakage

(b)

methane and hydrogen sulphide, which are naturally evolved from sewage or decaying organic matter. These are explosive in the range of 4% in air upwards

(c)

solvents, acetone, toluene, white spirit, alcohol, benzene, thinners, etc. These are explosive in the range of 2% in air upwards. The hazard generally results from process plants and/or spillage

(d)

hydrogen and other gases evolved from processes such as battery charging.

In an explosive or flammable atmosphere, a toxic or suffocating hazard may also exist.

Other causes of a hostile environment 15

Apart from the hazards dealt with above, other dangers may arise from the use of electrical and mechanical equipment, from chemicals, process gas and liquids, dust, paint fumes,

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welding and cutting fumes. Extremes of excess heat and cold can have adverse effects and may be intensified in a confined space. Consideration must be given to the timing of what would otherwise be considered 'standard' work. During hot weather, roof spaces and other types of confined spaces may reach temperatures which will lead to a dangerous increase in body temperature.

17

If work cannot be planned to avoid this, for example by starting early, then physical measures such as cooling and reducing the time spent working in the confined space must be introduced following an assessment by a competent person.

18

Further dangers exist in the sheer difficulty of getting into or out of, and working in a confined space. The potential hazard of an inrush of water, gas, sludge due to a failure of walls or barriers, or leakage from valves, flanges or blanks, must all be considered at the risk assessment stage.

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1.5.5.7 Information, instruction and training

The information, instruction and training given to employees must enable them to carry out work safely and without risks to their health. The extent of training needed will vary according to circumstances and the type of space being entered. An entry into a deep confined space using breathing apparatus would require a full breathing apparatus and rescue course. However, training to enter a bund around a large diesel tank where the risks are less significant, such as fumes and possible drowning in diesel, would not require such an intensive course, and indeed adopting the use of breathing apparatus in this instance may be entirely inappropriate.

2

Training should involve demonstrations and practical exercises. It is important that trainees are familiar with both equipment and procedures before working for the first time in confined spaces.

3

Practical refresher training should be organised and available. The frequency with which refresher training is provided will depend upon how long it is since the type of work was last done, or if there have been changes to methods of work, safety procedures or equipment.

4

No person should enter a confined space unless they are trained and competent to do so safely.

5

The training needs of each of the four categories of employee considered for confined space working should be considered. The categories are:

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(a)

supervisors

(b)

employees entering confined spaces

(c)

people employed as attendants outside confined spaces

(d)

rescue teams.

Some of the roles identified may be carried out by the same person.

1.5.5.8 Safe working 1

Safe working in a confined space can only be achieved by the use of a Permit to Work system in which each step is planned and all foreseeable hazards are taken into account. Such a system, backed up by adequate rescue facilities, should enable work to be carried out safely.

2

At the planning stage it will be necessary to determine;

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(a)

whether an entry into the confined space is required, or whether an alternative method of doing the work exists (see Checklist 1 at Appendix 1)

(b)

if an entry is necessary, whether it can be carried out without the use of breathing apparatus (see Checklist 2 at Appendix 1)

(c)

whether the entry must be made with the use of breathing apparatus (see Checklist 3 at Appendix 1).

In respect of (3) above, it should be emphasised that entry into a confined space using breathing apparatus should not be made routinely or undertaken as a matter of convenience, where the use of mechanical or forced ventilation would achieve a safe atmosphere.

4

If it is decided that the work can be done without anyone entering the confined space, provided that a safe system of work exists and the confined space has been isolated from potential sources of hazard, the work can proceed. It is important to avoid systems or plant being re-energised while work is proceeding and everyone involved should be advised accordingly.

5

Once it has been decided that people must enter a confined space, a preliminary meeting should be held with all concerned, and effective lines of authority and communication established in order to minimise any risk of subsequent misunderstanding.

6

The exact routine to be followed will vary, depending on the type of confined space to be entered. The provisions and precautions required for entry into a large empty surface water tank will obviously be different from those needed for entry into a narrow service duct containing pipes and valves, but the fundamental principle of a safe system of work applies to these and other cases. The risk assessment, as mentioned previously, will have identified many of the above points and should be used as the basis for developing the safe system of work.

7

It is stressed that all personal protective equipment in general, and respiratory protective equipment in particular, must have been specified by a competent person who is clearly aware of all of the circumstances surrounding its use.

8

If the fire and rescue service forms a part of the rescue plan, they must be given a warning that a confined space entry is to be made. This will give them the opportunity to assess the risks to their own staff and identify any equipment they might need.

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1.5.5.9 Isolation 1

The confined space must be isolated from all possible external sources of danger to persons entering it.

2

A full Permit to Work system should be used to record the location and types of isolation, and the hazards being guarded against.

3

Electrical isolation must never rely on a switch or fuse. The switch gear or fuse holder must be locked off and a warning notice applied.

4

Mechanical isolation of pipework should not rely on a single valve or on a non-return valve; these may let-by and create a hazard. Whenever possible, a section of pipe should be removed or a blank or spade should be put into a flange between the valve and the confined space and a warning notice displayed.

5

Paddles, stirrers or agitators, whether electrically or mechanically operated, should be physically disconnected by the removal of an operating arm, and a warning notice displayed.

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1.5.5.10 Cleaning There are a variety of methods of cleaning the inside of confined spaces to remove hazardous solids, liquids or gas. Cold water washing, hot water washing and steaming will remove many contaminants, while solvents or neutralising agents may be necessary for others. If hot water or steam is used, with or without a solvent, care must be taken to ensure that adequate ventilation exists for steam pressure and that condensation does not build up to unacceptable levels.

2

If steam is used or water is boiled in a confined space, account must be taken of the vacuum that can be created on cooling.

3

When steam or solvents are used, these may in themselves create a toxic, suffocating or flammable hazard. Even though a space has been well cleaned, it must not be entered until it has been monitored.

4

Great care must be taken if encountering any sludge or heavy deposits which may release toxic gases if disturbed.

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1.5.5.11 Purging and ventilation

Air purging and ventilation can be carried out by removing covers, opening inspection doors, etc. and allowing ordinary air circulation, or by the introduction of compressed air via an air line. However, higher rates of air exchange can be achieved by the use of air movers, induction fans or extractor fans.

2

It is especially important that when an inert gas (such as nitrogen) has been used to purge or render inert a flammable atmosphere, the inert gas itself is properly purged with air.

3

When air purging is taking place, the flow of air should be of a sufficient volume and velocity to ensure that no pockets or layers of gas remain undisturbed.

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Atmospheric monitoring

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Depending on the circumstances, as a result the risk assessment, continuous atmospheric monitoring may well be necessary when any work is to be done that would expose employees to any substance hazardous to health.

5

Before an entry is made into a confined space, tests must be carried out to establish the levels of oxygen, toxic gas or flammable gas in the atmosphere.

6

The external atmosphere around the opening should be monitored first and if the results are satisfactory, internal monitoring should be carried out by lowering a gas monitor into the confined space before it is occupied.

7

If entry into the confined space is necessary to carry out the tests, breathing apparatus or other respiratory protective equipment must be worn.

8

Suitably trained and competent personnel may use simple, reliable instruments to measure oxygen and flammable gas levels. The accuracy of the instruments must be assured by periodic calibration.

9

A satisfactory oxygen content must not in itself be relied on to indicate safety since flammable, explosive or toxic gas may exist alongside oxygen and need only be present in minute quantities to create a serious hazard.

10

The tests applied should take account of what the space is known to have contained, including any inert gas used to purge a flammable atmosphere which may itself produce

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toxic hazards or the risk of asphyxiation. Account must also be taken of hazards arising from other sources such as materials used for cleaning. Methane, hydrogen sulphide and carbon dioxide can all evolve naturally due to the decomposition of organic matter or, in some cases, by the effect of rainwater percolating through certain types of ground. It is necessary to test the atmosphere of a confined space at both high and low level as well as in any corners, etc. where pockets of gas may exist. Instances have occurred of carbon dioxide displacing oxygen at lower levels while a normal oxygen level continues to exist at higher levels of the same confined space. 11

The sense of smell must never be relied upon to detect gases. Some are odourless, and hydrogen sulphide, in particular, can paralyse the sense of smell to such an extent that even fatally high concentrations of the gas cannot be detected. In any case, the sense of smell varies from person to person and deteriorates with age.

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Providing that the specific contaminant is known, tests can be carried out by competent persons using the individual detector tubes available for the detection of specific toxic and asphyxiant flammable or explosive fumes or gases.

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Monitoring and testing equipment

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A wide range of portable gas detection equipment is available for flammable and toxic gases; some are specific to one gas (for example, hydrogen sulphide), while others can sample a range of different gases. Such instruments need to be properly calibrated.

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Continuous monitoring

The initial monitoring and testing must establish that the confined space is safe to enter. Monitoring should then be carried out at intervals to ensure the continued safety of personnel. Tests should be repeated after any breaks, such as lunch or overnight, or after the time limit set out in a Permit to Work has expired.

15

It may be necessary to issue individual monitors to people working in a confined space, so as to give them an instant warning of low oxygen, or toxic or flammable gas hazards.

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Competence of monitors 16

All atmospheric monitoring must be carried out by persons who are trained and competent to use the instruments and interpret the results. They must have sufficient practical and theoretical knowledge to enable them to make a valid judgement based on the results. They must be fully aware of their responsibilities in permitting an entry into a confined space.

Hazards of excess oxygen An oxygen-enriched atmosphere is, in itself, a major hazard. Organic materials, such as oil and wood, become highly combustible and ordinary materials, like paper and clothing, will burn with exceptional ferocity.

18

An increase of only 4% oxygen is sufficient to create a hazard and this may occur inadvertently. In oxyacetylene and oxypropane processes, sometimes not all of the oxygen supplied to a cutting torch is consumed. Some may be released, increasing the atmospheric oxygen above the normal 21%. The oxygen enrichment of the atmosphere in a confined space also results from the practice of using oxygen to sweeten or enrich the atmosphere when it has become oppressive, stale, hot, fume-filled or otherwise unpleasant. This is a very dangerous practice and must be prohibited.

19

Another way in which the atmosphere may become oxygen-enriched is through leakage from torches or hoses during meal breaks or overnight. For this reason, they should be removed at each breaktime. The deliberate kinking or nipping of an oxygen hose while changing a torch does not usually cut off the supply completely and can result in the release of substantial quantities of oxygen.

20

If excess oxygen is discovered, the space must be quickly evacuated and ventilated until normal levels of oxygen are regained.

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1.5.5.12 Selection of personnel

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Care is required in selecting the right people to work in confined spaces, since conditions can be difficult. They must be physically fit, agile and, most importantly, not be claustrophobic. People who suffer from asthma, bronchitis, or other respiratory conditions, or whose immune system has been suppressed, must be assessed by a medical practitioner as to their suitability to work in confined spaces.

2

Other health conditions which might indicate that a person is not suitable for working in a confined space, or that further checks need to be made before it is allowed, are:

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(a)

high blood pressure

(b)

partial or complete deafness

(c)

lack of mobility through joint problems

(d)

diabetes

(e)

depression or other mental illness

(f)

defective eyesight (which is not corrected by wearing glasses)

(g)

sensitivity of the skin to some substances

(h)

taking some types of medication.

3

Stamina is also required. The wearing of any form of respiratory protection tends to lead to an increase in respiration and a higher use of energy; the amount of work which can be done in confined spaces is less than that expected under normal conditions.

4

When respiratory protection is to be used, it should be remembered that facial hair and

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spectacles often prevent a respirator from fitting properly and thus achieving the assumed degree of protection. 5

Face-fit testing should be carried out to ensure that the chosen mask fits the wearer. This can be achieved quantitatively using a 'Portacount' for half or full face masks or qualitatively using bitter/sweet solutions for half or disposable masks.

1.5.5.13 Communications Adequate and effective communications must exist between those inside and those outside the confined space, so that, in the event of an incident, a warning can be given and the space evacuated or those inside rescued. The system needs to be 'fail safe', ensuring that if a reply is not received or a scheduled call not made, the procedure for rescue starts immediately.

2

When a confined space is relatively small, such that the person entering it cannot move far from the entry point and there are no other factors that could hinder effective communication, the method of communication may be relatively simple such as a pre-arranged system of tugs on the safety rope, which must be fully understood by all involved. However, if the nature of the confined space, the job to be carried out and other factors necessitates the 'entry person' travelling some distance from the entry point, a more elaborate communication system might be required.

3

Factors that could hinder effective communication and may need to be considered in the risk assessment are:

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the level of noise inside or outside the confined space, which may or may not be associated with the confined space work

(b)

the physical nature of the confined space or the presence of substances that could reduce visibility

(c)

the distance between the point of entry and the place of work

(d)

the presence of workers with little or no understanding of English, although it could easily be argued that such a situation should not arise in connection with working in confined spaces.

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Depending upon the findings of the risk assessment, prior communication with the emergency services regarding the location and nature of the work, might be considered necessary.

5

All types of respiratory protection affect verbal communication to some degree and, whatever method of communication is chosen, it should be tested and proved outside the confined space before entry is made.

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1.5.5.14 Work equipment 1

Due to the potential for a flammable or explosive atmosphere in confined spaces, selecting tools and other work equipment with which the work can be carried out safely is essential.

2

If there is any possibility of flammable gas existing in a confined space, all tools must be of a non-sparking material and all lighting and electrical equipment must carry BASEEFA* or equivalent approval. Smoking and naked lights must be strictly prohibited and care must be taken to avoid the generation of static electricity with the consequent risk of sparks. * British Approvals Service for Electrical Equipment in Flammable Atmospheres

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1.5.5.15 Fire safety 1

Hot works must not be carried out in a confined space unless atmospheric testing has confirmed that flammable or explosive gases are not present and the findings of a risk assessment show that it is otherwise safe to do so.

2

Where there is still a residual risk of fire, appropriate fire extinguishers may need to be kept in the confined space at the entry point.

3

Where 'hot works' are being carried out inside a confined space, the operative carrying out the work must also have a suitable and serviceable fire extinguisher at the place of work. In the event of a fire, the local fire service should be called in case the fire cannot be contained or extinguished.

Appropriate first-aid equipment and trained first aiders should be provided and available for emergencies and to provide first aid until professional medical help arrives.

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1.5.5.17 Rescue

The arrangements for the rescue of persons in the event of an emergency, both in terms of trained persons and equipment, need to be suitable and sufficient. The arrangements must be in place before any person enters or works in a confined space.

2

Where there are no qualified in-house emergency rescue services, the external emergency rescue services should be informed of the area and type of work taking place in a confined space.

3

Proper and effective rescue training is quite hard and arduous and is not to be undertaken lightly. Persons selected for such training need to be physically fit and able to adapt to situations as they arise during a rescue.

4

If a person is injured in a confined space which has been certified safe to enter without respiratory protection, an entry can be made to rescue and remove them straight away.

5

When a person collapses in a confined space and the cause is not known, irrespective of whether or not the confined space was certified fit for entry without respiratory protection, no one must enter unless they are wearing breathing apparatus. The collapse may have been due to a deterioration in the atmosphere within the confined space. The first duty of any rescuer is to ensure that they do not become a casualty themselves.

6

Each year, would-be rescuers who are insufficiently trained or equipped die by going into confined spaces where a person has collapsed.

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Rescue equipment 7

Every person entering a confined space wearing breathing apparatus must also wear a safety harness. The harness must be attached to a lifeline, attended by a person outside the confined space.

8

The harness must be one that is suitable for confined space rescue in that it must enable an unconscious person to remain in an upright position whilst being hoisted (see the following illustration). An unsuitable harness will allow the unconscious person to bend at the waist, making recovery through a narrow opening difficult or impossible.

9

This equipment forms part of a safe system of work for any entry into a confined space. Properly used, it may enable a rescue to be carried out successfully without the need for a

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rescuer to enter the confined space. Rescue equipment must include some means of lifting or pulling a person up from a confined space, since it is virtually impossible for the average person to achieve this solely by muscular effort. There are a variety of tripods, winches, blocks and tackles which, when used in conjunction with a safety harness, enable a person to be lifted quickly and safely out of a confined space.

11

This would mean testing and inspection in accordance with the schedule drawn up by the competent person. In practice, harness, lines and accessories such as carabiners should be subjected to a formal thorough examination, by a competent person, every six months and checked by the user weekly and before each use. Tripods, hoists and other lifting devices need to be load tested every six months in the same way that a scissor lift used for lifting people would.

12

Dependant on circumstances, rescue equipment may have to include first aid equipment, oxygen or resuscitation packs and rescue breathing apparatus. A secure line of communication to the emergency services may also be required.

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1.5.5.18 Respiratory protective equipment (RPE) Respiratory protective equipment must be selected by a competent person, be 'CE' marked and be suitable for the type of hazard against which it is to protect the wearer.

2

A wide range of types of respiratory protective equipment is available from various manufacturers. The equipment functions on the basis of two distinct principles outlined below.

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By purifying the air breathed 3

The air inhaled is drawn through a filter or medium that removes the harmful substance or pollutant. The nature of the filtering agent depends on the type of pollutant to be dealt with. These types are commonly called respirators.

4

The simplest form of respirator is the 'dust mask', a preformed cup made of filtering material

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which fits over the nose and mouth to filter out nuisance dust. These masks give no protection against harmful or toxic gases or fumes and the protection factor of the mask may not offer adequate protection against the level of airborne dust that can be experienced in a confined space. 5

More complex types have filter cartridges that may be general for various types of dust or fume, or specific to a particular substance.

By supplying clean air The air can be supplied straight through an air line via a pump or compressor or, alternatively, the person may carry compressed air in cylinders.

7

These types are known as breathing apparatus.

8

An alternative type of breathing equipment is the self-rescue set. This comprises a small compressed air bottle, the necessary hoses and valves and a face piece. Self-rescue sets can be carried by operatives who enter confined spaces in which the air is initially safe to breathe.

9

Should the air quality deteriorate, the face piece is placed over the nose and mouth and the air valve opened. The air bottle supplies fresh air to the operative whilst an escape from the confined space is made. The air bottle of a self-rescue set has a duration of typically 15-20 minutes.

10

The chart reproduced from BS 4275 at Appendix 2 details the different types of respiratory protective equipment and the system of classification. Whilst BS 4275 has now been withdrawn, it is considered that the chart still offers good guidance on general principles of selecting appropriate respiratory protective equipment.

11

Care must be taken to select the correct type of protection for the conditions. Respirators (as opposed to breathing apparatus) do not protect against oxygen deficient atmospheres and should not be used in any atmosphere dangerous to life. Respiratory protective equipment should not be used unless all other methods of control or protection have been examined and it is established that the use of RPE is the only reasonably practicable solution.

12

Respirators can only be used for protection against the gases or dusts for which they are specifically intended. It is important to note that dust masks and canister and cartridge respirators have a limited period of usage before becoming clogged with the contaminant. They may also have a limited shelf life, indicated by a use-by date.

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1.5.5.19 Permits Permit to Work Every entry into a confined space must be made under a Permit to Work, whereby a competent person must be satisfied that all necessary precautions have been taken and provisions made to secure the safety of those entering the confined space, before signing the Permit to Work. The signed Permit thus gives an assurance that work may safely take place.

2

Appendix 3 to this module shows an example of a Permit to Work. The content may be varied to meet individual requirements.

3

Permits should only be issued by named authorised persons, who must sign them. Such persons must be competent, have authority and possess sufficient practical and theoretical knowledge and actual experience of working conditions to enable them to judge whether everything necessary has been done to ensure the safety of personnel. It is quite common for several authorised persons to sign a Permit to Work, each certifying that they have taken the necessary actions with regard to their own area of responsibility, for example, electrical isolation, atmospheric testing. Where a Permit to Work system involves the use of padlocks and keys, for example for locking-off electrical isolators or other sources of energy, the keys must stay with an authorised person until such time as the Permit is returned for cancellation.

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Permit to Enter

Depending upon the nature of the confined space and the inherent risks of carrying out the work, some Contractors may choose to run a separate Permit to Enter system.

2

An example of when such a system might be used is where all preparatory work is carried out to meet the requirements of the Permit to Work and then the Permit to Enter is issued when final pre-entry checks of the atmosphere have been carried out.

3

Such a system would cover situations where:

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(b)

successive shifts of workers are each authorised to enter the confined space under a newly raised Permit to Enter.

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1.5.5.20 Access and egress 1

Where it is practical, a safe way in and out of the confined space should be provided and, wherever possible, allow quick, unobstructed and ready access, such as a fixed, vertical ladder inside an underground chamber that terminates just below the entry/exit point at ground level.

2

The means of escape must be suitable for use by the individual who enters the confined space so that, ideally they can quickly escape in an emergency. However, it must be accepted that in many cases the entry/exit point will be of a restricted size that will not necessarily allow an easy escape route in an emergency, particularly if the person who is escaping is wearing a compressed air cylinder. The means of achieving a prompt escape or rescue must be considered in the risk assessment.

3

Suitable means to prevent access, for example a locked hatch, should also be in place when there is no need for access to the confined space. There should be a safety sign that is clear and conspicuous to prohibit unauthorised entry alongside openings that allow for safe access.

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1.5.5.21 Conclusion

poorly trained and equipped workers

(b)

the failure to put in place adequate emergency arrangements before work starts

(c)

the failure to carry out an initial check of air quality

(d)

the failure to set up a safe system of work, including continuous air monitoring, based around a Permit to Work system

(e)

the failure to follow an established safe system of work

(f)

the incorrect use of respiratory protective equipment

(g)

the use of the incorrect type of respiratory protective equipment

(h)

the failure to use safety harnesses and lifelines

(i)

ill-conceived and badly executed rescue attempts.

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All such accidents are avoidable. If an accident does occur, it demonstrates that a breakdown has occurred in the supposed safe system of work.

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For work to be done safely in a confined space, great care has to be taken over the detail of each step of the procedure. Common causes of accidents are:

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Construction Site Safety 1.5.5 Appendix 1 Checklist 1 -Work in a confined space without entry of persons Ensure that entry into the space is totally prohibited.

2

Ensure that the isolation of services and processes is carried out as necessary.

3

Wash, clean, and purge the workplace, as appropriate, for work to be done.

4

Ensure that there is a safe system of work for the people concerned.

5

Ensure that other people know that work is going on.

6

Authorise work to start only on the issue of a Permit to Work.

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Checklist 2 - Entry into a confined space without breathing apparatus

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1

Follow a safe system of work.

8

Put in place adequate emergency arrangements before work starts, which will also safeguard rescuers.

9

Initiate a Permit to Work which includes the requirements of a Permit to Enter unless separate permits are raised.

10

Withdraw the space from service.

11

Isolate the workplace from electrical, mechanical, chemical, heat and all other sources.

12

Check that no inward leakage of gas, fumes, steam or liquids is possible.

13

Clean, drain and purge the workplace as necessary for the type of work to be carried out and entry to be made.

14

Test the atmosphere for oxygen, flammable gas, toxic gas, etc.

15

Carefully check any sludge or deposit that may harbour gas, fumes or liquids.

16

Carry out a COSHH assessment, if necessary.

17

Arrange for any checking to be carried out remotely.

18

If necessary, clean, purge and ventilate the workplace again until the atmosphere is safe to enter.

19

Ensure that all tools and equipment are safe to use in the area.

20

Check the provision of protective clothing, harness, lifelines, rescue equipment and rescue personnel.

21

Ensure that rescue personnel are trained in the use of the equipment and capable of using it.

22

Ensure that the fire and rescue service is informed of the location and nature of the work, where appropriate.

23

If appropriate, ensure that the external emergency rescue services are informed of the location and type of work being carried out.

24

Brief all personnel on what is to be done and arrange communications.

25

Issue the Permit to Work which

26

authorises entry and fixes a timescale within which the work must be completed.

27

Constantly monitor the workspace and communications.

28

If the task is completed within the timescale, advise all concerned, cancel the Permit to Work and return the space to service.

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If the work is not completed in time, withdraw all staff, cancel the Permit to Work and consider how best to proceed.

Checklist 3 - Entry into a confined space with breathing apparatus Follow a safe system of work.

31

Put in place adequate emergency arrangements before work starts, which will also safeguard rescuers.

32

Initiate a Permit to Work.

33

Withdraw the space from service.

34

Isolate the workplace from electrical, mechanical, chemical, heat and all other sources.

35

Check that no inward leakage of gas, steam or liquids is possible.

36

Clean, drain and purge the workplace as necessary for the type of work and entry.

37

Test the atmosphere for flammable gas, toxic gas, oxygen, etc.

38

Decide which type of breathing apparatus is to be used.

39

Ensure that the personnel involved have a current valid certificate for the type and use of breathing apparatus.

40

Ensure that all tools and equipment are safe for use in the work area.

41

Check the provision of protective clothing, harness, lifelines, rescue equipment and rescue personnel.

42

Ensure that rescue personnel are adequately trained in the use of rescue equipment and are capable of using it correctly.

43

Ensure that the fire and rescue service is informed of the location and nature of the work, where appropriate.

44

If appropriate, ensure that the external emergency rescue services are informed of the location and type of work being carried out.

45

Brief personnel on what is to be done and arrange communications.

46

Issue the Permit to Work which authorises entry and fixes a timescale within which the work must be completed.

47

Constantly monitor the workspace and communications.

48

If the task is completed within the timescale, advise all concerned, cancel the Permit and return the space to service.

49

If the work is not completed in time, withdraw all staff, cancel the Permit to Work and consider how best to proceed.

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Construction Site Safety 1.5.5 Appendix 2 Classification of types of respiratory protective equipment

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Construction Site Safety 1.5.5 Appendix 3 Possible Layout for a Permit to Work Certificate

Page 94

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PLANT DETAILS (Location, identifying number, etc.)

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The above plant has been removed from service and persons under my supervision have been informed

COMPLETION OF WORK

Signed Date Time The above plant has been isolated from all sources of ingress of dangerous fumes, etc. Signed The above plant has been isolated from all sources of electrical REQUEST FOR EXTENSION and mechanical power Signed The above plant has been isolated from all sources of heat Signed Date The above plant has been freed of dangerous materials EXTENSION

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ISOLATION

CLEANING AND PURGING

Material(s):

I have read and understood this certificate and will undertake to work in accordance with the conditions in it Signed

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WITHDRAWAL FROM SERVICE

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WORK TO BE DONE

ACCEPTANCE OF CERTIFICATE

Date

Time

The work has been completed and all persons under my supervision materials and equipment withdrawn Signed

Date

Time

The work has not been completed and permission to continue is requested Signed

Date

Time

I have re-examined the plant detailed above and confirm that the certificate may be extended to expire at

Method(s): Further precautions:

TESTING

Signed Contaminants tested

Date

Time Signed

Results

Signed Date Time I CERTIFY THAT 1 HAVE PERSONALLY EXAMINED THE PLANT DETAILED ABOVE AND SATISFIED MYSELF THAT THE ABOVE PARTICULARS ARE CORRECT *(1)THE PLANT IS SAFE FOR ENTRY WITHOUT BREATHING APPARATUS (2) BREATHING APPARATUS MUST BE WORN Other precautions necessary: Time of expiry of certificate: * Delete (1) or (2) Signed Date Time

Date

Time

THE PERMIT TO WORK IS NOW CANCELLED. A NEW PERMIT WILL BE REQUIRED IF WORK IS TO CONTINUE Signed RETURN TO SERVICE

Date

Time

I accept the above plant back into service Signed

Date

Time

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Construction Site Safety 1.5.6

Safety in Demolition

1.5.6.1 Key points Demolition can be dangerous and should be left to competent persons. Almost all demolition projects will encounter asbestos.

2

Planning and supervision is vital to ensure a successful project.

3

Ensure the appropriate survey has been undertaken.

4

Ascertain if the structures are stable before starting and that instability can be avoided unless planned.

5

Ensure written risk assessments and method statements are developed, communicated and understood.

6

Salvage or soft stripping is hazardous and must be planned and controlled to avoid the risk of falling objects or collapse.

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1.5.6.2 Introduction

Safe demolition is a very complex and technical skill. It is also potentially very dangerous if carried out by Contractors who are not fully competent in demolition techniques.

2

Information, planning, responsible implementation and controls are the essential elements for safe and successful demolition projects.

3

Whether demolition is required for a small building or for a complex factory site, you must be aware of the hazards and risks. These need to be identified, assessed and effectively controlled to reduce the potential for injury to persons and damage to property.

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1.5.6.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity. This is to identify any hazard that employees, or any other person who might be affected, may encounter during the work and to put control measures into place. These measures will aim to remove the hazards, or reduce the risks to health and safety arising out of those hazards, as far as is reasonably practicable.

2

The Contractor must provide comprehensive and relevant information on risks that exist in the workplace and on any control measures that are in place, ensuring these are fit for purpose and monitored for ongoing safety.

3

Employees have a duty to tell their Contractor of any work situation, including near misses, which presents a risk to the health and safety of themselves or of any other person who might be affected.

4

Where specific health hazards are identified, the Contractor must offer health surveillance to the at-risk employees. Given the nature of demolition and the potential hazardous substances that may be encountered, this duty could be particularly relevant to demolition contractors.

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1.5.6.4 The Provision and Use of Work Equipment These Regulations cover equipment used in demolition. They require that a Contractor supplies work equipment that is safe, correct and suitable for the job, and that the equipment is maintained.

2

Demolition has traditionally involved some work being carried out at height, which has in the past been the cause of deaths and injuries to demolition operatives. Due to advances in demolition techniques, and the increasing size and reach of the machines used, there is no longer such a need to work at height. However, where work at height is carried out, it must be done in a safe manner.

3

Under these Regulations, falling object protection is required for machinery. A demolition specification excavator must have a cab guard, as it is foreseeable when working overhead that material could fall onto the cab. The use of reinforcing bars as make-shift retaining pins for attachments would be contrary to these Regulations.

4

It is common to see mobile crushers used in the demolition process to process the demolition arisings for reuse as part of the next use of the site. These machines pose great risks to the untrained. Issues such as machinery guarding and clearing blockages, as well as noise and vibration, must be considered.

1.5.6.5 Work at Height

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These Regulations require Contractors to:

avoid the need to work at height where reasonably practicable

(b)

select the most appropriate work equipment when work at height cannot be avoided

(c)

(as far as is reasonably practicable) prevent falls

(d)

reduce the distance and consequences if there is a fall

(e)

where harnesses are being used, ensure emergency recovery arrangements are in place

(f)

ensure that all work at height is based upon a risk assessment and carried out safely.

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Where the use of work equipment involves a specific risk to health and safety, the use of the equipment must be restricted to competent, specified workers authorised to carry out the task.

3

The use of demolition machines, and in particular ultra high reach machines, is an important part of the strategy to reduce the need for employees to work at height during demolition activities.

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1.5.6.6 Personal Protective Equipment 1

These Regulations require that where a risk has been identified by a risk assessment, and it cannot be adequately controlled by other means which are equally or more effective, the Contractor must provide and ensure that employees use suitable personal protective equipment.

2

In essence, personal protective equipment (PPE) may only be used as a last resort after all other means of eliminating or controlling the risk have been considered and are not practicable.

3

Whenever PPE is to be issued, the Contractor must ensure that employees have been given adequate and appropriate information, instruction and training to enable the employees to

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understand the risks being protected against, the purpose of the PPE and the manner in which it is to be used. 4

Whilst the Contractor must ensure that personal protective equipment is supplied and used, the employee has a duty to properly use the equipment provided, follow the information, instruction, and training that they have been given, and know the procedures for reporting loss or defects to their Contractor.

5

These Regulations require that the Contractor provide employees with adequate information, instruction, training and supervision to be able to carry out any work safely and without risks to their health.

1.5.6.7 Construction (Design and Management) CDM CDM applies to all demolition and dismantling work, as defined in BS 6187, regardless of the project's size or duration.

2

Every contractor undertaking demolition operations must appoint one or more competent person(s) to plan and supervise the work. Under CDM it is a requirement that any dutyholder who puts 'another person' to work on a construction site, for example a contractor engaging the services of a demolition contractor, must ensure that the person is competent to do what is required of them.

3

The client has to ensure that there are adequate welfare arrangements. The demolition contractor is therefore expected to control and co-ordinate all aspects of health and safety regardless of the size of the project.

4

The National Federation of Demolition Contractors (NFDC) and the Institute of Demolition Engineers (IDE) can provide information regarding the competence required for particular projects.

5

CDM requires the following:

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The demolition or dismantling of a structure or part of a structure shall be planned and carried out to prevent danger so far as is reasonably practicable, or reduce the danger to as low a level as is reasonably practicable.

(b)

The arrangements for carrying out demolition or dismantling work shall be recorded in writing, prior to the commencement of the work.

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1.5.6.8 CDM duty-holders 1

The client is responsible for the provision of information such as Type 3 asbestos surveys/service information and must appoint various other duty-holders. The client must also ensure that adequate welfare facilities are provided, and not permit work to start until there is evidence of adequate health and safety management systems and planning.

2

The designer is responsible for making the client aware of the client's responsibilities under these Regulations as well as the design of the project. Many duty-holders can have designer responsibilities as outlined in CDM.

3

The Engineer is responsible for the co-ordination of health and safety design and planning aspects for projects, including: (a)

identifying and collecting pre-construction information

(b)

informing the client if there are gaps in the pre-construction information, which need to be addressed (for example additional surveys)

(c)

distributing relevant parts of the pre-construction information to contractors to enable

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(d)

generally managing the flow of information between all parties

(e)

preparing the health and safety file

The Engineer is also to advise - the client on the competency and resourcing of contractors and to ensure that the Contractor's health and safety plan is adequately developed prior to the work starting on site.

5

The minimum lead times for the project must form part of the information pack. This is a very important development as, historically, the mobilisation period imposed by clients for this sector of the industry has been too short to allow for adequate planning. Engineers must themselves be competent; demolition and asbestos issues may be too specialist for many who normally perform the Engineers role and they should be prepared to take specialist advice.

6

The Contractor must ensure that the client is aware of their duties and is responsible for the overall construction phase, taking into account health and safety issues and the development of the health and safety plan.

7

Contractors and other workers must all work together as a team to achieve high standards in health, safety and welfare on site. The contractors, which normally include utility companies, must co-operate with the Contractor by obeying site rules, and so on.

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1.5.6.9 The health and safety plan and the health and safety file The health and safety plan provides a focus for the construction phase of a project.

2

Relevant pre-construction information, relating to the health and safety hazards associated with the work, should be provided by the client regardless of the size of the project.

3

In the context of this section, such information is likely to include:

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the location and physical state of any asbestos where its presence has been identified by a comprehensive invasive asbestos survey (Type 3 as defined in MDHS 100

(b)

the results of structural surveys

(c)

plans identifying the location of underground services

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the possible presence of contaminants, for example: (i)

poly chlorinated biphenyls (PCBs) in old electrical transformers

(ii)

the residual contents of tanks and pipelines

(iii)

the location and nature of contaminated ground

(iv)

other information which is required to ensure that the work can be planned safely.

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After being appointed by the client, the contractor must use the pre-construction information provided by the client to develop the construction phase plan to the satisfaction of the client, as advised by the Engineer.

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The health and safety plan must be:

6

(a)

completed prior to any work commencing on site

(b)

reviewed and amended as often as is necessary for the duration of the project.

The health and safety file is a record of information for the client or end user of the premises. It tells those who might be responsible for the structure in future, of the risks that will have to

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be managed during any maintenance, repair or renovation. Generally, for demolition work the health and safety file will contain information such as details of: (a)

any services, which have been capped or discovered and worked around

(b)

the presence of any voids and details of any areas that may have been filled

(c)

the actions taken to remove or treat contaminated land

1.5.6.10 British Standard 1

BS 6187:2000 is the British Standard for Demolition. It recommends good practice methods for the demolition (both partial and whole), as well as decommissioning, of sites including buildings and structures. It takes into account safety, health and issues which affect protection of the environment.

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1.5.6.11 Definitions and terms used by the demolition industry Competent person in demolition: someone who has practical and theoretical knowledge, with actual experience, of the type of demolition which is taking place on the site. This person is generally accepted to be on site full time as the person responsible for the demolition activity.

2

Demolition; the deliberate pulling down, destruction or taking apart of a structure or a substantial part of a structure. It includes dismantling for re-erection or reuse.

3

Exclusion zone: an area where people are fully (sometimes partially) excluded during a demolition activity. This zone should be determined by a competent person, detailed in the health and safety plan, and may need to be defined by physical barriers on site.

4

Facade retention: where the outer wall of a building or structure is retained in its original position during the demolition phase. It is usually supported by a facade retention system, internal or external.

5

Fan: a protective screen fixed to scaffolding to contain falling debris during demolition. Any fan must be designed to withstand the intended load.

6

Felling: the deliberate collapse of a structure in such a way that the debris falls in a predetermined area.

7

Hot work: the application of heat (including the use of tools that can produce an incendiary spark). It generally uses oxygen and propane gas cutting equipment.

8

Propping and shoring: a system of temporary supports to prevent movement.

9

Safe working spaces: areas where demolition work is taking place, often protected by physical barriers (e.g. machines protected by ROPs, FOPs and MOPs as applicable).

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Machine-mounted attachments 10

Brock: a trade name for a range of remote control excavators, which can carry most demolition attachments.

11

Combination Cutter: a tool which can crush concrete and also cut steel reinforcing bar.

12

Demolition ball: a cast steel ball (drops or pendulum swings in line with the jib) used to demolish a structure (slew balling should be avoided; this technique is very rarely used now).

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Grapple: a powered claw for handling waste and recycled material.

14

Impact hammer: a large breaker, mounted on an excavator, and usually powered by hydraulics (occasionally by compressed air).

15

Pulveriser: hydraulically powered jaws for crushing concrete. It may be hand/machine/ crane mounted.

16

Pusher arm: an extension to an excavator, which enables it to carry out high reach demolition.

17

Shear: powered jaws for cutting metal.

18

Rotator: an attachment fitted between the tool and the end of dipper arm of the excavator, which allows the tool to be turned. Essential for most work in restricted sites.

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Control of Asbestos: (a)

state that all asbestos containing materials should be removed prior to demolition so far as is reasonably practicable

(b)

require that the necessary planning actions and notifications are carried out.

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1.5.6.12 Asbestos considerations

The management process should be based upon the information from an Asbestos survey, carried out before contractors are invited to tender for the demolition. This should include a drawing of the building footprint (all floors) and a list of the approximate amounts and locations of asbestos-containing materials found.

3

From the survey, an inventory of asbestos containing materials should be made and ticked off when they are removed. This should prevent creating risk during soft strip and demolition.

4

There are many occasions when asbestos containing materials are only revealed during the demolition.

5

Machine drivers need to be trained in basic asbestos recognition so that they can stop work and take advice if they discover suspicious materials.

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1.5.6.13 Planning for demolition

It cannot be emphasised too strongly that demolition is dangerous and must be left to the experts.

Planning and supervision are of paramount importance.

1

Before any work starts, the implications of the demolition to be carried out must be determined, for example: (a)

What is the age of the building(s) and what was (were) the previous use(s)?

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(c)

How much is to go?

(d)

Are floor slabs or piles involved?

(e)

Where are the separation points?

(f)

Are there any dangerous substances in, around or under the buildings which are to be demolished, e.g. asbestos, lead paints, flammable liquids, unidentified drums or packages, etc.?

(g)

Is the building on contaminated land?

(h)

Are there any site restrictions?

(i)

Are there people and adjacent properties that may be affected by the proposed working hours?

(j)

Will people be affected by noise or vibration emanating from the site?

(k)

You may need to carry out a dilapidation survey of the adjacent buildings and or highways.

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Once these things have been determined, decisions should be taken as to what are the acceptable or unacceptable methods to carry out the demolition.

3

Two important final questions remain.

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How should the job and site be left safe?

(b)

What is the time scale for the job to be carried out and is it sufficient for the demolition to be carried out safely?

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1.5.6.14 The selection and appointment of a demolition contractor The Contractor, in selecting a demolition contractor, should satisfy themselves of the contractor's competence, knowledge, ability and resources to carry out the work safely.

2

Expertise is vital.

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Some or all of the following points may be covered in the risk assessment and method statement for the proposed job.

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1.5.6.15 Essential elements of a demolition health and safety plan

1.5.6.16 Project information 1

Names, addresses, contacts and telephone numbers should be detailed indicating the project managers, quantity surveyors, architects, structural engineers etc

1.5.6.17 Scope of work 1

An explicit and concise opening paragraph should be included, outlining the extent of work along with any other related activities, e.g. asbestos removal, facade retention, etc.

1.5.6.18 Existing environmental information and drawings available 1

Where available, construction drawings should have been supplied to the contractor, along with information on the former use of the site or buildings to be demolished. This information (if any) physical or chemical hazards are on the site or in the buildings, e.g. underground tanks and/or potential chemical or biological hazards or contaminated land.

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1.5.6.19 Risk assessment and special hazards 1

Having gathered all available information and visited the site to assess the work involved, along with identifying all known hazards and confined spaces, the contractor's appointed person on site should ensure that risk assessments, and assessments for asbestos, COSHH or noise are made. Method statements should then be drawn up.

2

Consideration must be given at an early stage to control the access for workers and any visitors, and ensure separate access and egress for vehicles, plant and machinery.

3

Finally, assess the impact that the site environment will have on any people who might be affected by the activity, such as neighbours or members of the public.

1.5.6.20 Programme The programme time allocated must be adequate to allow the demolition work to be carried out safely. This should detail the correct sequence of the works with any stop and review points.

2

Where the programme has unavoidable interfaces with other trades or contractors on site, this must be recognised as a potential area of risk. Good communications, planning and management are therefore essential to ensure high standards in health and safety.

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1.5.6.21 Services

Before any work starts, all utility companies should be contacted by the Contractor and sent a site plan, showing the footprint and extent of the planned demolition, and requesting the disconnection or isolation of the appropriate service (i.e. electricity, gas, water, telecommunications or other cables).

2

These requests should be made in good time and be acknowledged in writing by the relevant utility, with confirmation that the services have or will be isolated or disconnected.

3

Where such disconnection is not possible, any pipes or cables should be clearly identified, marked and protected to ensure that they are not disturbed during the works.

4

If overhead power lines are present, care needs to be taken, particularly where machines, cranes or excavators with high reach are to be used. Adequate control measures should be put in place (e.g. warning goalposts).

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1.5.6.22 Contractors 1

Competent contractors should be carefully selected and appointed. Their activities should be detailed in the health and safety method statement and incorporated into the health and safety plan.

2

All contractors must be adequately supervised, controlled and made aware of any site rules and emergency procedures.

1.5.6.23 Plant and equipment on site 1

Confirmation that personnel operating the machinery and equipment have been trained in their safe and proper use for the types of machine being operated) should also be kept readily available.

2

All plant, machinery and any associated equipment should be properly isolated and secured at the end of each shift.

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1.5.6.24 Site signage and security 1

The demolition area must be clearly defined by both physical barriers and adequate signage.

2

The demolition zone and exclusion areas may vary quite dramatically during the different activities which will take place on the site and must be properly maintained and controlled.

3

Typical signage on demolition sites includes the following text:

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Danger – demolition in progress - No unauthorised access

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Safety helmets must be worn at all times

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existing walls with adequate secured hoarding to a minimum of 1.8 (but preferably 2.4) metres high, sheeted in plywood or corrugated iron sheeting

(b)

an existing access scaffold with hoarding around the base as above

(c)

temporary ready fencing securely bolted together.

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Typical physical barriers may include the following:

Where there is the likelihood of trespassers or vandals, 24-hour security arrangements may have to be implemented.

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1.5.6.25 Protection of people

The hierarchy of risk management must be applied, i.e. where possible avoid the risk, then reduce, manage and control to an acceptable level of protection.

2

Where demolition is being carried out above or unavoidably close to the public, adequate protection must be provided, e.g. fully sheeted scaffold with either 'Monarflex' or debris netting. If necessary, also provide scaffold fans and walkways.

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1.5.6.26 Access and egress

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Safe access and egress, both to the site and the workplace, must be clearly defined and maintained at all times for use by personnel, equipment, vehicles and emergency services.

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Where practicable, pedestrians should be segregated from vehicles, plant and equipment movements.

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1.5.6.27 General site safety 1

Adequate procedures for action in the case of an emergency should be developed, implemented and communicated to all on site.

2

Adequate fire-fighting equipment must be available at all times, especially when any hot work is being undertaken.

3

A telephone or another form of communication must always be available on site to summon emergency services as necessary.

1.5.6.28 Welfare 1

The Contractor is responsible for ensuring that there are adequate and maintained welfare facilities.

1.5.6.29 First aid 1

An assessment should have been carried out by the demolition contractor.

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2

This will confirm the adequacy or otherwise of the company's arrangements for first aid. Any shortcoming identified by the assessment must be rectified.

3

On a demolition site it is envisaged that the minimum requirement will be a trained first aider or a number of trained emergency aiders, all with access to adequate first-aid facilities.

1.5.6.30 Scaffolding and access equipment platforms All access scaffolding or equipment must be fit for its purpose, properly designed, constructed of sound material and not so overloaded as to risk a collapse.

2

Scaffolding that is to be fitted with fans, debris netting or sheeting must be designed to take into account wind loadings and the changing conditions on site (e.g. the partial removal of structures which will affect the wind loading and ties). It is essential to ensure that the scaffold contractor fully understands the intended demolition method so that they can decide on the placement of scaffold ties.

3

Whenever scaffolding is provided as a means of access to the workplace, the contractor should ensure that the completed scaffolding has a handover certificate before allowing any of their personnel to work on it. Alterations to scaffolding must only be carried out by specialist competent persons.

4

It is the responsibility of the Contractor that scaffolding is inspected regularly and that suitable records of inspections are kept.

5

Mobile tower scaffolds should be erected in accordance with the manufacturer's instructions by trained personnel only.

6

In line with good practice, access should be by stair towers; however, ladders that are used for access to working platforms should be:

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free from defects and not painted

(b)

placed on a firm footing

(c)

used at an angle of approximately 75° (1 part out at the base to 4 parts up)

(d)

securely fixed at the top

(e)

extend at least five rungs (1 metre) above the working platform unless an adequate, separate handhold is provided.

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Where the demolition work requires that a progressive dismantling of the scaffolding takes place, attention must be paid to the remaining scaffold's stability, for example the adequacy of the remaining working platforms, ties and bracing.

8

After each time that the scaffold is modified and before it is next occupied, it must be inspected by a competent person to certify that it is still safe to work on, and a record of the inspection made

9

Where self-propelled mobile access platforms are used, Contractors must ensure that the operator is properly and adequately trained.

10

Additionally, care must be taken to ensure ground conditions are acceptable for these platforms.

11

Where the work requires employees to work from cradles (and/or suspended baskets) attached to a crane, a deadman's handle should be fitted with the ability to be power lowered only.

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1.5.6.31 Fall-arrest equipment Operatives must receive training in the inspection and safe use of safety harnesses, worn at all times when working in such equipment. These harnesses must be secured to an anchor point in the equipment. The harness and lanyard must be inspected each time they are worn. This is very important for anyone involved in hot works which could result in damage to a harness or lanyard.

2

With the progressive nature of demolition projects, harnesses are commonly used to prove a quick solution to a difficult access problem. It is vital that the following basic check is performed to avoid selecting an anchor point that is simply too close to the ground. The wearer needs to allow for: their height

(b)

the length of the lanyard

(c)

the extended length of any fall absorption device.

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In many instances this will mean that a minimum of a 5.5 m 'fall distance' is required to enable a fall to be safely arrested. This needs to be factored into the plan for working at height. It does not mean that harnesses may not be the safest way to do the work; just that restraint lanyards or work positioning harnesses, as opposed to fall-arrest equipment, are more appropriate in some circumstances.

4

There is significant concern regarding how long someone can survive if they do fall whilst wearing a harness and are suspended in it. Unless they are rescued immediately they are likely to suffer from a potentially serious medical condition known as 'suspension trauma'. Before work starts an effective rescue plan must be developed, which would ensure that someone who has fallen is rescued as soon as is practical and certainly within 10 minutes.

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in the design of a facade retention scheme

(b)

where there is doubt over the building's stability

(c)

where there is doubt about the proposed method of demolition

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where there is doubt about the capacity of the building to take loadings.

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The expertise of a structural engineer must be used in the following cases:

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1.5.6.32 Structural engineers

It is good practice to consult a structural engineer at the planning stage of demolition to avoid uncontrolled collapse.

1.5.6.33 Methods of demolition 1

This section gives an outline of the types of demolition techniques commonly employed.

Risk assessments, method statements and sequence 2

The key to a successful demolition is to ensure the appropriate risk assessments and method statements have been developed to identify the correct sequence of carrying out the work. These must be fit for purpose, clearly communicated and understood by the persons using them.

Partial demolition 3

Partial demolition is often carried out where refurbishment is being undertaken and can include facade retention. In any demolition, daily or, if required, more frequent checks should

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be carried out to confirm the stability of the remaining structure. 4

If at any time during the demolition the structure appears or becomes unsafe, all workers should be withdrawn until actions have been taken to remove any danger.

Complete progressive demolition Progressive demolition is generally carried out in the reverse order to construction, and often follows the soft strip-out phase.

6

This is the most commonly used method of demolishing structures and should be detailed in the health and safety plan.

7

In high-rise buildings where a floor-by-floor demolition is being carried out, danger points should be recognised such as:

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structural stability

(b)

on floor loadings

(c)

falling debris

(d)

maintaining clear access and egress

(e)

risk of fire hazards

(f)

the need for secure edge protection.

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Demolition by deliberate collapse

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(a)

Demolition by deliberate collapse can be achieved by pre-weakening the structure, followed by explosives, remote mechanical demolition or pulling, using a wire rope.

9

When explosives are being considered, only fully qualified explosive engineers should be used.

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Manual demolition techniques

Manual demolition techniques are used when other methods of demolition are not suitable or possible.

11

Some of the types of tools or operations that can be used in manual demolition are:

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(a)

hand tools

(b)

breakers, compressors or hammers

(c)

concrete nibblers or hydraulic pulverisers

(d)

stitch drilling

(e)

drilling and hydraulic bursting

(f)

drilling and expansive pastes

(g)

oxygen and propane cutting equipment

(h)

diamond cutting and sawing

(i)

steeple jacking.

General precautions 12

For brick or concrete structures: (a)

identify any pre-stressed or post-tensioned concrete beams that may be present within

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(b)

wherever practicable, carry out demolition in the reverse order to construction

(c)

maintain tools in good condition, and use them safely

(d)

use compressed air or portable electric power tools, from a 110 volt supply

(e)

make operatives fully aware of the safe procedures

(f)

in addition to site induction, ensure task and tool box talks are prepared, delivered and understood at key stages of the work.

As far as is reasonably practicable, employees should not work above each other and care must be taken to ensure that debris does not drop into other working areas.

14

If lift shafts or other formed openings are used to drop debris down, the openings must be adequately protected by either suitable guard-rails and toe-boards (with no gap between guard-rails and toe-boards exceeding 470 mm) or by other substantial, effective barriers. It may not be possible to guard an opening where plant such as a 'bob cat' is being used to bulldoze arisings into a shaft or chute. In such cases a safe system of work must be developed which is sufficiently robust to:

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stop the item of plant falling into the chute or shaft

(b)

control when materials will be loaded and unloaded to stop materials being tipped onto someone below

(c)

protect other workers from falling down the shaft.

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(a)

It is still acceptable to use window openings as a means of removing debris from upper floors under certain conditions. The opening would need to be protected so that operatives cannot fall whilst throwing the debris out and the landing zone must be completely protected so that materials cannot fall on anyone. Typically the area will be fenced off with mobile fence panels and then the material loaded with an excavator into a hook bin container. If the structure has more than two storeys, consideration should be given to creating an enclosed drop zone within a scaffold chute.

16

With regard to falling materials and exposed edges, where necessary danger areas (exclusion zones) must be created.

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Oxy-propane cutting equipment:

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Oxy-propane cutting equipment

(a)

should be inspected and tested for leaks before use

(b)

cylinders should be secured in an upright position

(c)

hoses should be secured with crimped fittings not jubilee clips

(d)

flashback arresters should always be fitted between cylinder gauges and hoses

(e)

operatives must be trained in the safe use of the equipment and wear the appropriate PPE (e.g. goggles and gloves).

18

Whenever oxy-propane cutting equipment is used, the correct fire-fighting equipment should always be available. All operatives should be trained in the safe use of fire extinguishers.

19

Hot work should generally be stopped for an agreed period before leaving site, typically one hour before finishing, to avoid the potential of fire.

Mechanical demolition techniques 20

Machinery used should be fit for purpose, used in safe working spaces, adequately protected

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(e.g. by ROPs and/or FOPs) and operated by authorised competent persons. Remote control demolition 21

This utilises specialised equipment, often in hazardous or aggressive environments (e.g. nuclear installations). The use of 'Brock' type machines is becoming more common and they offer possible solutions to the difficulties of complying with the problems of noise and vibration experienced during hand demolition.

Using a 360° excavator with multi-functional attachments This type of demolition is commonly used to demolish low buildings, or is used after other height reduction techniques have been carried out.

23

To avoid physical injury from movement of the parts of the building being demolished, the machine should work in its own zone and be guided by a signaller. The signaller should always be in visual contact with the machine driver when positioned close to the machine.

24

Whilst the machine driver is isolated from noise and dust, the signaller is not and may need to wear PPE depending on the findings of the risk assessments for the work being done, for example if an impact hammer is being used.

25

The height of the wall or building to be demolished should not normally be greater than the attack (maximum) reach of the machine.

26

In some circumstances, it is possible to create a ramp for the machine to sit on to increase the reach using rubble from previous demolition. Care must be taken to ensure that there has been sufficient compaction to avoid the machine sitting on an unstable base.

27

If the ramp is being created within a building, it is very important to keep the ramp separated from the outside walls to avoid surcharging them. In some very limited circumstances, undermining or undercutting when the machine cannot reach the top of the building may be acceptable. Any contractor selecting this method must implement a safe system of work that ensures: the stability of the structure is maintained

(b)

the protection of the driver from falling material.

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With regard to the second bullet-point, it is likely that a combination of methods, such as preweakening, will be employed to ensure the direction that the material will fall is controlled.

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Super high reach 360° excavators 29

Typically these machines have a reach between 15 and 50 metres plus the length of the fitted attachments for crunching concrete or shearing steels. The recommended working height for this type of machine is 75% of the maximum reach.

30

These sophisticated machines are often fitted with variable width tracks, which usually make them much heavier, giving increased ground-bearing pressure and reduced working envelopes. It is vital that any voids and ducts located where the machine will track are discovered and adequately filled. In terms of ground conditions, these machines should be considered more as a crane or piling frame in terms of stability, rather than an excavator.

General precautions Before using the demolition equipment, steps must be taken to ensure that the building is completely empty and that all services are isolated.

32

Because of the danger of debris falling onto the excavator and its driver, the machine should have a fitted cab guard and, as an added precaution, should be fitted with shatterproof glass.

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Demolition ball

Demolition using a ball is extremely rare due to the advent of super high reach machines. When a ball is used, the crane equipment must be heavy duty and only drop or pendulum (e.g. in line with the jib) balling techniques should be employed.

34

When a ball is employed, regular (e.g. hourly) inspections of the equipment must take place, paying particular attention to the attachments and shackles.

The demolition of bridges, pylons, masts, etc. requires specialised planning and techniques.

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General precautions

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Bridges or steel structure demolition

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An assessment by a structural engineer should be undertaken to see if the structure could be safely broken down into small component lifts.

37

A comprehensive safe working plan must be developed providing a safe means of access, using a competent crane hire company and experienced slingers and signallers.

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Environmental considerations 38

Noise, dust, fumes, vibration and fire control need to be properly addressed before and during the demolition operation. Consideration should be given to the following points.

Noise 39

The contractor must ensure that a noise assessment has been carried out and that, where possible, people are kept out of the danger area.

40

Any machinery which is to be used in the demolition process should, as far as possible, be fitted and used with soundproofing equipment (e.g. exhaust silencers).

41

Where it is necessary for people to work within the area of noisy operations, adequate hearing protection must be provided and used as necessary. If the upper exposure action value is exceeded, or likely to be exceeded, hearing protection must be worn and hearing

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protection zones clearly indicated. 42

Where the findings of a risk assessment indicate that the hearing of any employee is at risk due to noise exposure at work, health surveillance, including hearing checks, must be provided.

43

British Standard 5228 gives advice on the provisions for noise control on demolition sites.

Dust 44

Nearly all demolition activities create dust and many require a COSHH assessment.

45

Taking simple precautions, such as the following, ensures the dust nuisance can be reduced to a minimum. Implementing techniques that reduce dust generation.

(b)

The use of light water sprays both before and during demolition are very effective. However, consideration should be given to any potential run-off contaminants that may be produced and to the proximity of demolition work to electrical services and drains.

(c)

Where demolition is being carried out inside a building and water sprays are inappropriate, local ventilation, using air movers and filters, can help to alleviate dust levels.

(d)

Dust masks, as any other personal protective equipment, should be used only as a last resort. Where any mask is used, the wearer must be face-fit tested for the mask.

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(a)

A comprehensive ' invasive asbestos survey must be undertaken prior to the demolition being started and preferably before contractors are invited to tender for the demolition.

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Fumes

A cutting torch, used on steelwork, may produce toxic gases such as nitrogen dioxide. If a phosphate coating is present, phosphine may be produced. If a chlorinated solvent has been used, sulphides may be formed which have no smell until high toxic levels are present. Additionally, toxic metal fumes may be given off.

48

Attention is drawn particularly to lead (lead painted steelwork), cadmium (cadmium bolt heads) and zinc.

49

Before any hot work cutting is allowed, available information or paint samples may be required for analysis, a COSHH assessment should be undertaken, and the necessary control measures implemented.

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Vibration transmission 50

Vibration from demolition operations can cause damage to adjacent property and injury to personnel working on site or, in extreme cases, to members of the public. Exposure to vibration must be controlled.

51

The following points should be given consideration. (a)

Attempts should be made to establish the presence of any existing sources of vibration and whether vibration monitors are needed in sensitive locations.

(b)

Where buildings adjoining those to be demolished are being retained, separation should be carried out using hand tools rather than machinery.

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(c)

Necessary precautions should be taken or alternative equipment considered to alleviate the risk of hand-arm vibration syndrome (HAVS), e.g. 'vibration white finger' from continued use of vibrating tools.

52

With regard to the last point, the exposure time for most demolition hand tools is extremely short, and the contractor will need a robust policy which includes health surveillance to carry out hand demolition using demolition picks.

Fire and explosion risks Where flammable liquids, gases or vapours have been used, or were released in a building which is under demolition, any equipment, tank or pipes, etc. which could have contained such substances must be purged and tested for explosive gases prior to work taking place. Any work should be done under a Permit to Work system.

54

General hot work, using oxygen and propane cutting equipment, should be carried out only by operatives trained in its safe and proper use, wearing the appropriate personal protective equipment, i.e. goggles, gloves, overalls.

55

If the occasional burning of debris, such as wood or paper, is allowed on site, the fire must be as small as possible, well away from buildings, roadways, fuel stores, and kept under constant supervision.

56

All fires must be completely extinguished at least one hour before work stops for the day and checked again, to ensure there are no glowing embers before operatives leave the site.

57

Adequate fire-fighting equipment must be available, with fire points containing extinguishers in prominent and well-marked areas adjacent to the demolition operations.

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Recycling

Demolition works should therefore be reviewed carefully to identify what wastes will be produced, what actions will be taken to deal with these wastes.

59

In addition to removing recoverable items from demolition operations, it is becoming increasingly common to crush the resultant brick and concrete into a sub-base material for future construction purposes. Crushing on site should only take place when environmental conditions permit such actions. Environmental emissions (noise, fumes and dust) are required to be recorded at least three times daily on a check sheet. Operations should cease if there are excessive emissions which cross the site boundary.

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(b)

All materials to be recycled should be checked for any contaminants and dealt with in the correct manner to the required specification e.g. 6F2.

(c)

Operatives working on the crushers must be properly trained (both general training on the use of crushers and specific training in respect of the equipment being used).

(d)

Serious consideration must be given to the need for machinery guarding on crushers. A daily check sheet should be completed by the operator, which confirms that all guards are in place and the emergency stops are working.

(e)

Robust safe systems of work are required to deal with blockages. These often happen because the operator loading the crusher simply feeds in lumps that are too big, or because during the demolition process the machine driver did not sort the materials well and large lumps of timber have entered the stockpile.

(f)

All crusher operators are likely to require hearing checks and monitoring as the noise levels are normally high.

(g)

Even with the dust suppression systems operational, it is unlikely that disposable

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(h)

In many circumstances the operator acts as a picker. On some machines it is an accepted practice that the operator wears a full body harness and is attached to a strong point by a restraint lanyard to avoid them being pulled into the machine and crushed.

Removal and disposal of materials Before any materials are removed from site, both vehicular access to, and egress from, the site must be agreed. Where applicable, bog mats and wheel washing facilities should be provided to ensure that debris is not carried onto the highway. Depending on the nature of the material, consideration should be given to covering lorries to prevent dust and debris.

61

Daily records must be kept of materials taken off site.

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Demolition is not an exact science and if the job does not look or sound right there may be a problem. If you have any doubts about the job, or how it can be safely carried out, request further clarification before proceeding.

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Common errors and assumptions

Provide daily briefings to the workforce on complex projects.

(b)

Check for continuing safe working practices.

(c)

Ensure access and egress routes are properly maintained.

(d)

Ensure the site is kept tidy.

(e)

Ensure the site is, as far as possible, free from any piles of combustible rubbish.

(f)

Ensure that sufficient signs are available and clearly visible to warn of hazardous areas and activities.

(g)

Check the contractor's operatives are continuing to wear suitable protective equipment.

(h)

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Daily inspection by the site supervisor and/or Contractor

Check that an approved safe system of work is being followed.

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(i)

Check the progress and sequence of the job to ensure that it is being carried out in compliance with the health and safety plan.

The key to a successful and safe demolition project is to plan, implement, monitor and maintain a safe system of work.

DEMOLITION IS DANGEROUS, TECHNICAL AND ONLY FOR THE

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EXPERTS

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PLANNING AND SUPERVISION ARE PARAMOUNT

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Construction Site Safety 1.5.7

Safety in Piling

1.5.7.1 Safety in Piling 1

Piling operations can give rise to different hazards dependent upon the type of piling being undertaken. Certain hazards are, however, generally common on all types of piling and the following gives both the general precautions to be taken and the special precautions relating to the different types of piling. Section 4 of the QCS covers technical aspects of piling operations.

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1.5.7.2 General precautions

For all types of piling it is essential that a working surface designed to support the plant & equipment safely when working and moving, is provided. Failure of the Working Platform (piling mat) accounts for 30% of dangerous occurrences involving piling equipment. Any such failure is potentially fatal. It is important that the responsibility for design, construction and maintenance of the working platform is established and agreed, before work commences. Piling contractors will provide details of their equipment to assist contractors in constructing suitable access and working surface in the piling area. Piling contractors are to ensure that their access and work area remains suitable and in good order.

2

Prior to piling, all underground services in the area should be located and marked where they cannot be rendered safe. It is important to consult the services authority in the area on these matters. A check should also be carried out to ensure that there are no cellars, underground watercourses, ground conditions or made up or soft ground, etc., which could create hazards during the operation. Consideration must also be given to potential instability, which may be caused by the weather.

3

Where the site is contaminated, consideration must be given to the type of piling used and additional welfare facilities provided.

4

Piling contractors should be requested to provide an appropriate written method statement to the contractor. It is essential that induction training and information specific to the method statement is provided to piling and site operatives.

5

Particular attention should be given to planning activities concurrent with piling including identifying safe working distances and pedestrian and traffic access routes.

6

All persons working on piling operations must wear safety helmets and footwear. Ear and eye protection must be provided and worn where necessary.

7

When piling from a pontoon or adjacent to water, personnel should wear self-inflating life jackets. Rescue equipment (e.g. a safety boat and lifebuoys with lifelines attached) must be kept ready for immediate use and enough men must know how to use it.

8

Where fluid concrete is used provision for the washing out of static plant and delivery vehicles must be made, as you must protect watercourses against pollution.

9

Rated capacity indicators / limiters (RCI/L) are not required to be fitted on piling rigs when used for normal piling operations. Likewise, an RCI/L - is not required when a rig is being used to erect another rig,provided that the weight of components is accurately known and does not exceed 75% of the safe working load (SWL) of the rig. However, if a rig with a SWL

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of more than one tonne is used for general lifting operations, such as the loading and transport of materials on site, it must be fitted with an RCI/L. 10

Machine operators must be trained, competent, medically fit and authorised by the contractor to operate the machine.

11

Piling rigs are classed as lifting equipment and therefore require a thorough examination after assembly and before being put into service at a new site or in a new location and at least every 12 months. Inspections should also be carried out at suitable intervals. Accessories for lifting (lifting gear) require a thorough examination at least every 6 months.

12

Piling rigs and cranes should only travel on slopes at gradients approved by the machine manufacturer and "slew pins" must be used in these circumstances to reduce the risk of overturning.

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Guards must be fitted to the dangerous parts of the rig.

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1.5.7.3 Use of Cranes with piling It is important to differentiate between cranes and piling rigs.

2

Cranes are widely used conventionally for load handling in association with piling activities. Some techniques (e.g. sheet piling) also use cranes to install piles.

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Piling rigs are either purpose made machines or cranes specially adapted for piling by the fitting of masts / leaders and / or sub assemblies to power boring equipment.

(b)

Cranes must be selected and used in accordance with BS 7121 or equivalent international standard.

(c)

Cranes, which have been employed on piling duties, should be subjected to a thorough examination before being returned to general lifting operations.

(d)

Any crane used for raising or lowering people must be fitted with a dead man's handle and the descent must be effectively controlled; the latter is currently achieved by power lowering. Properly constructed man carrying cages, designed to prevent crushing and falls of people that are unable to spin or tip, must be used. The cages should be regularly and carefully inspected. Any item of lifting equipment used to carry persons must be thoroughly examined by a competent person at six monthly intervals.

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1.5.7.4 Materials handling 1

Piles and other materials should be stacked safely on ground of equal bearing ability, with safe access for subsequent removal and use in mind.

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Circular objects should be chocked to prevent rolling.

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Where there are marked lifting points they should be used. Never lift bundles by their security ties, use the correct sling.

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Flat and bundled items (e.g. sheet piles, bundles of reinforcement) must be lifted with the correct lifting accessories and spacers placed between layers so that chains etc. can be safely removed after setting down.

5

Hand tag lines should be used for long or bulky items which are likely to spin, especially in windy conditions.

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1.5.7.5 Piling Techniques Driven piling - other than sheet piling Specialist piling rigs incorporating a leader or mast which guides the pile driving hammer and driving head are used. Piles are fitted to the driving head, pitched at the required position by the rig and driven to the required depth. No spoil is generated. Piles may be extended to meet technical criteria. All machinery should be in good condition and no lifting equipment should be used unless there are current records of thorough examination and where appropriate, testing of the equipment in existence.

(b)

All control levers on the piling rig should be clearly marked to indicate their purpose and mode of operation.

(c)

Persons not directly involved must stand well clear at all times when the rig is operating.

(d)

Hearing protection will be required.

(e)

When piles are extended by welding, full precautions for temporarily securing the additional length and welding must be observed.

(f)

When piles are extended using proprietary jointing systems the manufacturer's safety and technical procedures must be followed.

(g)

Where persons have to approach the rig mast and the raised hammer for alignment and, or maintenance purposes the hammer must be secured to prevent its unintentional release.

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Driven sheet piling 2

The Contractor must consider the following simple factors in connection with the sheet piling process: (a)

how the piles are held in position during driving, – how the piles are to be threaded,

(b)

how the first pile is secured whilst the second is threaded, the overall scheme to devise a system to prevent the falls of persons and materials.

(c)

Piles can either be held in position during driving using a special leader arrangement attached to the crane or piling plant or, alternatively, a gate system may be used.

Gate systems A supporting system should be chosen which is appropriate for the operation, e.g. where short runs of sheet piling are required and accuracy is not the main criteria', then a single gate system may be used.

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A single gate system is made up of a simple frame of either timber or steel gates supported by block a suitable distance above ground level. A shallow guide trench is normally dug to assist with the location of the sheet piles.

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The "gate support system" shown is a two-gate system, made up from timber H-frames, set in concrete

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Kelly Blocks. These H-frames are then spanned by RSJs (gates). If the gates are over 2m high, or over any potentially dangerous area, they must not be used as working platforms unless fitted with toe boards which rise at least 150mm and main guardrails at least 950mm above the walkway. Additionally, intermediate guardrails, or other rigid barriers, must be fitted so that there is not an unprotected gap of more than 475mm in height in the means of protection against a fall. Where such protection cannot be provided, access to slinging points must be gained by ladder and NOT by means of the gates.

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Permanent ladder access must be secure and extend above the gates sufficiently to provide a safe handhold. (A distance of 1.05m is recommended).

8

If using a cantilever system, a tie-back should be used where possible, as well as kentledge to provide safe anchorage and stability of the frame.

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When piling is progressing and temporary piles are used to support the gate system, it is advisable to use purpose made brackets and bolt them to the piles. Any welding necessary should be carried out by competent welders.

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When constructing Kelly Blocks, reinforcement should be placed in the concrete base. Vertical RSJs should have a good "key". Vertical timber should not be cast into the block but should be wedged and bolted. Where doubt exists over the stability of Kelly Blocks, guy lines should be used. Lifting eyes should be cast into the blocks.

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When using Kelly Blocks, it is essential to ensure that these are temporarily landed on an adequate foundation to prevent subsidence and overturn during piling operations. This is particularly applicable during works in rivers, etc.

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Pitching sheet piles 12

If shackle holes have to be burned in the pile, sharp burrs should be removed to prevent damage to shackle pins.

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Remote release shackles should be used where possible and the sheet pile must not be lifted vertically without first checking that the pin is properly engaged through the sheet. The

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length of the operating rope must be less than the length of the pile and the rope should be secured around the pile to prevent snagging, or being caught in the wind and becoming inaccessible. If piles are too heavy for a remote release shackle and work cannot safely be carried out from a ladder, a lifting cage should be provided to gain access for unscrewing the shackle.

15

If a special lifting eye is to be welded to the pile for angled pitching, the weld should have a factor of safety of at least 2.

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Long sheet piles should be pitched with a pile threader following the manufacturer's guidance for use. Where this is not possible, a pile pitching cage should be used. The cage should hang from an adjacent pile, the operatives wearing safety harnesses hooked to the adjacent pile before the crane hook is removed from the cage.

17

When sheet piles are being pitched it is essential to take particular care to ensure the stability of the first few piles, but especially the first pile. This may be achieved by fixing the pile to the gate at two points so that it cannot move within the plane of the gate. This action will also ensure that the pile is stable if an effective toe-in is not achieved due to hard/stony ground conditions.

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When feeding sheet piles through top and bottom gates, use wood blocks or a bent bar. Never use a straight pinch bar, as fingers can easily be trapped.

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Additional precautions are required for work carried out from ladders, e.g. Clutching: the ladder must be placed in the valley of a previously placed pile; the ladder must be footed and, when at the top of the ladder and both hands are required for clutching, a safety harness must be worn and secured to the pile using a girder grip.

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Wedging: the ladder must be placed against the RSJ and footed; wedges should be prepositioned on the RSJ A 4lb lump hammer should be used as this can be swung with one hand. If two hands are required, a safety harness must be worn, with the lanyard wrapped around the RSJ or connected to a girder grip.

21

The work method must not be changed without the approval of the contractor responsible for the piling operation. If windy conditions make the handling of the sheet piles difficult, work must stop until the responsible person has been consulted and a safe method of continuing the work has been devised.

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Piling Hammers 22

The recommendations of BS 5228 Pt. 4: Code of practice for noise control applicable to piling operations, should be closely followed.

23

Hammers, and in particular all clamping bolts, should be regularly inspected and a record kept.

24

Use guide rope when positioning a hammer.

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Stand clear when starting and operating.

26

ALL personnel should be at ground level during pile driving.

27

Should the piston of a hammer jam, the trip-lever should be pulled to the open position before removing the hammer from the pile.

28

Damaged high-pressure airlines or high voltage cables, feeding the hammer, can present a

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serious hazard to persons working in the vicinity of the operation. 29

Therefore it is important to keep supply lines/cables under constant observation to avoid damage by trapping or from sharp objects.

Double acting air hammers 30

All hose couplings should be properly manufactured and matched. The joining of rubber pipes to brass spigots should be by clamp and not hose clips.

31

Ensure that the oil bottle/filter lid is secure.

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Internal drop hammers Always place a swivel between the hammer and hoist rope.

33

Attachment of a hoist rope should always be done using a properly matched anchor and pear; the dead end of the rope should be secured to itself using a bulldog clip or other approved means.

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Intermediate linking shackle pins should be secured.

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Hoist ropes should be inspected regularly during piling operations and a record of inspections kept

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Helmets and inserts

Pile helmets or crowns must be well constructed, strong enough and free from defect. Should packing or spacers be needed, they should be drilled, tapped and screwed, to secure in place, and then be welded. Remember that any welds to a solid cast helmet will eventually crack.

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Pile extraction

Where pile extraction is necessary, due allowance should be made for the frictional forces occurring between the pile and ground, in order to determine the correct size of crane and extractor.

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It is good practice to use a tag line between hook and adjacent pile to prevent the extractor swinging out of control should the pile snap.

39

Care should be taken when lowering extracted piles to ensure that the load on the crane hook is kept vertical.

40

Where a crane is used to extract piles it is common practice for the rated capacity indicator to be disconnected to prevent damage. This is a legal operation in that the crane is effectively a "piling rig" whilst this work is taking place. However, the competent person for lifting operations must ensure that the machine remains within its safe working capacity throughout the operation. The RCI/L must be promptly connected before any other lifting work is attempted.

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Rotary Bored piling 41

This technique involves specialist piling equipment that bores a hole which, depending on ground conditions may be lined (cased). Relatively short rotating boring tools are used which are withdrawn from the ground fully loaded with spoil. Once the tool is above the ground the

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rig is commonly slewed off the bore and the spoil is discharged. Reinforcement bars and concrete are placed in the hole and any temporary casing is extracted to complete the process. Personnel not directly involved with the activity should be kept clear at all times, particularly from the boring and spin off (spoil discharge) areas.

(b)

Fixed guarding to Rotary Bored Piling Augers is not practicable due to the nature of the equipment. A controlled zone must be identified at each pile location and can be defined as a zone at 2m radius from the centre of the auger. A banksman must be in attendance at all times while the piling rig is active and must be given authority and responsibility to ensure only authorised persons are permitted within the zone. No person is permitted within the zone while the auger is rotating (this precludes manual cleaning of the auger). Should any manual intervention be required the auger must be stopped. An excavator can be used within the zone for the purposes of clearing spoil but only under the banksman’s supervision.

(c)

To remove spoil from the auger the loaded auger should be carefully slewed off the pile position to the discharge point in a controlled manner. When the auger is being spun off it should be as close to the ground as possible to minimise the spread of spoil and the auger spin speed should be only sufficient to empty the tool so as to minimise the spread of spoil.

(d)

Spoil from bores should be kept clear of access to the borehole.

(e)

Open bores must be fitted with a cover or other suitable protection to prevent people falling into them. Common practices include leaving the casing 1m above working platform level and the auger or other boring tool in the borehole.

(f)

Freshly completed piles must be marked individually or in blocks to minimise trip hazards from reinforcement and soft concrete. They should be backfilled as soon as technically possible, remembering that soft spots must remain highlighted for the safety of people and plant stability.

(g)

In the majority of circumstances there is no need for a person to enter a pile bore/shaft and this should be avoided. Remote means of inspection and sampling the sides of shafts should be used wherever possible.

(h)

Where entry into a pile bore / shaft is unavoidable the recommendations of British Standard BS 8008 or equivalent must be followed.

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(a)

All persons entering the controlled zone must be properly informed and instructed on the risks associated with this operation. The banksman must be trained on slinger signalling matters. The banksman must be identified.

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The guard forms a “natural” resting position for the banksman, this position is away from the auger.

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Auger guarding and mechanised cleaning

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CFA (Continuous Flight Auger) Piling With this technique specialist piling rigs screw an auger into the ground the full depth of the pile bore. Concrete is then pumped through the hollow auger stem and spoil is removed as the auger is withdrawn. Reinforcement is placed in the bore after concreting.

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The majority of rigs used for this type of piling have a certain amount of guarding achieved by extending the gate (guide), which is used to maintain the position of the augers. However this gate does need to be opened to allow the piling rig to achieve its full depth and to facilitate the rigging of the augers and the gate will not allow work immediately adjacent to structures, especially in corners.

(b)

A controlled zone must be identified at each pile location and can be defined as a zone at 2m radius from the centre of the auger. A banksman must be in attendance at all times while the piling rig is active and must be given authority and responsibility to ensure only authorised persons are permitted within the zone. No person is permitted within the zone while the auger is rotating (this precludes manual cleaning of the auger). Should any manual intervention be required the auger must be stopped. An excavator can be used within the zone for the purposes of clearing spoil but only under the banksman’s supervision

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All persons entering the controlled zone must be properly informed and instructed on the risks associated with the CFA piling operation. The banksman must be trained on slinger signalling matters. The banksman must be identified. Providing this procedure is strictly adhered to then this may be adopted as an alternative approach to the guarding of CFA augers when mechanical means of guarding is not reasonably practicable. (a)

Mechanical or automatic auger cleaning devices should be used. All control levers on the piling rig should be clearly marked to indicate their purpose and mode of operation.

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(c)

When ropes are subject to heavy wear, they must be frequently inspected and changed as necessary.

(d)

Similarly, the auger section joints and their wedges must be inspected on a daily basis for excessive wear.

(e)

Freshly completed piles must be marked individually or in blocks to minimise trip hazards from reinforcement and soft concrete. They should be backfilled as soon as technically possible, remembering that soft spots must remain highlighted for the safety of people and plant stability.

Tripod bored piling 46

A tripod is set up over the pile position and various tools are used to advance boring. These are raised and dropped by a rope winch attached to the tripod. Casings are driven to line the bore, their depth varying with ground conditions. Spoil is removed as boring progresses. Reinforcement and concrete is placed before the casings are withdrawn.

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(a)

Each tripod leg must be identity marked and every tripod and winch marked with its safe working load (SWL). Identity marks must correspond with the examination records.

(b)

Ropes should be secured with suitable fastenings, e.g. bulldog clips. Where appropriate, properly constructed saddles or hard eyes should be used.

(c)

Knots must not be tied in any rope used for lifting.

(d)

The tripod legs must not be overspread or overloaded. The base plates should be adequate and secured to prevent any accidental movement of the rig.

(e)

Only the correct pins should be used in the sheerlegs (tripod).

(f)

All parts of the winch should be effectively guarded, although it is acknowledged that access to the winch drum is required to enable the rope to be pushed across the drum during a gear change.

(g)

Constant attention must be paid to the condition of rope, which should be changed as soon as it becomes necessary.

(h)

When a rope/chain block is being used to extract the casings, the capacity of the block must not exceed the capacity of the rig.

(i)

Under no circumstances must there be less than 2 full turns of the rope on the winch drum at any time.

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There are many other piling techniques. Specialist suppliers should be contacted for alternative safe working procedures.

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Construction Site Safety 1.5.8

Safety in Formwork/Falsework

1.5.8.1 Formwork/Falsework and reinforced concrete structures 1

Falsework is any temporary structure used to support a permanent structure during its erection and until it becomes self-supporting. This definition applies not only to in-situ concrete construction, but also to precast concrete structures, structural steel erection, and even such items as brick arches, indeed, any construction method where the permanent structure may have a period of instability, requiring support in the erection process. Note: Section 5 of the QCS covers use and handling of concrete.

1.5.8.2 Standard solutions Falsework covers an extremely wide range of temporary support methods and BS 5975 recognises that, in simpler and more commonplace situations, e.g. support of floors and beams involving light loadings and low height support (within the range of standard props) standard solutions can most likely be used instead of individual designs.

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Standard solutions are given in B5 5975. However, unless the job falls within the limitations of the particular standard solution, further design will be required.

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1.5.8.3 Causes of failure

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Incorrect estimation of loads to be supported.

(b)

Design error, or loading programme changes after design completed.

(c)

Inadequate detailing and/or execution of points of load transference.

(d)

Inadequate horizontal lacing and diagonal bracing to resist lateral loads.

(e)

Inadequate foundations.

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Within the above scope, it must be recognised that failure often does not result from one specific error or inadequacy. More likely it will be due to an accumulation of errors, not in themselves critical, which combine to erode the factor of safety to the point where failure occurs.

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Whatever category the work falls into, it is generally accepted by competent international authorities that the causes of failure fall into a number of well-defined areas:

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1.5.8.4 Design

The design of temporary works such as falsework comes within the scope of these regulations. Whether the falsework design is provided by standard solutions or by individual design, the parameters on which the design is to be based need to be clearly established. In this respect, it must be recognised that the loads imposed on falsework do not only arise from the permanent structure. Many will occur as a result of method and plant decisions.

2

BS 5975 covers with the preparation and contents of the design brief in detail.

3

The main risks are:

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people falling during erection and striking of formwork and assembly of the steel frame collapse of the formwork

(b)

materials falling while striking the formwork

(c)

manual handling of shutters, reinforcing bars etc

(d)

being struck by the concrete skip

(e)

silica dust and hand-arm vibration from scabbling operations

(f)

awkward postures and working positions for steel fixers

(g)

dermatitis and cement burns from wet concrete.

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(a)

designers should consider the manual handling risks when detailing size and length of the reinforcing bar;

(b)

fixing reinforcement steel in prefabricated sections in factory conditions and craning it into position so that work can be done on benches to reduce the need for bending down. Alternatively, using long-handled tools can reduce the need to bend over

(c)

using formwork systems that have edge protection and access designed in

(d)

minimising the need for scabbling by using retarders; and

(e)

using concrete pumps instead of cranes and skips.

The Contractor is to ensure that: a method statement has been agreed before work starts, and that it is followed.

(b)

guard rails or other suitable barriers to prevent falls are put in place as work progresses.

(c)

workers have safe access to the work -- it is not safe to stand on primary or other open timbers.

(d)

a safe means of access is used. Many formwork systems have purpose-designed fittings to allow access platforms to be fitted and they should be used (see Figure 29).

(e)

climbing up vertical sections of reinforcement or up the outside of column formwork is not permitted. A tower scaffold can provide safe access to columns (see Figure 30).

(f)

equipment is in good order before use. Do not use substitutes for the manufacturer's pins in adjustable props.

(g)

the formwork, falsework and temporary supports are checked, properly tied, footed, braced and supported before loading, and before pouring walls or columns.

(h)

workers are protected from wet concrete (provide gloves and Wellington boots and proper washing facilities) and silica dust (provide respirators or avoid the need to scabble by using a retarder).

(i)

loads are spread as evenly as possible on the temporary structure. Do not place large loads of timber, reinforcing bars or wet concrete in a localised area -- spread loads evenly.

(j)

it is known when back-propping is required and how soon the new structure can be loaded; and there is a planned safe dismantling procedure.

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Many of these risks can be reduced or removed by design and careful planning:

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Figure 29: A formwork system with multipurpose fittings

Figure 30: A tower scaffold provides a safe means of access to the columns

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Construction Site Safety 1.5.9

Explosives

1.5.9.1 Introduction 1

This subsection aims to give general guidance to Site Managers on the acquisition, keeping, transfer, storage, transportation and use of explosives in the construction industry. In addition, it is anticipated that the information will enable Sub Contractor's method statements and risk assessments to be assessed. Further guidance on the use of explosives is provided in BS 5607:1998 "Code of Practice for safe use of explosives in the construction industry". Advice on the explosives used in cartridge operated fixing tools is given in BS 4078 Part 1.

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Note: Section 2, Part 1.5 of the QCS covers explosives.

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Before any work involving explosives is planned and carried out the person responsible for the site, for example the Principal Contractor, must appoint someone with sufficient knowledge and experience to oversee this work. Even when a sub contractor will carry out the blasting the appointed Supervisor must satisfy him or herself that the planning, documents and implementation are satisfactory as this is obviously a high-risk operation. Similarly, the business actually carrying out the work with explosives must ensure that Supervisors and Shot firers are competent to carry out their work. The competence and training of Shot firers is dealt with later in the section.

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1.5.9.3 Preliminary survey

Before any work involving the use of explosives is started, a detailed survey should be made of the site and its adjoining areas. Where earthworks, tunnelling or demolition are involved, relevant information may be obtained from British Standards 6031, 6164 and 6187 respectively.

2

Special attention should be given to the character and structure of the geographical strata to ensure that they are not likely to transmit ground vibration to areas where it is likely to cause damage. The affect on utilities, including underground and over-ground services, should be carefully considered.

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Prior notice of the intention to use explosives should be given to all those who may be affected. For example, the water; gas, electricity and telephone authorities, the police and airports.

Documentation 4

Eplosives may be acquired, or stored only by persons who hold a valid Explosives Certificate. This is usually referred to as the "acquire and keep" certificate. An Explosives Certificate may be issued for both acquisition and storage of explosives or for acquisition only. Certificates permitting acquisitions only should be obtained where it is intended to use explosives on the day they are delivered to site. An Explosive Certificate is not required for the acquisition or storage of cartridge operated tool cartridges which carry the following UN numbers: 0275, 0276, 0323 or 0381.

5

In addition to the explosives certificate the person ordering or taking delivery of explosives must be competent to do so and have received the relevant approvals from the competent authorities.

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Storage Guidance on the methods of storing and types of construction required for a store for explosives may be ontained from the competent authority. In addition, advice may also be obtained from the manufacturer of the explosives which are to be used. The storage facilities will be inspected and therefore it is important that the guidance and advice is complied with.

7

The movement of explosives into and out of the store must be recorded, and there must be a formal procedure for accepting delivery of explosives and for checking that they conform to the contents of the advice note. It is essential to ensure that detonators are stored separately from other explosives. The loss of any explosives must be reported to the police. No person may transfer explosives to another person unless he is satisfied that the transferee has an Explosive Certificate certifying him to be a fit person to acquire explosives. This does not prohibit employers from giving explosives to their employees, but it does mean that a Principle Contractor must check that a Sub-contractor has an Explosives Certificate before providing the Sub-contractor with explosives.

8

Explosives stores must be kept clean and free from grit.

9

Rubber Overshoes must be kept in each store and worn by people who are not wearing rubber soled footwear and have to enter the store. No iron or steel implements should be taken into explosives stores and no naked lights or other means of ignition should be taken within 25m of them.

10

The issuing of explosives should be restricted to persons who have been authorised in writing by the Site Manager.

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Regarding the transport of explosives on public roads, various duties on operators of vehicles include: (a)

the requirement for vehicles to be suitable, having regard to the type of explosives and quantity of explosives carried; quantity limits for various types of explosives are also imposed,

(b)

restrictions on the carriage of loads of mixed explosives,

(c)

the requirement for the marking of vehicles and containers, except where small quantities of certain types of explosives are carried,

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(e)

the requirement to take all reasonable steps to ensure safe and secure carriage,

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the requirement for written, specified information about the load to be kept on the vehicle,

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Vehicle operators must ensure that drivers have received adequate instruction and training on dangers which may arise, action to be taken in an emergency and on their duties. Drivers must attend an approved course, on successful completion of which they will be awarded a Vocational Training Certificate. Drivers must carry these certificates.

13

Finally, where explosives are carried on the public roadway, the safe system of transport must be prepared by a person with training and knowledge of the health and safety implications of carrying explosives. This requirement will normally apply to the supplier who should be organised so that he delivers directly to the explosive store on the day when blasting is taking place.

14

Further transport of explosives on site must be in a vehicle provided solely for this purpose and be under the control of the shot firer. The vehicle should be clean internally and carry a red flag to indicate the presence of explosives. Detonators should be separated from explosives by at least 1m during carriage; explosives which have already been fitted with

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detonators must not be carried in any vehicle. Detonators should be kept in a suitable container, with no metal parts that will come into contact with the detonators; it should be kept locked until access is required. Explosives should be protected from the weather during transit. "No Smoking" restrictions and a ban on the use of CB radios and mobile telephones in the immediate vicinity must be strictly observed. When explosives are being transported on site, only sufficient explosives for the work in hand should be drawn from the explosives store, and the vehicle carrying the explosives should go directly to the shot holes.

16

When explosives are brought on to a site where there is no lawful storage facility, (as outlined under "Documentation"), liaison may be necessary between the explosives engineer making the delivery and site management on such matters as emergency arrangements and the provision of safe parking away from obvious sources of ignition and other dangerous goods.

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Before explosives mixtures are manufactured on site an application for an application for approval is required. In addition, a small amount of record keeping is required.

18

The actual mixing process itself is very simple although the manufacturers advice should be sought as to the provision and use of suitable equipment and the appropriate mixing ratios. Some further guidance on this subject can be found in BS 5607:1998.

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Suitable and sufficient steps must be taken to ensure that nobody is exposed to risk of injury from the use of explosives in construction work. In addition, persons undertaking the drilling of shot holes must be protected from the dangers associated with work at edges from which there is a risk of falling, dust from the drilling process, unguarded dangerous parts of machinery and the rupture of large diameter compressed air hoses. These are normally chained at the coupling to prevent them snaking about in the event of a burst.

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Before any blasting takes place, both audible and visual signalling systems, giving warning of blasting operations, should be established. These must be explained and publicised through the site Induction Training, Site Rules and clearly visible Signs affixed at the entrances to the site. Audible warnings should consist of a series of readily recognisable signals, which have a distinctive sound. Visual signs should take the form of clearly painted notices posted on all access roads and sited outside the danger area. Sentries should be posted with clear instructions as to when they can stop access to the site and when they can allow access.

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1.5.9.4 Shotfiring Competence of shotfirers 1

BS 5607:1998 sets out the training requirements for Shot Firers, these must be adhered to if safety is to be achieved.

General precautions 2

Before explosives are used on any particular site, a written system of work, applicable specifically to that site, should be prepared. The responsibilities of persons with specific duties, such as the Supervisor, Shot firer and Sentries should be detailed in writing. When the system of work is being prepared, consideration should be given to the following matters:

QCS 2014

Section 11: Health and Safety Page 129 Part 1.05: Other hazardous Activities (Regulatory Document) The development of the Blasting Specification.

(b)

The preparation of written Explosives Rules that, that can be easily understood by the workforce.

(c)

The need to post sentries and visual warning signs around the areas likely to be affected by the blast.

(d)

The need to ensure that the danger area is clear of all personnel immediately before firing occurs.

(e)

The need to have an audible means of giving warning that a shot is about to be fired and to sound the all clear.

(f)

The need to notify the police, the general public, or occupiers of adjacent properties of shot firing times.

(g)

The system of work should always emphasise the following general precautions: -

(h)

The importance of the shot firer satisfying himself that the danger zone is clear before firing a round and that, after firing, a complete check is made to ensure that no misfires or other hazards exist.

(i)

The banning of cigarettes, matches and naked lights within a radius of 10m from explosives and detonators. This is a legal requirement in quarries.

(j)

The prohibition of drilling into old sockets, as these may contain explosives or detonators, which may be detonated by a drill.

(k)

The use of only wooden rods for charging and stemming shot holes.

(l)

Shot holes should be minimum of 3mm larger than the cartridge diameter for normal holes and 13mm for deep holes. Before charging, shot holes should be proved clear by inserting a stemming rod to the bottom.

(m)

Cartridges should be inserted into the holes one at a time, and stemming should be completed only with suitable material, e.g. sand, clay, gypsum, etc.

(n)

As high explosives are initiated by the application of a powerful localised shock, exposure to any deliberate, accidental or random compressive action must be prevented.

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Electrical shotfiring

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Electrical detonation allows shot firing from a remote location and also controls the precise instant of firing, thus increasing the safety factor. In addition, the use of timing delay detonators in the firing circuit significantly reduces the levels of vibration. The method is generally used as a number of shot holes can be connected together and fired as a group.

4

The making up of primed charges should normally be undertaken by the shot firer immediately prior to charging. A non-ferrous pricker must be used for piercing the explosive, making it ready to receive the detonator. On no account must any other form of pricker be used. Detonators must be firmly secured to the primer cartridge in such a manner as to prevent the detonator or wire becoming detached or damaged. The ends of the detonator leads must remain twisted together until all holes have been charged.

5

Where it is not possible to achieve safe conditions at the charging place (e.g. in very wet conditions), it will be necessary for priming explosives to be transported to the charging place. Such procedures will require additional careful planning.

6

All rock surfaces, rails, metal objects, cables etc. must be considered as potential sources of stray current and great care must be taken to prevent detonator lead wires coming into contact with them.

7

Good connection of the detonator leads, connecting wire and shot firing cables is essential.

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Before attempting to fire a shot electrically, the shot firer must test the continuity of the circuit with a suitable instrument before he connects the firing cable to the exploder. This testing procedure must be carried out only after all persons have left the shot firing area and the shot firer himself is in the firing position. The removable handle of the exploder must be kept in the shot firer's possession at all times. The handle may be inserted into the exploder immediately prior to firing only and it must be withdrawn immediately after firing. After the shot has been fired, the appointed shot firer must inspect the area of the blast for misfires, or any other sort of danger, before allowing people to return to the area.

9

When detonating near overhead electrical cables, consultation should take place with the electricity supplier, who may be able to make the cables dead for a limited period. Advice should be sought on the minimum distance permissible between an explosive charge and an overhead electric cable. The following distances may be used for guidance: 11-70kV

20m

(b)

132-400kV

61m

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8

Premature ignition of electric detonators by electromagnetic energy from radar, radio and television transmitters is a possibility which should always be considered and this is why CB radios and mobile telephones should be excluded from the shot-firing area.

11

Beamed transmitters, such as navigational aids and military installations often operate at a high power and, if the station is in direct line of sight of blasting operations, adequate investigations should be made and suitable precautions taken. Commercial radio transmitters may be potentially dangerous as the wavelengths used are often similar to the overall length of the proposed blasting circuit.

12

Television transmitters are not generally a hazard as they transmit horizontal beams from a high mast, but portable walkie-talkie equipment and unmodified car transmitters up to 5W in output should not be taken within 10m of any blasting operation. Modified car transmitters and CB radio transmitters, which may have been illegally modified to increase their power, are potentially dangerous at much larger distances. Users of electric detonators are recommended to discuss this matter with the manufacturer or supplier of their detonators. In any event, the use of CB radios on sites should be banned by notices placed at all entry points.

13

Electrical means of detonations must not be used during storm conditions when there is thunder and lightning in the vicinity. The possibility of uncontrolled detonation should not necessarily prevent the use of this type of firing method. However, the manufacture/supplier must be consulted to ensure that the firing initiation system is appropriate for the circumstances.

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Detonating cord 14

Detonating cord is a very reliable initiator and its use for firing large groups of charges is free from some of the drawbacks of electrical shot firing such as current leakage problems. However, detonating cord must be protected from rain and ground water as moisture penetration can cause transmission failures. Covering the ends of the cord with waterproof tape may prove effective, but if conditions are very wet, the use of sealing compounds may be necessary. When laying out detonating cord, it is essential to ensure that branch lines do not cross over the main line, as on detonation a branch line may be severed, resulting in a misfire in the shot hole which it is serving. Detonating cord must not be kinked or knotted, otherwise transmission failure may occur. In use, detonating cord passes down the outside of explosive cartridges to the bottom of the shot hole, so care should be exercised when using a stemming rod otherwise the cord may be broken or damaged. Breakage of cord can also result from excessive tensioning, repeated stretching or the imposition of a sustained load. The power core of detonating fuse is liable to detonate, with the risk of serious injury if subjected to impact or shock. Detonating cord should always be protected from friction and

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heat. Shotfiring using safety fuse In surface blasting applications, the use of safety fuse is virtually restricted to single shotfiring operations such as the "popping" of large boulders. This is because accurate timing cannot be achieved and, if used in a group, an erratic timing sequence would result. However, safety fuse may be used where it is considered dangerous to use electrical detonation due to the presence of nearby electrical hazards.

16

Safety fuse is used in conjunction with a plain detonator. The fuse is inserted into the open end of the detonator, which is secured by crimping on to the fuse. The correct crimping tool must be used. A primed charge is made up by inserting the detonator into a hole prepared in the primer cartridge.

17

The length of safety fuse must allow the shot firer and assistants ample time to walk to a place of safety after ignition. No single shots should be fired by fuse less than 1m in length, nor any shot in a round be fired by fuse less than 1.25m in length. A shot firer must not attempt to ignite more than six individual shots in a round. Only fuse lighters, specifically designed for the purpose, should be used.

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The following additional precautions are relevant to tunnelling and shaft sinking:

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Storage

Where it is necessary to store explosives in the tunnel between blasting operations, proper reserve stations should be excavated and fitted with steel doors. Reserve stations should not be nearer than 300m to the tunnel face. Reserve stations are not authorised storage places. Any explosives remaining in them at the end of a shift should be returned to the licensed explosives store or magazine.

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1.5.9.5 Tunnelling and shaft sinking

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Explosives should be transported to the tunnel face in a clearly marked special mine car, lined with timber and having top or side lids fitted with padlocks. Explosives must not be carried on the driving locomotive itself.

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Drilling and charging 4

Drilling patterns should adhere to the agreed profile. All shot holes should terminate at the same vertical plane, except those drilled for cut shots and easers. If the presence of gas is suspected, tests should be made at the mouth of each shot hole, and within 9m of the face prior to charging. Plastic water stemming, water stemming under pressure, or water gel capsules reduce dust and toxic fumes. If possible, explosives with non-toxic characteristics should be used in tunnelling operations.

5

No explosives or blasting accessories should be conveyed to the face until all drilling operations for the round to be charged have been completed.

Sockets left after blasting 6

The most common cause of severe accidents with explosives in tunnelling results from drilling into sockets containing explosives which were not fired in the previous round. It is essential that drilling into such sockets be avoided.

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Section 11: Health and Safety Page 132 Part 1.05: Other hazardous Activities (Regulatory Document)

Electrical faults and hazards 7

Short-circuiting or current leakage from the circuit to earth is more likely to occur when conditions are wet. Ground water from rock fissures often contains mineral salts, which greatly increase its electrical conductivity. Bare wire connections should not be allowed to dangle in water, nor be allowed to hang against a wet rock face.

8

The risk of premature explosion during electric storms is particularly high in tunnelling work. Dangerous static charges can also build up in compressed air equipment, and it is essential that such equipment should be positively earthed. Another hazard is from portable electric lighting cables; such lights should be removed to at least 9m from the face when preparing or charging blasts. Power to drilling and other equipment should also be switched off or completely isolated, when explosives and detonators are in the vicinity.

Serious shock and flash wave effects can be experienced in tunnel blasting work. In straight tunnel work, the minimum distance from the face to the firing point should be at least 300m. A shorter distance may be acceptable where a cross- tunnel or special refuge provides protection but, in such cases, the dangers from ricochets and fumes must be assessed. Before the all clear is given, the shot firer must ensure that all fume has been adequately diluted or has dispersed. This may initially require gas testing with a stain tube detector or some other suitable testing device to establish the timescale at which fume dilution is such that it is safe for the workforce to return to the face. This testing must be repeating as the work progresses and written records kept to ensure that the re-entry timescales are appropriate. Miners are likely to be working on a bonus system and therefore re-entry may require a strong level of control!

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All shot-firing operations are likely to leave fragments of loose material on the face. These can fall and have been known to cause injury and in some cases, where inclined, sloping rock beds in tunnelling are concerned, death. These must therefore be removed or stablised before any work involving an approach to the face, where there is a risk from falling material, can begin. A cherry picker will provide a useful platform for scaling down and the Shot firer should not allow anyone to approach a face until he is satisfied that the face has been inspected and loose material cleared.

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1.5.9.6 Misfires Electrical shotfiring misfires 1

If an electrically initiated charge fails to fire, the shot firer must follow the following procedure: (a)

Remove the handle from the shot firing apparatus.

(b)

Disconnect the cable from the shot firing apparatus.

(c)

After waiting 5 minutes, examine the shot firing cable and connections for any defect. If one is found, it must be remedied.

(d)

Return to the firing point and make a further attempt to fire the shot.

(e)

If this second attempt to fire is unsuccessful, the circuit should be split in half and each half should be tested in turn to locate the fault.

(f)

The faulty half should then be split in two and again each half should be tested separately by continuing this process, the fault can be located. All such tests must be affected from the firing shelter.

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(g)

Once the faulty detonator has been located, the remainder of the circuit should be connected in series, omitting the faulty detonator. The leading wires of the faulty detonator should be connected by string to a suitable marker to facilitate recovery of the primer cartridge after firing.

(h)

After re-testing, the modified circuit should be fired. Dislodged material should then be searched for any undetonated cartridges.

(i)

If material in the vicinity of the misfired hole is not dislodged by the blast, recovery of the misfired charge may be attempted by firing shot relieving holes at a distance of at least 300mm from the misfired charge. A similar procedure should be adopted if a misfire is found after a blast has been fired.

(j)

Where misfires are encountered after firing a round, the face or structure is likely to be fractured and weakened. Any dangerous conditions must be rectified before the shot firer deals with the misfire.

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In the event of a misfire, the shotfirer must adopt the following procedure:-

Ensure that no one approaches the shot firing area until at least 30 minutes have elapsed.

(b)

At the expiration of the 30-minute period, inspect the safety detonation fuse and, if the cause of the misfire is clearly evident, rectify the fault and make a second attempt to fire the round.

(c)

If this second attempt to fire is unsuccessful, the shot firer may adopt one of the following procedures: -

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Remove the stemming by compressed air, or water, using a non-ferrous or rubber blowpipe. Insert a primer cartridge into the hole, re-stem and fire, or

(ii)

Drill a relieving hole at least 300mm away from the misfired charge, taking care to ensure that this hole is drilled parallel to the misfired hole. Load and fire the relieving hole in the normal way.

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After either of these procedures has been followed, a most careful search must be made of the debris for detonators and unexploded explosives.

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Records of misfires

Records should be kept of any misfires.

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1.5.9.7 Disposal of Explosives 1

Extreme care must be taken in the disposal of unwanted, or apparently deteriorated explosives. In general, explosives should be returned to manufacturers or suppliers although substances such as gelignite can be burned Manufacturers guidance is essential in this respect and the persons involved should avoid the fumes as they produce severe headaches. Guidance is also contained in booklet HS (G) 36 Disposal of explosives waste and the decontamination of explosives plant.

2

All empty explosive boxes must be thoroughly examined by the shot firer, taken to a safe place, at least 50m from the store or magazine, and burned.

END OF DOCUMENT

QCS 2014

Section 11: Health and Safety Part 1.06: Human Factors (Regulatory Document)

Page 1

REGULATORY DOCUMENT........................................................................... 1

1.6

HUMAN FACTORS ......................................................................................... 1

1.6.1

Accident Prevention and Control...................................................................... 4

1.6.2

Accident Reporting and Investigation (RIDDOR) ........................................... 22

1.6.3

Behavioural Safety ......................................................................................... 43

1.6.4

Drugs and Alcohol Misuse ............................................................................. 57

1.6.5

Safety Critical Communication ....................................................................... 72

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Section 11: Health and Safety Part 1.06: Human Factors (Regulatory Document)

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FORWARD

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This Section of the Regulatory Document (RD) was produced as a project deliverable under Ministry of Municipality and Urban Planning Contract Number P2009/3, entitled “Consultancy Services for the Preparation of Codes and Standards for Safety and Accident Prevention on Construction Sites”. During the latter stages of the project, the Committee responsible for the administration of the project decided that the RD and the associated Safety and Accident Prevention Management/Administration Systems (SAMAS) would be best delivered to stakeholders via the portal provided by the Qatar Construction Standards (QCS). The QCS includes references and certain sections which address occupational health and safety. To ensure that that users of the RD/SAMAS are fully aware of the where occupational health and safety issues are addressed in the QCS, the following table summarises where potential overlaps may occur. For consistency, it is recommended that in matters relating to occupational health and safety reference is made first to the RD/SAMAS. For the purpose of clarity, however, references are made in the relevant section of the RD/SAMAS to their comparable sections in the QCS and vice versa.

QCS 2014

Section 11: Health and Safety Part 1.06: Human Factors (Regulatory Document)

Page 3

Sr. No

QCS 2014 Section No.

Part No.

Part Name

1

1

7

Submittals

8

7.5.2

Health and Safety Organization Chart

2

1

7

Submittals

9

7.6.1

Health and Safety Plan

3

1

10

Health and Safety

All

All

All

4

1

11

Engineer's Site Facilities

10

11.4.6

Safety Equipment and Clothing

5

1

14

Temporary Works and Equipment

3

14.4

Test Certificates for Cranes and Lifting Tackle

6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1

General Requirements for Piling Work

7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

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42

Item Name

.

Page No. Item No.

Safety and Management

4.9.1.13 Protection of Testing Equipment 1.6

Temporary Fencing

15

7.8.13

Safety Requirements

Works in Relation to Services

4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

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4&5

8

1

17

8

8

Painting and Protective Coatings

6

8.1.9

Safety

18

8

9

Trenchless Pipeline Construction

7

9.2.5

Safety Requirements

19

8

10

Pipeline Cleaning and Inspection Survey

4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

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Sewer Rehabilitation

9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16

Noise Levels and Vibration

1

23

m

11

19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1

General Provisions for electrical Installation

7&8

1.1.11

Fire and Safety Precautions

25

21

1

General Provisions for electrical Installation

14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5

Fire Resistance Period

28

29

3

Geotechnical Specifications

4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4

Safety Measures and Systems

32

29

7

Concrete Structures

6

7.1.10

Safety Railing

QCS 2014

Section 11: Health and Safety Part 1.06: Human Factors (Regulatory Document)

Page 4

Construction Site Safety 1.6.1

Accident Prevention and Control

1.6.1.1 Key points The construction industry consistently accounts for a disproportionately high number of fatalities and major accidents.

2

Everyone on site has their part to play in accident prevention.

3

Accident prevention has to be actively managed; a good safety record will not 'just happen'.

4

Reported details of accidents show that in the vast majority of cases the accident could easily have been prevented by taking simple precautions.

5

You may have no influence over these decisions but find that you need to challenge the health and safety implications that arise as a consequence of them.

6

The true 'cost of an accident' encompasses many considerations and goes way beyond the financial implications.

7

Statistics show that new starters on site, and those at both ends of the age spectrum, are the most prone to accidents.

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1.6.1.2 Definitions

There are many interpretations of the words 'Accident/Hazard/Risk', but it is generally agreed that the following definitions apply:

2

Accident is an unplanned, unscheduled, unwanted event or 'occurrence', or any undesired circumstance which may result in injury to persons and damage to property. The injured person may not be an employee and property may not belong to a Contractor.

3

Hazard is the potential to cause harm, including ill health and injury; damage to property, plant machinery or environment; production losses or liabilities.

4

Risk is the likelihood that a specified undesired event will occur due to the realisation of a hazard by or during work activities or by products created by work activities.

5

An alternative word that is sometimes used for an accident is 'incident'. The main difference in the use of this word is that an incident is something that happened which may or may not have resulted in an injury or damage.

6

This diagram is a modified version of the Bird's triangle. Its aim is to simply demonstrate the approximate relationships between the different 'levels' of accident that occur. The triangle shows that for each fatality there will be several major injuries, a higher number of 'over-3-day' accidents and so on. In theory, if the number of minor accidents can be reduced, the base of the triangle will be shortened thereby having a beneficial effect at all levels with possibly no fatalities.

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Section 11: Health and Safety Part 1.06: Human Factors (Regulatory Document)

The problem with this theory, and most of the other accident reduction models, is that frequently an incident can occur which results in no injury or even particular loss. However, the same incident under a slightly different set of circumstances could be a fatal accident. This makes accident prevention more difficult, particularly if the incidents go unreported.

1.6.1.3 The cost of accidents

(b)

loss of earnings

(c)

extra expense

(d)

continuing disability

(e)

incapacity for the same job

(f)

incapacity for activities outside the job

(g)

consequent effect on dependants and friends.

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Cost to people directly responsible:

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pain and suffering

worry and stress

(b)

recriminations, guilt

(c)

extra work, for example, reports, training and recruitment

(d)

loss of credibility.

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Cost to the Contractor:

working time lost by victim

(b)

time lost by other employees out of sympathy, curiosity, discussion

(c)

time lost by supervisors and others investigating the accident

(d)

possible damage to machines or materials

(e)

idle time (replan, repair and reinstate job)

(f)

rise in insurance costs prosecution under Qatar Law

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Cost to the victim:

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Page 5

(h)

damage to reputation

(i)

possible failure to obtain work.

Cost to the working group: (a)

shock

(b)

personal grief

(c)

low morale

(d)

effects on production.

Cost to the State of Qatar: (a)

in social and economic terms, accidents are an unwanted expense

(b)

hundreds of thousands of person-day production lost each year

(c)

hundreds of hospital beds occupied

(d)

financial sums paid in death benefits

QCS 2014

(e)

Section 11: Health and Safety Part 1.06: Human Factors (Regulatory Document)

Page 6

countless scores of lives changed for the worse.

6

Whilst there can be no complete end cost figure, the size of the problem can be seen to be huge. Therefore anything that helps to reduce the number of accidents must benefit both the nation and the individuals concerned.

7

The consequences of each accident are considered from different standpoints: vocational - future job prospects

(b)

financial - loss of earnings

(c)

social - standard-of-life issue

(d)

behavioural - reliance on medication, inability to concentrate, inability to sleep, illtemper, and so on

(e)

psychological - mood swings, loss of memory, emotional instability and guilt.

.

(a)

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1.6.1.4 Causes of accidents

Examining accident details will help to establish common factors and trends, revealing any weaknesses in a Contractors health and safety management system.

2

Accidents can be caused by the unsafe acts and attitudes of people at work, which result in unsafe conditions being created. They are also caused by a lack of foresight or planning, which may be a failure to set up a safe system of work, or failure to appreciate the results of risk assessments, COSHH assessments or other similar activities.

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It is impossible to list all the different types of unsafe acts and unsafe conditions which are found to exist in the Qatar construction industry. However, it is worth recording those which have been the most frequent known causes of accidents on construction sites:

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and these accidents often result in

(a)

lack of planning

(b)

lack of management control and supervision

(c)

lack of knowledge of good safety techniques

(d)

lack of safety awareness

(e)

unsafe methods of working at height, including the use of working platforms, scaffolds, alloy towers, ladders and trestles

(f)

incorrect use of machinery, excavators, loaders, diggers, piling rigs, pneumatic drills

(g)

failure to segregate operating plant and pedestrians

(h)

failure to inspect and maintain all types of machinery, including ropes and hoists, lifting gear

(i)

incorrect use of tools and equipment, hand tools, power tools

(j)

use of faulty equipment with improvised repairs and modification of ladders, hand and power tools, trestles, ladders, fittings, fixings

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Section 11: Health and Safety Part 1.06: Human Factors (Regulatory Document)

Page 7

unsafe manual handling, lifting, loading, moving, stacking, storing

(l)

working at unsafe speeds on machines or with power tools, lifts, hoists

(m)

overloading of working places, scaffolds, false work, hoists, ropes, gin wheels, machines, vehicles, roofs

(n)

removal of guards from scaffolds, working platforms, machinery and excavations

(o)

failure to use protective safety

(p)

equipment, helmets, goggles, gloves, masks, clothing, footwear

(q)

unauthorised operation of tools, machinery, vehicles, equipment

(r)

ignoring or failure to use safety signals, signs and warning devices

(s)

ignoring established rules, safe procedures or work methods

(t)

throwing or accidentally dropping objects from heights

(u)

leaving nails or other objects protruding from timber

(v)

spillage of grease or oil

(w)

smoking, creating a naked flame or sparks in an area where flammable materials are stored or are in use

(x)

operating mechanical plant and vehicles at unsafe speeds, disregarding clearances necessary whilst manoeuvring

(y)

failing to adapt and adhere to established safe systems of work and procedures

(z)

illegal methods of access or egress to the workplace

(aa)

unauthorised interference with and misuse of plant and machinery

(bb)

carrying out work on moving parts with guards removed or safety devices inoperative

(cc)

riding on mechanical plant or vehicles in unauthorised and insecure places

(dd)

slippery or muddy conditions underfoot

(ee)

not obeying COSHH and risk assessments

(ff)

failure to warn others within the workplace

(gg)

failure to observe statutory or company or site requirements

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distracting people at work indulging in horseplay

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(hh)

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(k)

(jj)

failure to report faulty or unsafe equipment, or dangerous occurrences and incidents

(kk)

creating unstable structures.

1.6.1.5 Duties of the Contractors 1

The scope of Contractors responsibilities under this Regulatory Document is both wide and demanding. Some of these duties are detailed below.

1.6.1.6 The Health and Safety at Work 2

Contractor’s duties include: (a)

It shall be the duty of every Contractor to ensure, so far as is reasonably practicable, the health, safety and welfare at work of all his employees.

(b)

the provision and maintenance of plant and systems of work that are, so far as is reasonably practicable, safe and without risks to health;

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arrangements for ensuring, so far as is reasonably practicable, safety and absence of risks to health in connection with the use, handling, storage and transport of articles and substances;

(d)

the provision of such information, instruction, training and supervision as is necessary to ensure, so far as is reasonably practicable, the health and safety at work of his employees;

(e)

so far as is reasonably practicable as regards any place of work under the Contractors control, the maintenance of it in a condition that is safe and without risks to health and the provision and maintenance of means of access to and egress from it that are safe and without such risks;

(f)

the provision and maintenance of a working environment for his employees that is, so far as is reasonably practicable, safe without risks to health, and adequate as regards facilities and arrangements for their welfare at work.

(g)

It shall be the duty of every Contractor to conduct his undertaking in such a way as to ensure, so far as is reasonably practicable, that persons not in his employment who may be affected are not thereby exposed to risks to their health or safety.

1.6.1.7 The Management of Health and Safety at Work

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(c)

These Regulations require that all Contractors carry out a risk assessment of all work operations and workplaces.

2

Furthermore, the Contractors must:

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put into operation whatever preventative and protective measures are necessary, and take effective steps to monitor these measures

(b)

provide information both to employees and those not employed by him as to the risks to health and safety generated by his operations

(c)

provide adequate training:

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(a)

upon recruitment

(ii)

when new processes are introduced

(iii)

when new work equipment is installed

(iv)

when new systems of work are introduced.

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(i)

Refresher training should be carried out during working hours.

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1.6.1.8 Personal Protective Equipment 1

Every Contractor must: (a)

ensure that PPE is available, is compatible with and appropriate for the risk

(b)

carry out assessments for risks to health and safety

(c)

carry out periodic reviews of those assessments

(d)

ensure that any PPE is maintained and properly stored when not in use

(e)

give adequate training, information and instruction

(f)

take steps to ensure that any PPE supplied is properly used

(g)

provide any necessary PPE free of charge.

1.6.1.9 Provision and Use of Work Equipment 1

Contractors must ensure that:

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the work equipment provided is suitable for the purpose for which it is to be used

(b)

it is only used for the purpose it is intended

(c)

it is maintained in good working order

(d)

equipment logs are maintained, where necessary

(e)

the use of equipment is restricted to those so designated

(f)

repairs are only carried out by trained and competent personnel

(g)

any necessary maintenance or inspections recommended by the manufacturer are carried out

(h)

persons who are required to operate the equipment have received adequate information and training

(i)

safe systems of work are implemented and followed

(j)

maintenance can be done safely

(k)

controls are fitted to the machine.

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1.6.1.10 Lifting Operations and Lifting Equipment

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All Contractors must ensure that:

all lifting operations are properly planned by a competent person, are appropriately supervised and undertaken in a safe manner

(b)

each selected item of lifting equipment is suitable for the intended purpose, and is of adequate strength and stability for each load

(c)

the lifting equipment is positioned and installed to minimise the risk of:

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the equipment or load striking personnel

(ii)

the load drifting, falling or being unintentionally released

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(a)

an examination schedule is drawn up by a competent person and that all lifting equipment is thoroughly examined: before being used for the first time, following installation or assembly at a new location

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every six months for lifting accessories (abseil ropes/harnesses, chains, slings, and so on) and equipment used to lift people; or

(iii)

every 12 months for other lifting equipment

(iv)

after any activity or event liable to jeopardise its integrity

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(ii)

(e) 2

suitable equipment is installed to prevent anyone falling down a hoistway or shaft.

If the equipment is to be used for lifting people, the Contractors must ensure that: (a)

people cannot be crushed, trapped, struck or fall from the carrier

(b)

the equipment has devices to prevent a carrier from falling

(c)

if a person becomes trapped in a carrier, they can be freed.

1.6.1.11 Manual Handling Operations 3

Every Contractor must: (a)

ensure that employees avoid risks to health and safety when manual handling

(b)

make an assessment of all lifting operations

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(c)

take steps to eliminate injuries

(d)

give information with regard to weights and centres of gravity of items to be handled.

1.6.1.12 Workplace Disability Awareness 1

Where people with a disability are employed on site, even, for example, administrative staff in site offices or staff in catering facilities, this is a part of the accident prevention process Contractors may have to consider the appropriate safety management steps to be taken to ensure the safety of employees who have a disability, based upon the findings of a risk assessment.

2

Examples of such steps might be: the provision of a disabled toilet

(b)

Providing assistance for employees with hearing difficulties who may not be aware of alarms

(c)

ensuring the effectiveness of site induction for those who have hearing problems or learning difficulties

(d)

considering the needs of people with physical disabilities with regard to access to site offices and other areas

(e)

the provision of appropriate evacuation equipment for evacuating people with physical disabilities from site offices and other areas

(f)

emergency escape routes that can be used by people with disabilities and, where appropriate, those assisting them.

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1.6.1.13 Duties of employees

Responsibilities of employees as follows.

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It shall be the duty of every employee while at work:

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to take reasonable care for the health and safety of himself and of other persons who may be affected by his acts or omissions at work: and

(b)

as regards any duty or requirement imposed on his Contractors or any other person by or under any of the relevant statutory provisions, to co-operate with him so far as is necessary to enable that duty or requirement to be performed or complied with.

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No person shall intentionally or recklessly interfere with or misuse anything provided in the interests of health, safety or welfare in pursuance of any of the relevant statutory provisions.

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1.6.1.14 Manual Handling Operations 1

All employees must make full and safe use of systems of work implemented by their Contractors.

1.6.1.15 Personal Protective Equipment 1

Employees must report any loss of, or any defect in, personal protective equipment.

1.6.1.16 Control of Substances Hazardous to Health 1

Employees must: (a)

make full and proper use of any control measure put in place to prevent harmful exposure to a substance hazard to health

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report the fact to the Contractors if the control measure is thought to be defective.

1.6.1.17 Work at Height 1

Employees must: (a)

report to the Contractors (or supervisor) any work activity or defect which is thought could endanger the safety of anyone who is working at height

(b)

use any work equipment (including safety devices) provided for safe working at height in accordance with any training and instructions provided.

1.6.1.18 Planning for health and safety Despite the effort made by the majority to fulfil their legal, moral and social obligations, difficulties are often encountered in human behaviour which require time and tolerance before acceptable safety standards are achieved. It is essential that careful consideration is given to pre-planning, communication, training, supervision and the dissemination of information, if safe systems and places of work are to be developed and maintained.

2

All of the following measures can make a significant contribution towards the prevention of accidents through the implementation of safe systems of work and procedures:

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Allowing enough money and time to do the work safely.

(b)

Adequate protection and guarding of working places, platforms, machinery, tools, plant and equipment.

(c)

Implementation of an adequate system for the maintenance and repair of plant, equipment and tools.

(d)

Provision of appropriate training, instruction and information at all levels, including safety training.

(e)

Provision of adequate supervision and control.

(f)

Displaying the appropriate notices and warning signs.

(g)

Planning, siting and/or stacking materials and equipment to allow safe access or egress of site plant, vehicles and equipment.

(h)

Pre-planning and organisation of site layout which will provide maximum efficiency, safety and progression of the work sequences and operations.

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The provision of adequate resources and equipment to protect and maintain the health and welfare of all personnel.

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(a)

(j)

Producing, declaring, maintaining and supporting a safety policy, updating as appropriate to accommodate advancement and development.

(k)

Bringing about and maintaining an awareness of, and compliance with, all safety legislation and information relating to systems and procedures of work.

1.6.1.19 Factors likely to affect safety at work 1

Safety at work will be affected by: (a)

human and personal factors

(b)

job factors

(c)

environmental factors.

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1.6.1.20 Human and personal factors 1

Attitudes of people at work often play an important part in the prevention of accidents, and conversely, a wrong attitude can cause accidents to happen.

2

Attitudes differ depending on the person, for example their: age

(b)

general health

(c)

physique and ability

(d)

disabilities, if any

(e)

senses of smell, sight, hearing, touch and, sometimes, taste

(f)

natural dexterity, agility

(g)

education and qualifications

(h)

training and skills

(i)

home and social life

(j)

status at home and work

(k)

position in peer group.

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SAFE ATTITUDES

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= SAFE ACTIONS

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= SAFE CONDITIONS

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1.6.1.21 Job factors

Every work activity has a degree of inherent hazard. Building and construction sites can be particularly hazardous and demand the co-ordination of a large number of trades, skills and activities at any one time.

2

Particular attention should be given to: (a)

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(b)

adequacy, time and resources to do the job

(c)

provision of tools and equipment which are safe to use and properly maintained

(d)

implementation of safe systems of work

(e)

personnel who are unfamiliar with established safe systems of work and practices

(f)

personnel who are new to a specific worksite or unfamiliar with a new working environment

(g)

those lacking induction training and/or experience

(h)

the provision of adequate training, information and supervision

(i)

balanced workload

(j)

fatigue and boredom

(k)

the nature of the activity.

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the adequacy of time and resources to plan the job

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1.6.1.22 Environmental factors 1

The majority of people do not work in isolation. The attitudes of others in a working group, for example, managers, supervisors, safety advisors, may help to prevent accidents.

2

The following details should also be considered: the accident record of the firm, site and working group

(b)

the interrelationship of people within the group

(c)

information and communication processing methods

(d)

weather conditions - hot, cold, wet, windy

(e)

working at heights, in confined spaces or underground

(f)

working conditions - noise, dust, light, ventilation

(g)

health and welfare facilities.

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Types of hazard include: obvious dangers

(b)

potentially dangerous situations, often resulting from late changes to planned activities, forced by unforeseen circumstances

(c)

operational hazards, including high risk activities and operations creating health hazards or risk of injury.

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1.6.1.23 Hazards

Examples of dangerous conditions which may exist at the workplace include: failure to comply with safe systems of work

(b)

the presence of highly flammable material and other fire hazards

(c)

dangerous materials - acidic, radioactive, corrosive and gaseous

(d)

insecurely stacked, slung, lifted and transported loads

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unsafe machinery, equipment and tools

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1.6.1.24 Obvious dangers

(f)

unsafe working area due to weather conditions

(g)

unsafe electrical, dust and gaseous conditions.

1.6.1.25 Potentially dangerous situations 1

Examples of circumstances which might result in an accident: (a)

personnel entering a new workplace for the first time

(b)

personnel uninformed/unaware of emergency procedures

(c)

working with machinery or tools with guards or fences removed

(d)

unauthorised repair to plant and equipment

(e)

adopting incorrect methods of lifting and handling loads

(f)

use of incorrect type of plant, tools or equipment for the work involved

(g)

unauthorised removal of guard-rails, or failure to replace them following removal for access of plant or materials

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inadequate clearance around moving plant or equipment (minimum 500 mm)

(i)

transport of insecure or unstable loads

(j)

dropping tools and materials from a height

(k)

unauthorised improvisation

(l)

failure to wear PPE

(m)

spillage of oil, grease, paint, flammable and corrosive liquids

(n)

working in unstable excavations, without adequate supervision and control

(o)

untidy working places

(p)

congested walkways and areas -creating a tripping hazard

(q)

working at heights or over water without edge and/or personal protection

(r)

inadequate, incorrect or badly placed lighting

(s)

overhead carriage of materials

(t)

uncontrolled release of dangerous gases, steam, compressed air

(u)

unsafe electrical equipment

(v)

buried services and overhead cables.

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1.6.1.26 Operational risks

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(h)

Examples of work that require competence, careful monitoring and/or close supervision are listed below.

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High risk activities:

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demolition

(b)

anything involving tower cranes

(c)

working at heights

(d)

work involving explosives

(e)

excavations

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work in confined spaces

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(h)

operating cranes, lifting equipment and other moving plant

(i)

steel erection or sheet material cladding

(j)

steeple jacking and other rope access activities

(k)

use of chemicals or other substances for which the manufacturer has advised strict control and usage

(l)

work associated with live traffic.

Operations creating health hazards or risk of injury: (a)

work with lasers

(b)

jobs with continual high exposure to noise or vibration

(c)

jobs with continuous elements of the same type of manual handling such as block laying, kerb laying

(d)

work with asbestos and other toxic dusts

(e)

work with hazardous substances

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(f)

work involving radiography

(g)

work involving exposure to extremes of hot or cold.

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Activities which are tedious, repetitive, carried out in extreme climatic conditions, demand long periods of concentration or are physically tiring may require: (a)

careful selection of personnel

(b)

consideration of medical history of personnel involved

(c)

pre-planning and sequence of operation

(d)

frequent shift changing

(e)

use of mechanical handling aids.

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1.6.1.27 The implications of inexperience

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Young persons

In accordance with Labor Law 14 Article (86), a child who has not attained the age of sixteen may not be employed in a workplace of whatsoever nature and shall not be permitted to enter into any place of work such as a construction site.

2

A 'young person', is any person who is between the age of sixteen but has not reached the age of eighteen.

3

Contractors are to ensure that ALL young persons they employ are protected at work from any risk to their health or safety.

4

Before employing a young person, the Contractor must assess the risks to the young person's health and safety arising from the work they are required to do, in accordance with these Regulations. This assessment must take account of a number of factors, such as: the inexperience and immaturity of young persons, and their lack of awareness of risks

(b)

the type of any work equipment involved and the way it is used

(c)

the potential for exposure to physical, biological and chemical agents

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(d)

any health and safety training that is required for young persons.

Having carried out this assessment, Contractors must then determine whether the level of risk has been reduced to as low as is reasonably practicable. There is particular importance placed on avoiding work that:

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(a)

is beyond the young person's physical or psychological capacity

(b)

involves harmful exposure to agents which are toxic or carcinogenic, cause heritable genetic damage or harm to the unborn child or which in any way chronically affect human health

(c)

involves harmful exposure to radiation

(d)

involves the risk of accident, which it may be reasonably assumed cannot be recognised by young people owing to their insufficient attention to safety or lack of experience or training

(e)

involves exposure to physical agents such as extreme cold or heat, noise and vibration.

Consideration to the level of acceptable risk may be given for young persons between the ages of sixteen and eighteen, where the work is necessary for their training, and where they are properly supervised

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New starters 7

New starters on a site and inexperienced persons, of whatever age, have similar problems to those of young workers.

8

They are subjected to a new environment, rules, methods and procedures; under different supervision; working with new colleagues using a variety of tools, equipment and manual effort to produce the work required. The start of their health and safety training is usually an induction into the company that should cover the following:

(b)

company safety policy

(c)

health, welfare facilities, pattern of work, movement of materials, direction of movement, and so on

(d)

warning signals and signs

(e)

special processes, materials, precautions and restrictions

(f)

fire procedures, drills, alarms, escape routes

(g)

reporting hazards

(h)

good housekeeping

(i)

first aid procedures and the reporting of accidents

(j)

safety equipment and clothing

(k)

machinery hazards

(l)

introduction to supervisor, trainer, colleagues

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The need for refresher and continuance training should be reviewed at intervals and carried out as necessary.

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Older workers

(a)

over familiarity with the job general slowing of reactions

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It should be noted that the number of incidents to older workers is typically higher than average. There are various reasons which have been suggested, such as:

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responsibility of management and supervision

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(a)

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(c)

general loss of strength and flexibility

(d)

pre-existing damage to body and systems

(e)

age-related degeneration of hearing and eyesight

What is also noteworthy is that when an older person is injured, often the recovery time is longer, because the injury is more severe than it would be for a younger person. The classic example is a fall from height. A young person may well have the speed and strength to avoid the fall, and if they do fall they often seem to land better and do less damage. With the older person, the fall seems more inevitable, the landing harder and the recovery time longer.

1.6.1.28 Site security 12

Contractors must take all reasonable and practical steps to ensure that sites are secure, for example by: (a)

providing a perimeter fence not less than 2 metres high, either close-boarded or meshed (mesh not exceeding 30 mm)

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(b)

ensuring that the site access is gated and locked when the site is unoccupied

(c)

maintaining reasonable surveillance when the site is open

(d)

ensuring materials are not stacked dangerously near fences

(e)

displaying suitable warning notices

(f)

guarding or protect obvious hazards

(g)

regularly inspecting perimeter fencing, especially for holes near the bottom or other damage through which children might gain access.

Where complete fencing of the site is impractical: guard or cover all excavations and holes where there is a danger of any person or any materials falling in. And, if left open or unattended, fence at every accessible part with a barrier, preferably of chain link fencing, not less than 2 metres in height

(b)

effectively immobilise vehicles and plant

(c)

stack materials to prevent any possible displacement and use racking where possible. This particularly applies to manhole rings, large diameter concrete pipes and cable drums, all of which could roll and crush a child

(d)

lock off electricity supplies or switch off at isolators in locked enclosures or the building

(e)

isolate gas supplies, keep cylinders in a locked enclosure

(f)

keep all tools and harmful chemicals in a locked enclosure, when the site is unoccupied

(g)

for ladders to elevated positions; block off the first 2 metres and chain all loose ladders or lock them in enclosures.

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1.6.1.29 Accident prevention

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Supervision and control

The accident trend can be strongly influenced by providing adequate training and supervision to control the worker, the machine or the equipment and the working environment.

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Accident prevention is the control of these factors The worker 2

It is essential to ensure that the worker: (a)

is adequately trained and informed of the activities they are expected to do

(b)

is aware of all the hazards in any activity they are expected to do

(c)

is competent to do the work or is under adequate suitably qualified supervision

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(d)

adopts a safe system of work

(e)

uses the protection provided

(f)

is aware of accident and emergency procedures

(g)

is aware of the company's health and safety policy in addition to rules applicable to the work.

The working environment 3

This applies to all areas of the site including workshop, stores, offices, depot and welfare facilities.

4

Regular checks are essential to ensure: floors are clean and level, not slippery, and free from debris

(b)

stairs, gangways and working platforms are adequately guarded and maintained

(c)

openings, edges and holes are adequately protected

(d)

projecting objects or obstacles are protected and guarded

(e)

adequate lighting is provided at workplaces

(f)

materials and equipment are stacked or stored correctly

(g)

approved warning signs are displayed where required or where hazards exist

(h)

there is adequate ventilation, protection and control when working in confined spaces

(i)

there are established systems of waste disposal

(j)

passages and escape routes are clearly defined, and marked KEEP CLEAR

(k)

there is provision and maintenance of adequate welfare facilities

(l)

best possible standards in working conditions are provided

(m)

safe systems of work are maintained

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(a)

there is adequate fire-fighting equipment and extinguishers, which are properly sited



an adequate level of security is established and maintained to prevent unauthorised visitors.

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Equipment and machines

Ensure the following procedures and practices are observed:

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(a)

regular inspections by trained, competent persons

(b)

no defective equipment is used

(c)

defects are properly rectified

(d)

adequate servicing and maintenance

(e)

records and reports maintained

(f)

all moving parts adequately guarded or protected

(g)

manufacturers' literature and instructions available for operatives

(h)

proper handling, lifting and slinging of equipment

(i)

equipment and machines adequately secured when in use and parked

(j)

hand tools inspected and maintained.

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Near-miss reporting 6

The importance of learning from experience cannot be overstated. It is an essential element of accident prevention. A near-miss is an incident which had the potential to result in personal injury and/or damage to the structure under construction, plant and equipment or the environment. Contractors will decide on their criteria for categorising an incident as a near miss.

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The details of all near misses must be accurately and honestly reported to enable the circumstances to be investigated and measures put in place to prevent a recurrence. In many cases, the only person able to give a full and accurate account of what happened will be the person who 'got it wrong'.

8

To achieve an effective reporting system, the workforce must: trust that management will treat the incident fairly and objectively

(b)

be sufficiently trained in risk awareness to appreciate that a near miss has occurred. Some near misses may not be so obvious as the side of an excavation collapsing seconds after it was evacuated be encouraged to report near misses with the assurance that individuals involved will not be disadvantaged by their honesty

(c)

have confidence that the issues raised will be addressed, or else 'why bother?'

(d)

be provided with the means of promptly recording the details of exactly what happened and offering their opinion as to why it occurred.

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Contractors may find it is beneficial to provide easily accessible near-miss reporting forms which can be completed in privacy and anonymously if that is the individual's choice. However, anonymous reporting does not provide the opportunity for follow-up discussions to establish more details, and it may encourage malicious reports to be submitted.

10

There could be a case for rewarding the honesty of individuals who made a mistake but had the courage to compile a near-miss report, which ultimately resulted in a safer system of work being developed. Theirs was the first step in the chain of improvement. Evidence shows that near-miss reporting linked to a reward scheme has the best chance of succeeding.

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An example of a near-miss reporting form is given in the appendix to this module. This example; requires that the person involved outlines the circumstances of the event, then passes the form to their supervisor or manager as appropriate

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(b)

requires the supervisor or manager to assess the details of the event and declare what remedial actions have been, or will be, taken

(c)

incorporates a tear-off slip providing feedback on the investigation, which is returned to the person raising the issue as confirmation that the circumstances have been investigated.

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Construction Site Safety 1.6.1 Appendix Example of a minor event/near-miss report ANY CONTRACTOR: MINOR EVENT/NEAR-MISS REPORT (page 1) Please use this form to report:

Personnel safety - near misses (NM) Plant safety - minor events or near misses (ME/NM) Environment - minor events or near misses (ME/NM)

A report can be raised by ANY PERSON DATE/TIME OF OCCURRENCENE

Name:

LOCATION OF OCCURRENCE

.

PERSON INVOLVED

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Date:

Section:

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Time:

TYPE OF OCCURRENCE

People

Plant

Environment

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Please identify the plant/procedures/people involved and any relevant identified factors which can be used to improve safety

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DESCRIPTION OF OCCURRENCE

Thank you for completing this form. Please hand it to your supervisor immediately for completion of the second part. This portion to be detached and returned to sender after the investigation.  …………………………………………………………………………………………………………………. Please print your name and telephone number so that we can get back to you for more information if necessary and to let you know the outcome of our investigation. Name:

Section:

Please turn over to page 2 to complete the form

Tel:

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ANY CONTRACTOR: MINOR EVENT/NEAR-MISS REPORT (page 2) Potential for loss/severity STATE: minor/serious/ major

ASSESSMENT OF THE OCCURRENCE BY SUPERVISOR OR PERSON INVOLVED e.g. section head, manager NB: if major or frequent are appropriate, consider producing an event report instead

Possibility for recurrence STATE: seldom/occasional/ frequent

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Direct cause:

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Root cause:

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Corrective actions already undertaken: please give details of any immediate actions taken to prevent recurrence or make safe

Signature:

Date:

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Supervisor's name:

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Suggested corrective actions:

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Date:

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Construction Site Safety 1.6.2

Accident Reporting and Investigation (RIDDOR)

1.6.2.1 Key points It is important that all workplace accidents, no matter how minor, are reported to the injured person's Contractors, site manager or supervisor as appropriate.

2

Certain types of accident, cases of occupational diseases (when connected with specific work activities) and some dangerous occurrences, must be reported to the Qatar Administrative Authority.

3

Each Contractor should have a procedure for investigating workplace accidents.

4

The investigation of accidents will enable trends to be established and preventative measures put in place.

5

The level of investigation should be proportionate to the seriousness of the accident.

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1.6.2.2 Introduction

It may be said that there is no such thing as an 'accident'. An accident is always someone's fault and it is by no means always the fault of the injured person.

2

You have to report deaths, serious injuries and dangerous occurrences immediately, and less serious injuries within 10 days. Certain occupational ill-health issues and diseases also have to be reported.

3

Establishing the responsibility for investigation and enforcement will be carried out automatically after the accident report has been received.

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1.6.2.3 Accident records

Records can be stored in any medium, including electronic, providing that printable copies are readily available if required.

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Records must include details of:

date, time and place of accident

(b)

name and job of injured or ill person

(c)

details of injury/illness and what first aid was given

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what happened to the person immediately afterwards, e.g. went home, to hospital, back to work name and signature of the first aider or person dealing with the incident.

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Details of an accident should be recorded by the injured person, but can be completed by any employee.

1.6.2.4 The Reporting of Injuries, Diseases and Dangerous Occurrences 1

RIDDOR requires the following to be reported directly to the appropriate Qatar Administrative Authority: (a)

fatalities and major injuries

(b)

injuries resulting in incapacity for more than three days when linked to certain work activities

(c)

specified diseases

(d)

dangerous occurrences.

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People covered by these Regulations include: (a)

employees including trainees

(b)

self-employed

(c)

other people who have been injured.

1.6.2.5 Reporting deaths, major injuries and dangerous occurrences These Regulations place a duty on the Contractor to make reports to the Administrative Authority. In the case of employees, the responsible person will be the Contractors. In the case of the self-employed or a member of the public, the responsible person will be the person in control of the site where the event occurred.

2

All subcontractors must notify both the Administrative Authority and the Contractor of any reportable accidents.

3

Where an accident, occupational disease or dangerous occurrence takes place that requires reporting under RIDDOR

4

Contractors can send reports by post to the competent authority:

5

The following must be reported immediately to the Administrative Authority by the quickest practical method (usually by telephone) and a report submitted on the approved form within 10 days:

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death of any person as a result of an accident at work

(b)

an accident to any person at work resulting in major injuries or serious conditions specified in these Regulations (see list below)

(c)

any one of the dangerous occurrences listed in these Regulations (see summary opposite).

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(a)

Note: A fatality cannot be registered without a properly completed death certificate.

(a)

Any fracture of any bone, other than to the fingers, thumbs or toes. Any amputation.

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1.6.2.6 Major injuries and serious conditions

(c)

Dislocation of the shoulder, hip, knee or spine

(d)

Loss of sight (whether temporary or permanent) or any other listed eye injury.

(e)

Electric shock or burn causing unconsciousness, or requiring resuscitation, or requiring admittance to hospital for more than 24 hours.

(f)

Any injury leading to hypothermia, heat induced illness or to unconsciousness requiring resuscitation or admittance to hospital for more than 24 hours.

(g)

Unconsciousness due to asphyxia or by exposure to a harmful substance or biological agent.

(h)

Acute illness or unconsciousness caused by any poisoning by any route.

(i)

Acute illness caused by exposure to infected material or a biological agent.

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1.6.2.7 Reportable dangerous occurrences Collapse, overturning or failure of any load-bearing part of any lift, hoist, crane, derrick, mobile powered access platform, access cradle, window cleaning cradle, excavator, piling rig or forklift truck.

(b)

Collapse or partial collapse of any scaffold over 5 metres in height or fall of any cradle.

(c)

Collapse of 5 tonnes or more of any building or structure, or any false work, or any wall or floor in any workplace.

(d)

Explosion, bursting or collapse of any closed vessel or boiler.

(e)

Contact with, or arcing from, any overhead electric cable caused by any plant or equipment.

(f)

Electrical short-circuit with fire or explosion, for example, from hitting an electrical service.

(g)

Explosion or fire caused by any material resulting in stoppage of work or plant for more than 24 hours.

(h)

Uncontrolled release of 100 kg or more of a flammable liquid, 10 kg or more of a flammable liquid above its normal boiling point or 10 g of a flammable gas inside a building, and 500 kg or more of such substances outside a building.

(i)

Uncontrolled release of any biological agents.

(j)

Accidental ignition of any explosive.

(k)

Failure of any load-bearing part of a freight container.

(l)

Bursting, explosion or collapse, or fire involving a pipeline.

(m)

Specific incidents involving road tankers.

(n)

Specific incidents involving dangerous substances being conveyed by road.

(o)

Escape of any substance in a quantity sufficient to cause death, injury or damage to health, for example, asbestos.

(p)

Malfunction of any breathing apparatus whilst in use or when being tested before use.

(q)

Contact with or arcing of any overhead power line.

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1.6.2.8 Other reportable injuries and deaths The following must be reported to the Administrative Authority within 10 days on an approved form (F100). A copy of the form is reproduced at Appendix 3.

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(a)

Any accident at work where, because of an injury, a person is incapacitated for work of their usual kind for more than three consecutive days, not counting the day of the accident, but counting rest days, weekends, and so on.

(b)

The death of an employee, if it occurs within one year of the date of the reportable injury, even though the injury has been previously reported.

(c)

Any injury caused by a work activity to someone who is not at work that results in them being taken to hospital by whatever means, e.g. a taxi, ambulance or private car, for treatment of that injury. This would include all members of the public.

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1.6.2.9 Keeping records 1

Records of all reportable deaths, injuries and dangerous occurrences must be kept for a period of three years. No precise method is prescribed, but a photocopy of the approved form is acceptable, as are electronic databanks and computer storage. If an 'in-house' accident form is designed to record the same details as the approved form, it is acceptable.

2

The minimum particulars that must be kept are: (a)

the date and time of the accident or dangerous occurrence

(b)

the injured person's details: full name and occupation

(ii)

nature of the injury

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in the event of an accident to a non-employee: (iii)

full name and status (for example passenger, customer, visitor or bystander)

(iv)

nature of the injury

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(c)

(i)

the place where the accident or dangerous occurrence happened

(e)

a brief description of the circumstances in which the accident or dangerous occurrence happened

(f)

the date on which the event was reported to the Administrative Authority

(g)

the method by which the event was reported.

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1.6.2.10 Reporting diseases

A disease must be reported where it has been diagnosed in a person doing a specified type of work. These Regulations list diseases against the type of work which makes them 'reportable'.

2

The report must be made when the disease has been diagnosed by a registered medical practitioner, who will notify the Contractors of it in writing.

3

Diseases have to be reported to the appropriate Administrative Authority on the approved form. (Form F100A) A copy of the form is reproduced at Appendix 4. Refer to the SAMAS SHE PROCEDURE 8

4

Reports must be kept in the same manner as for accidents and the minimum particulars that must be kept are:

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(a)

date of diagnosis of the disease

(b)

name of the person affected

(c)

occupation of the person affected

(d)

name or nature of the disease

(e)

the date on which the disease AuthorityAdministrative Authority

(f)

the method by which the disease was reported.

was

reported

to

the

Administrative

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Diseases and work activities listed in these Regulations are:

Disease

Work activity

Chemical and metal poisoning

Any work activity

Chrome ulceration, acne, skin cancer, folliculitis

Work with chrome compounds, minerals, oil, tar, pitch, radiation

Occupational asthma

Work with epoxy resin, soldering flux, silica, sand, wood dust

Mesothelioma, lung cancer, asbestosis Leptospirosis

Work with asbestos

Hepatitis

Exposure to blood or human waste products

Nasal or sinus cancer

Working in a dusty building

Hand-arm vibration syndrome

Hand-held rotary or percussive tools, chainsaws and handheld circular saws

Pneumoconiosis

Work with silica, sand, grinding wheels, boiler descaling

Occupational dermatitis

Work with epoxy resin, oil, cement, solvents, hardwoods, plaster, concrete, bleach, acids, alkalis, wood preservatives and anything else which causes dermatitis

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Where there are rats, field mice, voles or other small mammals

1.6.2.11 Reportable or not reportable incidents under these regulations?

The following examples may provide some clarification:

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Note: For simplicity in the following passage of text, the word 'incident' is used to cover any reportable event such as injury, disease or dangerous occurrence.

1. A directly employed person breaks their arm at work. This must be reported by the Contractors, in their capacity as 'responsible person', as a major injury. 2. A self-employed subcontractor breaks their leg at work. The injury must be reported as a major injury by the Contractor acting in their capacity as 'the responsible person' who was in control of the premises. 3. An employee of a subcontractor on a project is informed by his doctor that he is suffering from work-related vibration white finger and subsequently informs his Contractors. The Contractors, in their capacity as 'responsible person', must report the incident as a reportable disease. 4. An employee inadvertently hits an underground electric cable whilst operating a road-breaker. There is minor damage to the external sheath, but the conductor is not exposed. This is not reportable as there was no electrical short circuit with fire and explosion. The incident, however, warrants significant internal investigation. 5. A member of the public is knocked down by a lorry entering the site as it crosses the pavement. They are taken to hospital by ambulance. This would be reportable as it involves a member of the

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public being taken to hospital. 6. A subcontractor employee burns his hand and is taken to the local hospital. He is back on site later that afternoon and continues to work as normal for the rest of the week. This would not be reportable. However, had the employee been admitted to hospital for 24 hours or more, the incident would be reportable. 7. An employed delivery driver twists his ankle on a Monday when he steps down from his cab. He receives first aid, insists he is fit to drive and later leaves the site. He subsequently takes the rest of the week off because of pain and swelling in his ankle. The incident should have been recorded in the site accident book, but it would seem unreasonable for the site to be aware of the consequence. The delivery driver's Contractors would have a responsibility to report this as an 'over-3-day' accident.

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8. An employee sustains a head injury as a result of falling over debris left on site. The accident occurred on a Thursday and because of the injury, the person is unable to return to work until the following Tuesday. Although only two actual working days have been lost, the accident must be reported as an 'over-3-day' accident because the Saturday and Sunday also count, as the injured person would have been unfit for work had these been working days.

From Contractors accident records and other statistics, it is possible to calculate the incidence and frequency rates for accidents at a particular place of work and for the types of injury, severity or duration.

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1.6.2.12 Calculating the incidence and frequency rates of accidents

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The incidence rate is based on the number of accidents, taken over a fixed period, per 100,000 employees.

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Accident incidence rate (AIR)

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Incidence rate =

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For example, if during a 12-month period there were six reportable accidents and during that year the company employed an average of 120 employees, the calculation would be: 6 x 100,000 = 5,000 120

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Number of reported injuries in a year x 100,000 Average number of employees in a year

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The following formula is also used to calculate the incidence rate, particularly when the number of employees is small. Number of reported injuries in a year x 1,000 Average number of employees in a year

Accident frequency rate (AFR) 5

The accident frequency rate allows a calculation to be made that balances the number of reportable accidents that occur against the number of hours worked.

Frequency rate = Number of injuries in a period x 100,000 Number of hours worked in that period

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For example, if a company had five reportable injuries in a period during which its 260 workers worked a total of 125,000 hours, the accident frequency rate would be: 5 x 100,000 = 4 125,000

7

Therefore, when comparing the figures of different companies, care must be taken to ensure that the same multiplier is used.

1.6.2.13 Analysis and presentation of data To visualise trends more clearly, accident statistics are often displayed as bar charts, histograms and graphs.

2

The proper and effective reporting of accidents, along with their thorough investigation, can have major benefits for a Contractor. A Contractor might consider that they could:

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reduce costs by that the Contractor has a pro-active implementing change and preventing accidents

(b)

identify training needs which will also improve performance

(c)

show Qatar Administrative Authority, Workplace Inspectors their approach to safety

(d)

satisfy stakeholders that their workforce is properly trained and totally safety orientated

(e)

benefit from a possible reduction of insurance premiums following years of hard work to reduce accidents.

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be factual and without bias

(b)

clearly show the sequence of events leading to the accident or incident

(c)

identify the immediate cause

(d)

identify the underlying cause, e.g. unsafe acts or conditions

(e)

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An effective investigation will:

show the root cause, e.g. lack of supervision, training or monitoring.

By discovering all causes, especially root causes, you will be able to learn from accidents and incidents and then aim to prevent re-occurrences.

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1.6.2.14 Accident investigation

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1.6.2.15 Accident procedure 1

The procedure below is given as general guidance and outlines the steps that should be taken immediately after an accident: (a)

attend to the injured person, call for assistance if necessary and arrange for first aid, doctor, ambulance, hospital

(b)

isolate machine, tools or equipment

(c)

do not disturb or move anything unless to release an injured person

(d)

inform the manager, safety adviser, safety representative and other appropriate persons (such as the Workplace Inspectors, Fire Officers or Insurers)

(e)

ensure any remaining hazard is guarded against

(f)

take notice of anything significant and make general observations at the scene of the accident.

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1.6.2.16 Conducting an investigation It is not usually practical to investigate every minor accident, but those involving major or serious injuries to persons and major damage to plant or equipment should be thoroughly investigated so that immediate action can be taken to prevent a recurrence. The following headings may be useful as a guide to the steps to be taken: investigate promptly

(b)

record evidence

(c)

identify types of evidence, e.g. factual, corroborative

(d)

interview the injured person, if possible

(e)

question the person in charge and other supervisors

(f)

obtain details of the injured person's job and what they usually or normally do

(g)

interview witnesses

(h)

inspect plant for signs of misuse or defects

(i)

establish the full sequence of events

(j)

ascertain the nature and extent of the injury or damage

(k)

complete the accident report and the accident book

(l)

notify the appropriate authorities.

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1.6.2.17 Investigate promptly

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The sooner an investigation is started, the better - provided it is safe to do so.

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Engineers and supervisors will be anxious to find ways and means of repairing the damage to plant, machinery or buildings, but the first priority should be to establish the cause of the accident. Safety specialists, managers and safety representatives will be concerning themselves solely with the safety implications and preventing a recurrence.

3

It is important that the investigation is properly supervised and organised.

4

Where the Police, Fire or Workplace Inspectors wish to investigate, any other persons responsible for, or involved in investigating, the accident must take extreme care not to disturb possible evidence at the scene.

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1.6.2.18 Recording evidence 1

Statements from witnesses should contain such details as their age and occupation. The time, date and place of interview should be indicated at the end of the statement.

2

Witnesses' statements should always be written in their own words, even if these include slang or expletives.

3

The completed statement should be read to the witness and, ideally, signed by them and by the person who took the statement.

1.6.2.19 Identifying the types of evidence 1

Evidence will usually include: (a)

statement of witnesses and others given orally, or in writing. 'Others' may include experts who, for example, might have been called in to examine a machine or the state of a scaffold

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(b)

documentation of all kinds

(c)

material exhibits of all kinds.

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Factual evidence comprises the facts related by persons directly involved, and by witnesses who are able to say what they felt, saw, heard, or give an expert opinion. This type of evidence is primary, direct and positive and should be written in simple language, keeping to the facts and avoiding inferences, opinions and beliefs. The facts should be recorded clearly, accurately and in sequence.

3

The best witnesses are those persons directly involved who are able to: listen carefully to the questions

(b)

answer directly, fairly, impartially and truthfully

(c)

state clearly when they do not know the answer

(d)

remain calm when they are being asked questions.

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Material evidence includes, for example, equipment, machines, scaffolds,ladders or hand tools, where the use of or the state or condition of the item has a bearing on the accident.

5

Corroborative evidence tends to support the truthfulness and accuracy of the evidence which has already been given. The confirming evidence may take the form of site records, plant or maintenance records, warning notices, written procedures, reports made by safety officers etc.

6

People in the vicinity of an accident should be asked to give an opinion. In this way a full picture can be built up of the circumstances of the accident.

7

Experts, or specialists, who are familiar with the type of accident, or technical and other factors surrounding the accident, may be called upon to express their expert opinions.

8

When there is a lack of real or factual evidence, other forms of evidence such as circumstantial and corroborative evidence tend to become more valuable.

9

Photographs taken immediately after an accident record the state of the scene and often highlight conditions which existed at the time. Machines, equipment, tools and obstructions, and factors such as floor conditions, space and dimensions, may show up very well on photographs.

10

If possible, it is best to engage professional photographers and to obtain the largest possible prints. Time, date and place or subject photographed should be written on the back of the pictures.

11

Too many photographs are far better than too few, and it is a good idea to make drawings of the area where the incident happened.

12

Digital photography may not be accepted as primary evidence but may be suitable as supportive evidence.

13

Procedures should be in place to ensure that photographs have not been, or cannot be, computer-enhanced as this would destroy their value as evidence.

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1.6.2.20 Interviewing the injured person 1

Interviewing the injured person should be an early priority. Even the briefest description of the accident should suffice initially.

2

The physical and mental state of the injured person will need to be considered, and tact and

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patience required during the interview. The injured person should be fit to answer questions. 3

The injured person should be encouraged to talk about how the accident happened and it is important they have confidence and trust in the listener. It is important to stress that the purpose of the investigation is to find the cause so that preventive action can be taken. Blame should not be apportioned.

4

Questioning should not take the form of an interrogation. Someone well known to the injured person is probably the best person to do this. Safety officials are more likely to receive the co-operation of an injured person if they are able to demonstrate a genuine interest in their welfare and recovery. This may involve visiting the injured person, with the doctor's approval, in hospital or at home.

1.6.2.21 Questioning the person in charge Establish from the injured person, manager, supervisor or the person in charge, what the normal job and tasks of the injured person were. Did they include the activity which led up to the accident? Other questions which might be asked include:

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what task or type of job was being performed?

(b)

was it planned or part of a planned activity?

(c)

at what stage of the work did the accident occur?

(d)

was the person involved trained, and if so, when?

(e)

was the person authorised to carry out that type of work or use machinery in that location?

(f)

was the person authorised to be where the accident occurred?

(g)

what instructions had been given?

(h)

how many other persons were involved, or should have been involved, in the activity?

(i)

was the activity or task covered by any these Regulations?

(j)

were safe and correct procedures being observed?

(k)

did unsafe acts cause the accident? If so, were they those of the injured person, workmates, or others?

(l)

did any unsafe condition contribute to the accident?

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what safety equipment or personal protection was available and in use? were other contractors' employees or plant and machinery involved or at fault?

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had the injured person been involved in previous accidents?

(p)

who was supposed to be supervising the work activity?

1.6.2.22 Interviewing witnesses 1

Skill is required when interviewing. Witnesses should be interviewed one at a time. If they wish to say anything before notes are taken, they should be allowed to do so.

2

Interviewers should seek answers to the following basic questions: (a)

what did the witness actually see or hear?

(b)

what was the witness doing at the time?

(c)

what was the proximity of the witness to the accident or occurrence?

(d)

what actions did the witness take?

(e)

what actions did others take before and after the accident?

(f)

what was the condition of the workplace at the time?

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(g)

what hazards or unsafe conditions existed and what unsafe acts were performed?

(h)

what was the probable cause(s) of the accident or occurrence?

Skilled interviewers allow witnesses to tell things in their own way, intervening only to clear up specific points or answers where necessary. Questions should be impartial, and should be recorded together with the answers.

4

It is quite acceptable to go through an incident with a witness making rough notes and then to take a statement after that. That way, the witness often has more chance to remember and sometimes provides far more detail on the second run through.

5

Many witness statements are taken by the interviewer rather than written by the witness, and this would normally be agreed during the interview.

6

It is common for certain details to differ in witnesses' accounts, and it would be suspicious if they were identical, but there should be agreement about basic facts if the true cause of an accident or occurrence is to be determined.

7

The important witnesses are those persons involved. Their evidence will be more valuable than evidence from witnesses who saw or heard only from a distance, although they, too, should be interviewed. Corroborative evidence and information is often required, particularly when witnesses are few or are not reliable.

8

As much evidence and information as possible should be collected, since the action taken to prevent a recurrence will be based on what is learned.

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1.6.2.23 Inspection of plant for misuse or defects

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Inspection of plant, equipment, tools and machinery immediately after an accident may reveal signs of misuse, or defects, which may or may not have contributed to the accident. The scene should also be carefully examined to see if trip hazards, slippery floors, or some other defect contributed to, or caused, the accident.

2

Assistance from specialists and persons directly involved or familiar with the type of plant, equipment, or machinery in question can provide valuable information.

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1.6.2.24 Establish a sequence of events Evidence gained from interviews and from inspection of the scene, plant, equipment or machinery, should give an indication of the sequence of events leading up to the accident.

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1.6.2.25 Ascertain the extent of injury or damage It is not always possible to ascertain the full extent of injuries and damage resulting from an accident.

2

There may be complications or delayed effects from injuries. The total time off work will obviously not be known at the time of investigation.

3

Whilst it may be easy to identify the extent of the damage caused to plant, machinery, equipment, buildings and materials, it is far from easy to measure the overall effects of the accident in terms of lost time, lost production and, of course, the suffering of the injured person or persons.

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1.6.2.26 Completion of the accident book and an accident report form 1

Accident report details will vary, depending on who produces the report and whom the report is for. To help eliminate or reduce this variation, guidance in making reports and the use of a standard form is recommended.

2

As far as possible, reports should be concise, based upon fact rather than speculation, unbiased and should summarise the essential information obtained during the investigation.

3

Sample accident and damage report forms are included as Appendices 1 and 2 of this section.

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Construction Site Safety 1.6.2 Appendix 1 Personal Accident Report 1.

Name of Contractors ............................................................................................................................

2.

Site address ...................................................................................................................................... .......................................................................... Contact................................................................... Injured person’s name ......................................................................................................................

4.

Injured person's address ..................................................................................................................

5.

Age ...................................................................................................................................................

6.

Normal occupation ............................................................................................................................

7.

Occupation at time of accident .........................................................................................................

8.

Exact location of accident .................................................................................................................

9.

Date and time of accident .................................................................................................................

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10. Date and time of ceasing work .........................................................................................................

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11. State precise nature of injury ............................................................................................................

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(If eye or limb, state left or right)

12. To whom was the accident reported? ........................... Date ..................... Time ..........................

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13. Entry made in accident book on ....................................................................................................... 14. Qatar Administrative Authority informed :

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Date ..................... Time ................................................................................................................... 15. F100 report sent to Qatar Administrative Authority on.................................................................................... 16. Accident recorded in the official Contractors register? (If applicable) .............................................. 17. Was first aid given on site? ............................................................................................................... If treatment was received from a doctor, state name ....................................................................... 18. Did the injured person go to hospital? .............................................................................................. Give name of hospital ....................................................................................................................... 19. Was the injured person authorised to be at the place of the accident for the purpose of his/her work? 20. How was the accident caused? ........................................................................................................

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a) Give a full description of what happened ..................................................................................... b) State what the injured person was doing at the time ................................................................... c) If falls of persons from heights or into excavations or holes are involved, state distance of fall in metres 21. What action has been taken to prevent a recurrence? ..................................................................... 22. If machinery was involved a) Give name and number of machine or part causing the accident................................................

.

b) Was it working at the time of the accident? ..................................................................................

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23. Names and addresses of witnesses to the accident. Always obtain witnesses wherever possible.

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a) ....................................................................................................................................................,.

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b) ......................................................................................................................................................

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c) ...................................................................................................................................................... Attach signed statements from each witness whenever possible.

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24. Use the reverse of this form or a separate sheet of paper for a sketch plan of the scene.

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This form was completed by:

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Name .................................................. Signed ....................................... Date ................................

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TO BE COMPLETED BY HEAD OFFICE

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Further medical reports on injured person

Date ........................... Date ...........................

New address for injured person

.....................................................................................

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Injured person ceased employment

..................................................................................... .....................................................................................

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Construction Site Safety 1.6.2 Appendix 2 Damage Report Contact ..................................................................................................................................................... Address of site .......................................................................................................................................... ……………………………………………………………………………………………………………………... Plant or equipment affected ...................................................................................................................... ……………………………………………………………………………………………………………………...

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……………………………………………………………………………………………………………………...

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Serial numbers or identifying marks .........................................................................................................

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Full name and address of owner of the plant or equipment ......................................................................

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……………………………………………………………………………………………………………………... ……………………………………………………………………………………………………………………...

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Place, date and time of accident ...............................................................................................................

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……………………………………………………………………………………………………………………...

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Details of defects or damage ....................................................................................................................

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Names of operators concerned ................................................................................................................ ……………………………………………………………………………………………………………………...

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……………………………………………………………………………………………………………………... Cause of the accident ....;.......................................................................................................................... ……………………………………………………………………………………………………………………... Names of witnesses .................................................................................................................................. ……………………………………………………………………………………………………………………... ……………………………………………………………………………………………………………………... Agent or supervisor's signature ............................................ Date ...........................................................

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Appendix 3

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Form F100 Reporting of an injury or dangerous occurrence

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1.6.2 Appendix 4

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Form F100A Reporting of a disease

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Construction Site Safety 1.6.3

Behavioural Safety

1.6.3.1 Key points Behavioural safety attempts to focus on why people act the way they do in relation to work activities and decision making. It is based on a process of observation, intervention and feedback, and aims to identify, in advance, any situations or conditions that may have an impact on completing tasks safely.

2

Situations or conditions may be influenced by an organisation, the individual or as a reaction to change by either.

3

Behavioural safety is proactive, trying to head-off potential problems rather than reacting to past accidents and mistakes.

4

For simplicity, this module and much of the text within it refers to 'behavioural safety; however, the principles apply equally to preventing incidences of occupational ill health.

5

To be effective, a behavioural based approach requires:

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clear and unambiguous leadership from the top down

(b)

'buy-in' at all levels to making the scheme work

(c)

an 'up-front' commitment in terms of time, effort and determination

(d)

scheme sponsors who believe in the value of making it work, who can be sympathetic to the reasons why some people behave in an unsafe manner and persuasive in convincing those people that they should not

(e)

effective communication on what the scheme is trying to achieve

(f)

a concerted effort to convince those affected that they will not be disadvantaged by the changes that will come about as a result of introducing the approach

(g)

effective engagement of everyone involved in the approach, not just those directly involved with the construction process.

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1.6.3.2 Why use a behavioral safety approach? Historically, improvements in health, safety and environmental performance have been achieved through improvements in engineering technology and enhancing safety management systems. In many ways, this methodology has reached its optimum performance and the related improvements in health and safety performance have begun to level off. Future performance gains will only be achieved by taking more account of the way people interact in every aspect of the workplace; and through integrating and understanding the human element of risk.

2

Trying to account for human performance in numerical ways is difficult. Many companies have tried to quantify human performance by using engineering methods.

3

For example, 'at risk' and 'safe' behaviors have been analysed to create a '% Safe' rating.

4

We all have our own perception of risk based on our individual experiences and it is not easy to make direct comparisons between different views and opinions. Despite this, most people have a genuine desire to work safely through adopting the 'best practice'.

5

This document defines behavioral safety as:

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'organisational, job and individual factors which influence behaviour at work in a way which can positively affect health and safety.'

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The practicalities of successfully implementing a behavioural approach involve: establishing an effective system of two-way communication to develop mutual trust between management and workforce

(b)

engaging the right people in the decision making

(c)

observing people at work

(d)

assessing their safe and unsafe behaviours (non-judgemental)

(e)

making timely interventions

(f)

establishing why unsafe behaviours take place

(g)

influencing those who behave unsafely not to do so in the future

(h)

recognising safe behaviours and if appropriate, rewarding

(i)

continuing assessment and research whilst looking for improvements in safety behaviour.

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The overall benefits are likely to be: more effective communication

(b)

a reduction in the number of workplace injuries

(c)

improvement in the standards of health and safety

(d)

reduced losses for the individual and the Contractors

(e)

the extension of safe working practices into the home life.

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There is a recognition that a behavioural approach attempts to: increase efficiency

(b)

achieve more flexibility and effectiveness

(c)

produce long-term changes.

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1.6.3.3 Developing a behavioural approach

The benefit for managers is to understand the motives behind why some people take risks and put themselves and others in danger, and thereby significantly reduce the potential for injuries and occupational ill health.

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A behavioural safety approach is very effective in preventing workplace injuries and instances of occupational ill health. However, the approach does not reach its full potential until people start to share problems and issues with each other and with their supervisors.

4

Any success is dependent upon free and effective two-way communication and engagement. There must be mutual trust as to the motives of all parties. Such trust can only be built upon a just culture where employees at all levels can voice their mistakes knowing that the information will only be used to prevent the situation occurring again.

5

If a health and safety discussion is a positive experience, people will think about safety more positively and take steps to create the necessary safe working environment. Everyone has a right to carry out their work without being injured or becoming ill. Equally, nobody should have to tell somebody's family that their loved one has been killed or injured because the Contractor hasn't organised its health and safety arrangements effectively.

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Behavioural safety has significantly contributed to improving the safety performance of Contractors that have committed resources and time to it.

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An effective behavioural approach must involve all levels of an organisation, not just those on the 'coal face'. However, when we look at why people do what they do, we often find that errors are rooted in the way that health and safety is organised. Unsafe situations found in the workplace reflect problems with the way the company is led and organised.

8

The principles of behavioural safety are well established but putting them into practice can be difficult. Low levels of trust, poor motivation, or management that is not visible and rarely visits the site mean that many organisations do not communicate effectively and do not obtain or sustain effective involvement from the workforce.

9

However, many workers are still sceptical about these processes because of their current working practices. For example, some people object to observing colleagues, while others feel that it is a judgemental process in disguise in which gathering information leads to allocation of blame. Others may just fill in the observation cards because they have a target to meet.

10

Furthermore, cultural issues such as poor leadership, completion bonuses, little or no worker engagement and not reporting accidents affect the ability to establish an open culture.

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When not everyone is open about what is really taking place on site, there is the obvious potential for someone to be injured.

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Organisations should provide a platform for productive debate, a chance to share best practice, air conflicting opinions that challenge existing working practices and provide an opportunity to learn more about the psychology of injury prevention.

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1.6.3.4 The psychology of behavioural safety

Behavioural safety applies tried and tested psychological principles in order to change the way people and organisations do things, particularly how people act or behave in respect of their own health and safety.

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A behavioural approach takes into account:

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how people think

(b)

how people act and behave

(c)

how people respond to certain situations

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Thought processes 3

The conscious or alert state of mind can only process on average seven thoughts at once. If a distraction disturbs a person's thought processes, they may, for example, trip over a toolbox they have placed on some steps or fall into a hole they recently dug. Other thoughts have entered their conscious mind and the hazardous situation is momentarily forgotten.

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Hence good workplace design and housekeeping practices, such as removing hazards immediately and always keeping walkways clear, are critical to prevent injury.

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It is difficult to convert emotions and opinions into usable information that promotes safety improvements. Often the ability to increase safety awareness by the individual doing a 'Mental Risk Assessment' (i.e. asking 'what is going to put me at risk while I do this job?') is lost. Yet future performance gains will only be achieved by creating a process that is simple, positive and, most of all, resolves the issues as soon as practicable.

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It is essential that employees feel that they are able to discuss the day-to-day aspects of their job, and it should be as natural as talking about their favourite sport. We should take

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into account the way people work alongside each other and try to work from a baseline of openness about what is going on. 7

By helping people to understand the implications knowledge, we will have identified a process that management system of the business, encouraging that resolves issues when they arise, rather than occurs.

of how they work and engaging their integrates human factors into the core positive, open and real communication keeping them hidden until an incident

Habits Habits are subconscious ways of thinking, both positive and negative. They are formed when a task and behaviour is repeated. The more repetitions, the stronger the habit, until no conscious thought is given to the job. An example of a negative habit is not wearing eye protection when using a disc cutter because the past is used to justify present actions - the worker has not been injured before so argues that they will not be injured now.

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A positive habit can be formed by communicating the benefits, consciously ensuring eye protection is worn, perhaps by raising awareness via posters or stickers on the disc cutter, keeping eye protection with the disc cutter, or spoken reminders from work colleagues and supervisors. Eventually wearing eye protection becomes a habit and the norm.

Beliefs, expectations, attitude and behaviour

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We all have our own beliefs (attitudes) that underlie how we think and hence define the way we act. If managers and supervisors are not committed or do not really believe that health and safety is a priority, a powerful negative message will be sent to employees.

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Low expectations and poor leadership from management can create negative attitudes from employees that result in poor methods of working that lead to poor health and safety performance.

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The challenge

It is increasingly being recognised that integrating a systematic, proactive process within the organisation's arrangements can add significantly more value by addressing behavioural aspects of health and safety at the same time as optimising efficiency and productivity.

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Significant improvements can be made to performance through open communication and a reporting process based on what is really happening. This will enable better assessment of risks, bridges to be built, trust to be enhanced and the workforce to participate willingly as issues are resolved and solutions found.

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The barriers to progress 14

If management promotes a negative or passive message, making the workforce believe that it is collecting unnecessary data or that the information will never provide solutions, any potential gains will be lost.

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Organisations that adopt a behavioural approach must fully understand that it is not a short term solution but a 'change in the way we do things round here' that will need an effective investment of resource and commitment.

The solution 16

A simple, fully integrated process that stimulates discussions on everything that is going on,

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whether safety or otherwise, is progressed through an action plan. Once people see that these positive discussions lead to a positive gain, even without the difficult observation process, even greater workforce involvement would occur.

1.6.3.5 Why observation processes can be difficult 1

People sometimes have major difficulties in carrying out a formal observation. To stand, observe, then to talk about what was seen in order to seek ways to improve work practices creates a challenging situation for many people.

2

Some of the issues are: people dislike being observed during any task

(b)

people will tend to change their behaviours whilst being observed, therefore defeating the purpose of the exercise

(c)

difficulty in interpreting the information to identify any trends

(d)

a focus on changing attitudes and behaviours means that training is likely to be via workshops and committees. This may be too expensive in terms of both available time and resources.

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Individuals vary in their perception of the level of risk associated with a particular situation. We all base this mental risk assessment on our own experiences and have a slightly different perspective on what is going on.

4

If a worker has not had an accident while carrying out a particular activity, they will often score the risk as zero in a personal risk assessment because they judge that it will not happen to them. For instance, an individual may work from an untied ladder, accepting there is a small risk of falling and not necessarily recognising the severity of the consequence if they did fall. However, they may observe a work colleague on the same ladder and can see the risk and potential consequence.

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People can cause or contribute to accidents, or mitigate the consequences, in a number of ways: A person can directly cause an accident by failing to carry out a job correctly. A person may hear but not listen and understand health and safety information that is associated with the task, thereby failing to work to expectations.

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1.6.3.6 Reducing human error and influencing behaviour

(c)

People tend not to make errors deliberately but they are often 'set up to fail' by the way the brain processes information. For example, errors may occur as a result of stress, fatigue, working long hours without sufficient rest, a lack of training, the poor design of equipment, weak procedures or because of the shortcomings in the culture of the organisation in which they work.

(d)

People can make disastrous decisions even when they are aware of the risks. A particular situation or the severity of its consequences can be misinterpreted and inappropriate action taken as a result. This poor assessment of the situation can lead to the escalation of an incident.

(e)

On the other hand, other people (such as workmates, supervisors and managers) can intervene to prevent potential accidents or mitigate their possible effects.

(f)

The severity of an accident can be reduced by the effectiveness of the emergency response. The effectiveness can be improved by planning and appropriate training.

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1.6.3.7 Active and latent failures 1

The consequences of human failure can be immediate or delayed. It is important to have an understanding of active and latent failures and how they impact on health and safety. (a)

Active failures have an immediate consequence and are usually made by front-line people such as drivers, operators or even the public. In a situation where there is no room for error, these active failures have an immediate impact on health and safety.

(b)

Latent failures are caused by people such as designers, decision makers and managers whose tasks are removed in time and space from operational activities. Latent failures are typically failures in the design, implementation or monitoring of health and safety management systems.

Latent failures provide as great, if not greater, potential danger to health and safety as active failures. These can be highlighted only through positive safety discussions that utilise the experience and knowledge of the workforce. Latent failures are hidden within an organisation until they are triggered by an event likely to have serious consequences.

3

Examples of latent failures are: Poor design of workplaces, plant and equipment

(b)

Gaps in supervision

(c)

Undetected manufacturing defects

(d)

Maintenance failures

(e)

Unworkable procedures

(f)

Clumsy automation

(g)

Ineffective competency assurance

(h)

Ineffective training

(i)

Ineffective communications

(j)

Uncertainties of role and responsibility

(k)

Ageing assets, plant, tools and equipment

(l)

Poor planning - insufficient people/time

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Poor intelligence on health and safety incidents.

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1.6.3.8 The management of change 1

Most people fail to plan for the human side of change and wonder why their plans rarely succeed. No single behavioural process fits into every company but some prescriptive processes may be a necessary step towards achieving open communication.

2

Any change creates 'people issues'. For example, there may be new leaders, changed roles, and the need to develop new skills and capabilities. Employees may be uncertain and resistant because they do not see the need for change or feel that they will be disadvantaged by it. Dealing with these issues on a reactive, case-by-case basis puts the progress of the job, workforce morale, and overall performance of the behavioural approach at risk.

3

Change is unsettling for people at all levels of an organisation. The team needs to work together and understand that individuals are going through stressful times and need support. Only after everyone aligns and commits to the change programme can the workforce deliver tangible results.

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Individuals (or teams of individuals) need to know what changes they will see as a result of a behavioural safety programme being - implemented, what is expected of them during and after the change programme, how they will be measured, and what success or failure will mean for them and those around them.

1.6.3.9 Lead by example The implementation of behavioural safety can pose particular problems with a fragmented and mobile workforce such as that found in the construction industry.

2

To be successfully implemented on site, it is fundamental that the principles of behavioural safety are embedded within the organisation's culture and understood by the workforce and management from the beginning. It cannot 'just be thrown in' as an initiative at a later stage.

3

The foundations, expectations and compliance processes must be made clear from the beginning. If employees and contractors receive the right induction, standards will be set for the future.

4

If people digress into non-compliance and break basic rules (such as not wearing hard hats or safety goggles), then subsequent batches of inductees will receive the message that safety is not taken seriously (they can get away without wearing their hats and goggles).

5

Similarly, when senior managers visit sites, they should receive the same induction and live by the same rules - body language and example can send a powerful message.

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1.6.3.10 Facilitation and coaching

Team leaders should be as honest and explicit as possible about what impacts on health and safety. People react to what they see and hear around them, and need to be involved in the change process.

2

Individual commitment, ownership and accountability for safety is vital to making change happen. Everyone must be willing to accept responsibility for change in the areas they influence or control. We do not expect machinery or plant to undergo alteration without appropriate engineering controls, why should we expect people to change without support.

3

Ownership is often encouraged by involving people in identifying problems and Grafting solutions. It is reinforced by coaching and facilitation, incentives and, sometimes, rewards.

4

These can be tangible (for example, financial compensation) or psychological (for example, camaraderie and a sense of shared involvement).

5

The best programmes reinforce the core messages of safety through regular, timely engagement and communication that is both inspirational and practicable. Communications are targeted to provide employees with the right information at the right time and to solicit their input and feedback.

6

Effective change requires continual review to ensure that new issues are identified and actioned.

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1.6.3.11 Staffing levels 1

Some companies operate with the lowest possible number of people required to achieve their commercial objectives. Margins are tight and contracts are won and lost on cost. This means that people can be stretched beyond acceptable limits, doing too much, working long hours and experiencing high levels of stress and fatigue - a recipe for disaster. Contractors should remember that if a job needs more people, then they should be provided, otherwise people get hurt.

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1.6.3.12 Training and competency 1

It is likely that if a workforce is: (a)

motivated and well trained

(b)

not under unreasonable time pressure

(c)

given the correct information and training

(d)

working with the right, well-maintained equipment

(e)

they will efficiently complete their tasks to a high standard.

Conversely, high workloads and tight timescales often result in training and competency assessments falling by the wayside, which can lead to ineffective decision making, poor working practices, out-of-date certification of plant, equipment and, of course, a negative effect on people's skills.

3

As part of managing change, it is essential that a training and competency assessment be carried out so that shortcomings are identified and addressed, and consequently people are not put at risk. Every Contractor is responsible to ensure that people are trained and competent to carry out their tasks. Greater production efficiencies are achieved through correct skill levels and further gains are made in completion times and work output.

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1.6.3.13 Fatigue

It has long been recognised that fatigue affects the mind and emotions as well as the body. The issue is important in any discussion regarding safety; operator fatigue has been implicated in many serious construction accidents.

2

The word 'fatigue' is, like 'stress', an umbrella term that encompasses many meanings. The phrase 'physical fatigue', for example, may refer to muscle aches and pains, shortage of oxygen, or a more systematic feeling of tiredness caused by sleep deprivation, illness or poor nutrition.

3

'Mental fatigue' is typically associated with tasks that demand intense concentration, rapid or complex information processing, and other high-level cognitive skills. Another form of fatigue is boredom, particularly when it results from repetitive or monotonous activity.

4

Symptoms of extreme fatigue would include obvious loss of concentration or difficulty in recalling information, poor decision-making, irritability, red eyes, uncontrollable yawning, and slow responses to questions.

5

A person suffering from mental fatigue may also spontaneously complain about being tired or having had too little sleep. Asking the person if they feel fit to start work may not result in a very reliable answer. Individuals may feel that they are under pressure to state they are fit for work, knowing that they are not.

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1.6.3.14 Shift work 1

Humans have evolved to be active during the day and to sleep at night. The timing of work, particularly shift work, can interfere with this pattern so the increasing demand for a 24/7 workplace has a serious impact on safety.

2

A disrupted sleep pattern can lead to fatigue and poor performance, which can increase risk. On a night shift, people are likely to be working when their bodies expect them to be asleep; they also then have to sleep during the day when they would otherwise be alert.

3

Other features of work schedules that affect levels of fatigue include the shift start time, the

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length of a shift, the number of shifts worked before a rest day, whether there is overtime, how much rest is taken between shifts, how much rest is taken during the shift, and whether the work schedule is regular and predictable. 4

Some shift patterns can result in a short daily rest interval of perhaps only 8 hours; this would be unfavourable for safety-critical workers.

1.6.3.15 Culture 1

Culture can be seen as 'the way we do things round here'.

2

Generally, people at work do unsafe things because:

(b)

it was a genuine slip or lapse-work patterns, working hours, fatigue and stress resulting from work or private issues etc. could be playing a part

(c)

a deliberate breaking of the rules - is the time allowed to do the job safely unrealistic? Is there a lack of management commitment to insisting on safe working? Peer pressure, particularly with regard to the young and inexperienced

(d)

management failure to devise and implement a safe working environment thus making unsafe working practices inevitable unless workers 'stand their ground'.

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they did not know that what they were doing, or the way they were doing it, was unsafe - an 'education' or 'training issue'

Safe working depends upon equal attention being given to: the conditions in which people are expected to work

(b)

safe systems of work being developed and implemented

(c)

safe behaviours being instilled in the people who have to do the work.

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The health and safety management system, as well as individual management practices, must support the desired culture. In fact, in the absence of a positive (or changing) culture, an observation and feedback process is unlikely to succeed.

5

Organisations rely on a number of processes and procedures to manage risk and thereby decrease the chance of incidents and injuries. Each of these processes has an important contribution to make, not only by improving workplace safety but also by influencing an organisation's culture.

6

These generally include systems such as:

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site rules and procedures

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health and safety training

(c)

hazard identification and correction

(d)

discipline

(e)

incident reporting and investigation

(f)

health and safety communications

(g)

worker engagement

(h)

health and safety suggestions

(i)

rewards and recognition.

When the system is poorly designed or operating ineffectively, its ability to accomplish its primary purpose will be compromised. At worst, a poorly designed, badly implemented or illfunctioning system can also have a negative influence on an organisation's overall health

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and safety culture. 8

For example, the culture cannot improve when: (a)

incident investigations create an air of mistrust and blame

(b)

safety incentive programmes discourage injury reporting

(c)

accountability processes fail to recognise individuals for their accomplishments

(d)

performance evaluations only consider safety performance in terms of whether or not the individual was involved in an incident, i.e. the outcome of an incident and not the potential.

Poor features of one system can have negative influences on other systems. For example, when employee incentive programmes or supervisor performance evaluations are based primarily on reducing injury rates, is it reasonable to expect employees to embrace an open injury reporting and investigation system?

10

Similarly, when the incident investigation process is viewed as extremely blame-oriented, is it reasonable to expect employees to feel uncomfortable in having their safe and at-risk behaviours observed and recorded? The above factors will stifle open and honest communication and can impact upon each other.

11

Hazard identification and correction requires a climate that fosters:

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willing employee participation

(b)

sufficient training so that employees can recognise and correct hazards

(c)

open communication about the hazard and/or its suggested solution.

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1.6.3.16 Intervention

There are many recorded instances of people failing to intervene when they see an unsafe or illegal act, which is taking place in public. Whilst it is fully understandable that someone might not want to become involved in a violent confrontation in the street, in the context of work the personal risk to say, a supervisor who intervenes to prevent someone working unsafely, should not be so great.

2

However, the behaviour of supervisors and managers can directly affect the behaviour of operatives. The effect of failing to intervene in an unsafe situation is to condone that activity, practice or behaviour. This in turn sends a message to the operatives that the activity concerned is permitted and confuses the site teams. Therefore, intervention by managers and supervisors is critical in every case.

3

From the information available, the reasons for a failure to intervene appear to be split between a lack of knowledge that anything was wrong and a conscious decision not to take any action.

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1.6.3.17 Lack of knowledge 1

The situation in which there was a lack of knowledge is self-explanatory; the person in control of the activity had not received adequate training and was not sufficiently competent to appreciate that work was being carried out in an unsafe manner.

1.6.3.18 Conscious decision 1

The conscious decision not to intervene may possibly be based upon financial or time considerations, for example, a supervisor might ignore the unsafe use of a ladder because it saves the time and expense of hiring-in a MEWP.

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However, there may be other personal factors for not intervening: (a)

overload, the supervisor or manager is suffering from a heavy workload and is simply unable to identify the unsafe situation developing

(b)

actions of others, especially other managers or senior managers, can shape the decisions of the supervisor. Usually the fact that no one else involved in the operation is concerned is excuse enough for not getting involved

(c)

ownership of the situation where the supervisor or manager does not actually believe or understand their duties, or where they are not directly in charge of the operation and believe they have no jurisdiction

(d)

having the skills to resolve the issue is also important. Where a supervisor or manager lacks knowledge about the task or the important communication skills, then they are less likely to get involved

(e)

the risk of possibly entering into a situation where they may be required to make a difficult decision that could have a significant effect on the project. The support of senior managers is critical to allow junior managers and supervisors to become involved in safety issues and empowering them to take whatever action they deem necessary if an unsafe situation arises. At worst, this could even involve the cessation of work until the safety issue is investigated further.

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1.6.3.19 Risk and safety

Making assessments about risks and reaching an informed decision cannot be achieved without information - or at least that's what most management systems require.

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The process of obtaining information begins with the recognition that the problem exists, and then raises questions to which answers are required. Deciding the level of accuracy and precision depends on the sampling and measurement methods.

3

In behavioural terms, this is done through identifying 'what' is happening during an observation and asking 'why'. The 'whats and whys' are collated, analysed and tabulated to identify trends, often by interpreting the data. Interpretation is based on the personal perception of what has been observed and so identifying trends can be difficult. Although risk can be quantified as abstract principles, health and safety cannot.

4

Whilst risk assessment is based on knowledge of the job and past experience, the corresponding judgement on safety is normative and can be 'political'. It may be possible to obtain group agreement on objective and rational measures of risk for various activities. However, there will often be . controversy over what are considered to be safe conditions.

5

Attempting to define acceptable levels of risk immediately raises the question of 'to whom' or 'on what terms' is the risk acceptable?

6

The distinction between risk and safety is more than a semantic one.

7

There are a number of factors to be considered in defining the acceptability of risk:

8

Cost: Safety is always compromised by available budget yet it costs far more to investigate and restore safe working conditions after an accident than it does to resolve the issues in the first place.

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Controls: Who has control? Those at the place of work should have control over the safety requirements of the task. Ownership is critical for a safe working environment.

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Customs: Many risks are taken because certain activities have always been done that way.

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Conditions: Many people are put at risk because conditions have changed resulting in

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longer working hours, tight timescales, lack of resources, workload, fatigue, stress or an ageing workforce. This leads to errors, particularly in plant maintenance. 12

Consequences: Managers rarely evaluate in advance the consequences of something going wrong. Often the thought process seems to be 'if it hasn't happened yet, it won't happen at all'.

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Benefit: What benefits does the individual get from taking a 'short cut' such as getting the Job done and an early finish.

1.6.3.20 Communication 'Actions speak louder than words'. For trust to be built an individual's behaviour and body language must reinforce what is being said -'walk the talk' as some people say.

2

Communication is at the heart of all that we do, both at work and in our own time. It takes place in many forms and can be transmitted via various media, e.g. face to face, radio, telephone, email or video conferencing. It is essential, especially within our working environment, that we get it right. Difficulties in achieving efficient communication may include background noise, the type of language used and sociocultural issues, so the potential for confusion and misinterpretation can be high.

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It is vital to give the person receiving information the time and space to be able to think and formulate a response. In communication, it is the quality, not the quantity, which matters.

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what is said

(b)

how it is said

(c)

body language (conscious or not).

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Studies have shown that, generally, individuals assess what is being communicated to them by subconsciously attaching an 'importance value' to each of the above three factors in the following proportions: (a)

7% of the communication is by words that are said 38% is through the way we say it, and

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During a normal conversation, we usually transmit and receive in three ways:

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1.6.3.21 Verbal and non-verbal communication

(c) 3

55% by the use of our 'body language'.

During periods of high workload or stress, our body language goes largely unnoticed. This is when the words we use and the way in which we say them become more important. In addition, our listening capability reduces as our workload or stress increases. Key points are: (a)

communication involves both a listener and a receiver. What we say, how we say it and when we say it are very important

(b)

we need to watch out for overload - if the receiver is overloaded then there is no point in trying to communicate with them. If the message is important then we need to lessen the workload

(c)

ensure you have the receiver's attention - some, or all, of the message will be lost or misunderstood if the recipient is not paying attention.

1.6.3.22 Hearing and listening 1

There is a difference between hearing and listening. Hearing is a mechanical process

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involving the way sound waves are translated by our ear into sound. When listening, we actively engage the brain and apply logic and context to the sound. 2

We only listen to about one-third of what we hear and that is only if we are interested. The proportion is much less if we are not interested. A productive exchange would usually involve: (a)

Listening by actively engaging the mind

(b)

Evaluating by considering what is being said; asking ourselves if it makes sense, if it is in context; whether we wish to respond

(c)

Planning what we are going to say and waiting for an opportunity to respond.

1.6.3.23 Questioning skills The way in which questions are asked can control the discussion.

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There are several types of question and the most used are:

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Closed

A fact or YES/NO

Open

Invites an extensive reply

Leading

Indicates the required answer

Limiting

Restricts options

Multiple

Many questions in one -confusion

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Type

We are always communicating. Even silence communicates something and may imply annoyance or criticism. Consider what effect your own personal style can have on others.

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Some good practices in communication

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Control distractions.

(b)

Where possible make visual and eye contact.

(c)

Clearly identify the transmitter and receiver.

(d)

Be clear, precise and concise.

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Obtain verification from the receiver that the message is understood.

(h)

Acknowledge the verification (closed loop communication).

1.6.3.24 Nationality, language and culture 'Safety must be a common language' 1

Construction has become a globalised business, with Qatar worksites typically staffed by multinational as well as multilingual and multicultural crews. This trend has posed risks, in particular with respect to communication.

2

Areas for consideration when working with a multicultural team include their: (a)

capability in Arabic and/or English

(b)

work role expectations

(c)

leadership expectations

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(d)

attitudes to safety

(e)

mutual understanding.

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Cultural differences can be overcome by all parties, especially the leader, practising mutual respect and by taking the trouble to understand the differing cultures and getting to know the team members as individuals.

1.6.3.25 The benefits of health and safety discussions Discussion/Consultation/ Involvement/Feedback Improvements to working practices will reduce the potential for accidents, create a better system of work and raise awareness of issues and solutions.

2

One method of enhancing any safe system of work is through frequent and open discussions. The heart of any process is communication: everyone involved needs to share ideas and knowledge. This can have a massive influence on bottom line profits with everyone working more efficiently towards achieving a high quality product.

3

The Contractors image will also benefit if, by the actions exhibited, it is shown to be committed to a safe and healthy working environment where no one is injured or becomes ill as a result of coming to work.

4

One option is for site managers to have an informal 10-minute chat with their employees and/or contractors' supervisors at the start of every day. The manager should encourage them to tell each other where they will be working and how their activity could affect other people. This will help supervisors to plan their day as well as improving co-ordination, consultation, production and, ultimately, safety.

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The aim of a behavioural safety discussion is to identify any difficulties in completing tasks safely and to aid the supervisor or manager in identifying problems to achieve a safe system of work. Participants in the discussion should:

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use open questions

(b)

smooth the way forward

(c)

be clear in what they are saying avoid any misunderstanding proactively resolve issues through positive actions rather than reactively observing unsafe actions.

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Those with more knowledge and experience can assist newer colleagues in understanding the hazards around them and stop people putting themselves at risk. Learning from a friendly, coaching manner is by far preferable to formal observations.

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All employees should be involved in these discussions. Above all else, problems or issues should be resolved immediately with someone who has the authority to make the necessary changes.

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Construction Site Safety 1.6.4

Drugs and Alcohol Misuse

1.6.4.1 Key points Managers and supervisors should know the signs and symptoms of taking drug and alcohol.

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People who take drugs and alcohol and are still under the influence when they arrive at work are far more likely to suffer an accident and be a danger to others.

3

There is also likely to be an impact on productivity, sickness absence and morale generally.

4

If staff are under the influence of drug or alcohol misuse at work, firm decisive action must be taken by the Contractor; it is unlikely that the problem will just go away.

5

Contractors should have a written policy for dealing with employees who are unfit for work through drug and/or alcohol misuse.

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Such a policy must be reflected in employees' contracts of employment to cover such eventualities as the 'right of search', random testing, suspension/dismissal from work.

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Policies should be tailored to the specific needs of the company, be fully integrated with existing procedures and strike a balance between appropriate support and robust discipline.

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Unless there is related misconduct, substance misuse should be seen as a treatable illness.

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Anyone facing up to suffering from a drugs/alcohol misuse problem should be offered support and rehabilitation in strict confidence; there are many agencies who can offer professional advice and help.

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Drugs testing is expensive and can introduce more problems than it solves, so the rationale for introducing a testing programme must be thoroughly thought out.

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1.6.4.2 Introduction

The influence and use of alcoholic drinks and illegal drugs by employees on site is of growing concern to Contractors, given the risks to the health and safety of those employees and others who may be affected by the employees' actions or omissions.

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Drug use poses a serious threat to the health, safety, well-being and livelihood of employees. Drugs may reduce perception, concentration and awareness, which can affect the safety and welfare of users and of others. The inability of a person to function competently and with reasonable care is a problem that must be addressed to prevent accidents occurring in the workplace.

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It should also be appreciated that taking some prescription and over-the-counter drugs can result in a reduction in alertness, concentration and, therefore, safety performance. This is covered in greater detail later in this text.

4

Alcohol-related problems can be detrimental to the individual's state of health and their safety awareness.

5

This can affect the smooth operation of an Contractors business, and can result in waste and inefficiency. Both alcohol and drug problems can be effectively treated by a variety of means. The earlier the intervention, the higher the likelihood of a positive outcome.

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Research findings show that drug and alcohol misusers are:

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3 times more likely to be absent from work for 7 consecutive days or more

(b)

at least 25% less effective overall

(c)

nearly 4 times more likely to be involved in workplace accidents.

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Drink driving 1

Driving on site under the influence of alcohol is equally, if not more dangerous than driving on a public road, and Contractors are required to develop a written policy on the matter. Contractors may also need to consider what their policy would be if an employee whose duties include driving (either on or off site) was convicted of drink driving.

Approximate detection times of alcohol and commonly used drugs in urine Approximate detection time

Alcohol Amphetamine

Dependent on amount consumed (approx. 1 unit per hour) 2-4 days

Barbiturates

2-10 days

Cannabis

2-30 days

Cocaine

12 hours - 4 days

Dihydrocodeine

1-2 days

Ecstasy

2-4 days

Heroin detected as morphine

1-2 days

Lysergide (LSD)

2-3 days

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1.6.4.3 Prescription and over-the-counter drugs

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In addition to the dangers which can be caused on site by the use of illegal drugs, some drugs prescribed by doctors or bought from pharmacies may also have unwanted sideeffects. On every drug packaging, there is a notice giving details of the correct dosage to be taken and at what intervals. This dosage must be strictly adhered to, as taking more than directed may have adverse effects. Similarly, there is often a warning on the packaging of over-the-counter drugs of the side-effects that they may have. This is suggested to be the case particularly with painkilling drugs and antihistamines. Some direction labels may also give a warning, for example:

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Such warnings should not be ignored - they are there for the guidance and safety of the person for whom the drugs are prescribed and should be strictly adhered to.

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If an employee is taking these forms of medication, a supervisor should be notified.

1.6.4.4 The scope of the problem 1

Problems at the workplace relate not just to consumption at or before work. Drugs or alcohol taken outside the workplace can affect performance long after the substance is consumed. The indirect effects of alcohol and drug problems on individuals' actions within the workplace can also be severe. When considering the scale of the drugs or alcohol problem within a company, the following must be taken into account.

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The risk of accidents due to under-performance caused by drugs or alcohol.

(b)

Inept and poor decision making.

(c)

Lower standards of work.

(d)

Low productivity caused by employees' inability to cope with workplace situations.

(e)

Disruptive actions by employees under the influence of substances, bringing about a breakdown in discipline.

(f)

The amount of time lost from the workplace due to absenteeism, lateness or habitual sick leave.

(g)

The general long-term health of the workforce.

(h)

Stress factors on employees due to home circumstances.

(i)

Stress factors on employees due to financial implications brought about by the need to feed a habit or addiction.

(j)

The adverse effect drugs or alcohol use could have on a Contractors image.

(k)

Security considerations.

(l)

The adverse effect on staff retention rates.

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Successfully tackling alcohol and drug misuse can benefit both your business and your employees. For example, you would save on the cost of recruiting and training new employees to replace those who left work because of untreated misuse.

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Offering support to those employees who declare a drug-related problem will also help to:

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reduce the risk of accidents caused by impaired judgement

(b)

create a more productive environment, and improve employee loyalty and morale

(c)

enhance public perception of your organisation as a responsible Contractor

(d)

contribute to Qatar society's efforts to combat alcohol and drug misuse.

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The misuse of alcohol or drugs (or solvents) by employees may come to light in a variety of ways. The following actions may indicate that a problem exists: (a)

absenteeism without notice poor time-keeping

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1.6.4.5 Identifying substance misuse

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(c)

high accident levels and a tendency to be clumsy

(d)

tendency to become confused and disorientated

(e)

poor performance of duties, a sloppy approach to work and poor presentation of the finished article

(f)

irritability or aggression, argumentative with superiors or work colleagues

(g)

misconduct

(h)

failure to remember, or failure to comply with, common instructions

(i)

a sudden need for increased supervision

(j)

leaving site either without permission or at lunch times to visit licensed premises

(k)

the finding of empty beer cans, bottles or drug-related paraphernalia.

Physical symptoms of substance misuse may include: (a)

rapid loss of weight

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(b)

gaunt appearance

(c)

tremors or sweating

(d)

constant tiredness

(e)

trackmarks, severe bruising or abscesses on arms

(f)

overdilated or very small pupils

(g)

cravings - ice cream, nicotine, sweet foodstuffs.

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(b)

severe mood swings

(c)

avoidance of authority or supervision

(d)

deteriorating relations with other staff

(e)

swings in morale

(f)

minimum involvement with other staff

(g)

obsessive or compulsive behaviour.

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Behavioural symptoms may include:

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The benefits of such identification need to be clear and, should a Contractor seek help, the Contractors may need to guarantee that the employee will not be disadvantaged.

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Supervisors and managers may need training so as to be effective in identifying and addressing drug or alcohol misuse problems. The focus should be on specific examples of how work performance is being affected and not on direct confrontations or accusations of drug or alcohol related problems. Full training on effectively raising the issue with employees should be given. Contractor’s policy on the subject should be clear and specific.

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1.6.4.6 Developing a workplace policy The substance misuse policy that is adopted will need to take account of the particular needs of the Contractor and the practical situations, including those brought about by working on building and construction sites.

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However, there are a number of minimum requirements for such a policy, which should: contain a clear statement of the behaviour that is expected of employees

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apply equally to all employees, including managers and supervisors, at the workplace

(c)

be made known to all employees

(d)

be an integrated part of an overall health and safety policy

(e)

include clear statements on the roles and responsibilities of all employees in relation to the policy (e.g. site-based operatives, site based managers)

(f)

encourage those with a problem to come forward under a promise of strict confidentiality and future support

(g)

to the greatest possible degree, be non-punitive

(h)

state the conduct likely to result in action being taken under the policy

(i)

provide for appropriate treatment and rehabilitation for those with problems

(j)

be evaluated after implementation and amended, if necessary, in line with the outcome of the evaluation.

The policy is likely to be proportionate if:

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(a)

it is instituted to protect and promote employee safety

(b)

employees are aware of the policy

(c)

the process of collecting, transporting and testing samples can be proven to be independent and beyond reproach

(d)

employees will know what the Contractors will do with the test results

(e)

the Contractors has no other reasonable alternative way of obtaining the same result.

1.6.4.7 Implementing a substance misuse policy Implementing such a policy has four essential components: the education and information of all levels of management and employees and their representatives

(b)

the organisational support shown by the company

(c)

the addressing of issues in the work environment

(d)

the prevention and rehabilitation support offered by the Contractor to its employees.

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Information about a substance misuse policy, covering alcohol and drugs, must be provided to all employees, and be included as part of any induction training for new recruits. The policy must be supported by education about the harmful effects of alcohol and drugs

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It is important that management demonstrates its full support for the policy by ensuring observance by all staff, at whatever level, and endorsing changes to the working environment to facilitate the full and proper implementation of the policy.

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The provision of treatment and/or referral services is an important component of implementing the policy. If problems are detected early, before serious physical and social effects occur, a brief intervention may be all that is needed.

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Confidentiality for employees undergoing treatment and rehabilitation must be guaranteed. Equally, employees should not be disadvantaged in terms of promotion or seniority because they have sought or are accepting help.

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However, as with all workplace health and safety matters, consultation with employees and the provision of education and information at an early stage may prevent the onset of alcohol and drug problems at work.

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1.6.4.8 Misuse outside of the workplace 1

Generally, an employee's conduct outside of the workplace is not within the Contractors’ control. However, if drug or alcohol misuse during recreational times creates a risk to their health and safety, or to that of others who may be affected by the employee's actions during working hours, consideration must be given to the situation and to what action should or can be taken.

1.6.4.9 Alcohol or drug screening and testing 1

Introducing drug testing in the workplace is a difficult and potentially expensive initiative. It is essential to be completely clear on the reasons for doing so, or not. Testing is far from the whole answer and has inherent limitations.

2

Before any decision is taken by a Contractor to implement an alcohol or drug testing regime, care must be taken to ensure that an alcohol and drugs policy is fully established and communicated to all employees.

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Why test Drug testing might be introduced for a number of reasons. Other than where there is a clear clinical imperative (i.e. rehabilitation testing), the effectiveness of each approach has not been proven.

4

Recruitment screening usually refers to testing or assessing the health of potential employees during the recruitment process. Testing of this kind presents far fewer legal and logistical problems than introducing testing for existing employees.

5

Routine testing is done at specified times, and gives a clear message that it is not acceptable to be affected by alcohol when working. It might be used in situations where employees are in 'safety critical' posts, such as operating driving construction plant on a public road or operating machinery.

6

Random testing or unannounced testing is used as a deterrent to identify previously undetected drug or alcohol misusers. As with routine testing, any use in situations that are not safety critical may cause feelings of resentment amongst the workforce.

7

Reason or 'With Cause' testing might be used if a manager has reason to believe that an employee has been using drugs or drinking. This might be because of their behaviour or by physical signs, such as smelling of alcohol. It may also form a part of a post-incident or accident investigation.

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Rehabilitation testing may be used where an employee has agreed to treatment and the treatment provider is testing to ensure compliance with a prescription (e.g. urine testing to ensure that an individual who has been prescribed methadone is not using heroin as well as the prescribed dose). Similarly, testing may be introduced as part of a return to work agreement between employee and Contractors.

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Is testing necessary?

Drug and alcohol testing is a controversial and complex issue which has scientific, ethical, legal, social, industrial and economic ramifications.

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It is reasonable to expect employees to be unimpaired by drugs or alcohol whilst at work, but it could be argued that requiring an employee to undergo a test 'without cause' (randomly or without specific evidence that they are impaired) is unfair and intrusive.

11

Whether testing is appropriate or necessary should be carefully considered, as the damage to Contractors-employee relations can potentially outweigh the benefits.

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Whether you decide to introduce testing or not, it must be emphasised that it is not an end in itself. Drug testing is no substitute for good management practice and should never be introduced without:

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(a)

full co-operation from employees

(b)

a programme of education for managers and employees

(c)

robust systems for referral to adequately trained health professionals.

Before considering the introduction of a testing programme, Contractors should be able to fully answer the following questions. (a)

Why do we want to test? (i.e. what do we hope to achieve by it?)

(b)

What substances will we test for?

(c)

Which employees will we test?

(d)

How will we select them?

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When will we test them? (e.g. routinely, randomly, pre-employment)

(f)

How often will we test?

(g)

How will we test (e.g. what method)?

(h)

Who is best placed to conduct the test? (e.g. independent company/laboratory, occupational health department)

(i)

What will we do with a positive result?

(j)

What training will be necessary and for whom?

(k)

What will be the financial costs?

(l)

What may be the other costs? (e.g. staff morale)

(m)

How will we involve the workforce and gain their consent?

(n)

What will be our safeguards? (i.e. how do we ensure that test results are accurate and legally defensible?)

The conclusions that are drawn from these questions should guide you to a well thought-out and rational decision.

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Methods of testing

There is a variety in both the methods used for employee testing and in the standards of service offered by drug testing companies. As yet there is no universally accepted accreditation scheme or quality standard.

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It should also be clearly understood that there is a significant difference between testing for alcohol and testing for other drugs.

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Alcohol testing indicates whether an individual is under the influence at that time. Drug testing - shows traces of drugs used in the past but does not necessarily confirm impairment at the time of testing.

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Alcohol use can be tested by: Breath testing - a 'breathalyser' measures the level of alcohol in the breath. This is convenient and inexpensive. Employees may be tested prior to commencing a shift, or immediately following an incident.

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Methods of testing for alcohol use

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Blood testing is the most accurate measure of alcohol in the body although it is more invasive than a breath test. It is often inappropriate in a workplace setting due to lack of staff suitably trained to take samples.

Methods of testing for drug use 19

Drug use may involve the use of illegal drugs, or prescribed and over-the-counter medicines. These can be detected by gaining samples from: (a)

oral fluid: not as invasive as other methods but a relatively new technology so may be expensive or inaccurate

(b)

hair: not accurate for recent use, but depending on hair length the sample may reflect the individual's drug use pattern over a course of months

(c)

blood: very invasive, but can be more accurate than others

(d)

urine: potentially invasive, but well established science

(e)

sweat.

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1.6.4.10 Disciplinary procedures 1

The majority of Contractors will have a disciplinary procedure in place. It may be appropriate to ensure the procedure covers the consumption of alcohol or drugs in the workplace. You may also wish for the policy to contain a provision that possession, dealing or trafficking in drugs will be reported to the police.

2

For a drug and alcohol policy to be effective, it is essential that it is consistent with disciplinary procedure.

Taking disciplinary action Employees with a substance misuse problem or suspected of misusing drink or drugs should have the same rights to confidentiality and support as they would if they had any other medical condition

4

It can be very difficult for employees to discuss or openly admit to having a drink or drugs problem, because of the stigma or fear of reprisals, or the difficulty they have facing up to the issue.

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Construction Site Safety 1.6.4 Appendix 1 Example drink and drug misuse policy and procedure Any policy should reflect the requirements of the Contractor and must be implemented in practice. Introducing a policy that is not followed or is inappropriate to the business may be worse than not having a policy at all. The policy imposes obligations on you as a Contractor as well as your employees. If you have a policy you may, for example, have to agree to treatment for employees where you may otherwise have simply followed the disciplinary procedure.

2

Furthermore, if a policy is adopted it must be reviewed regularly to ensure that it is working and changed as necessary. You must also ensure the employees remain aware of the policy and its consequences.

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Policy

The company recognises the potential dangers of alcohol, drug and solvent misuse, known as substance misuse, to both the individual and the company.

4

The company aims to prevent, where possible, alcohol, drug and solvent misuse amongst employees and to detect at an early stage employees with problems.

5

The company aims to prevent misuse, where possible, and will offer assistance such as counselling or leave of absence from work if required for treatment. There may be, however, some instances when this offer may not be appropriate and managers must assess each case individually.

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Rules

Employees must not use, possess, conceal, transport, promote, or sell prohibited substances whilst on company premises, in company vehicles, on client premises or at the work site.

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Employees must not report for work under the influence of alcohol or other drugs

8

Employees must not consume alcohol in the office or on site except on occasions approved by a senior manager.

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Establishing the problem 9

Managers should be aware that the misuse of drugs, alcohol or solvents by employees may come to light in various ways. The following characteristics, especially when arising in combinations, may indicate the presence of a substance problem.

Absenteeism 10

Instances of unauthorised leave.

11

Frequent Friday/Monday absences.

12

Leaving work early.

13

Lateness (especially on returning from lunch).

14

Excessive level of sickness absence.

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Section 11: Health and Safety Part 1.06: Human Factors (Regulatory Document)

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Strange and increasingly suspicious reasons for absence.

16

Unusually high level of sickness for colds, flu, and stomach upsets.

17

Unscheduled short-term absences, with or without explanation.

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High accident level 18

At work.

19

Elsewhere, for example driving, at home.

Work performance Difficulty in concentration.

21

Work requires increased effort.

22

Individual tasks take more time.

23

Problems with remembering instructions or own mistakes.

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Mood swings Irritability.

25

Depression.

26

General confusion.

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Self-referral 27

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In some instances, employees may come forward voluntarily and seek help themselves.

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Manager's responsibility

A manager is the individual responsible for a specific set of tasks and who has the power to issue orders, decisions and controls the resources and expenditures

29

A manager who suspects one of their employees of having a substance misuse problem must discuss the matter with the relevant manager/director before approaching the employee with their concern.

30

The manager will then discuss the matter with the employee and try to establish the cause of the problem (although it must be pointed out that individuals with a drugs or alcohol problem will often go to great lengths to conceal the situation).

31

The employee should be reminded or informed of the assistance the company is prepared to give employees who are trying to overcome an alcohol or drugs problem and should be informed of outside agencies where help can be obtained.

32

The employee should be informed that the company requires his or her performance to be improved to an acceptable and specifically outlined standard and that failure to achieve this will result in dismissal. The manager, having consulted with the director, should agree with the employee what follow-up action is to be taken. Where it is established that alcohol or drugs is or could be the problem, an appointment should be arranged with the company doctor or local drug and alcohol service provider.

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33

If the employee denies that either alcohol or drugs are the cause of the problem (whether believed or not), he should be treated as for any other disciplinary/capability problem, whichever is judged as appropriate by the manager and director.

34

However, if there are strong signs that the employee's unsatisfactory performance is drug or alcohol-related and he will not admit or acknowledge this, further encouragement should be given at all stages of the disciplinary/ capability procedure to face up to the problem.

Treatment and assistance Where employees acknowledge that they have a problem and are given support and treatment, this will be on the understanding that the company will give employees, assessed as having a substance misuse problem, all reasonable time off in accordance with the company's Absence Policy.

36

Every effort should be made to ensure that, on completion of the recovery programme, employees are able to return to the same or equivalent work.

37

However, where such a return would jeopardise either a satisfactory level of job performance or the employee's recovery, the appropriate director will review the full circumstances surrounding the case and agree a course of action to be taken. This may include the offer of suitable alternative employment, or the consideration of retirement on the grounds of ill health or dismissal. (Before a decision on dismissal is made, it should be discussed with the employee and an up-to-date medical opinion obtained.)

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Where an employee, having received treatment, suffers a relapse, the company will consider the case on its individual merits. Medical advice will be sought in an attempt to ascertain how much more treatment or rehabilitation time is likely to be required for a full recovery. At the company's entire discretion, more treatment or rehabilitation time may be given in order to help the employee to recover fully.

Recovery unlikely

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Relapse

Drug screening programme Procedure 40

Employees may be required to submit to a test to check for the presence of drugs or alcohol under the following circumstances. (a)

Following an accident or incident on company or client premises, at a work site or involving a Contractors vehicle.

(b)

Following the discovery of a prohibited substance on company premises.

(c)

Where there is reason to suspect that the employee may be under the influence of a prohibited substance.

(d)

Where it is suspected there has been a breach of the policy, for example high individual accident experience, excessive absenteeism, observed erratic behaviour and/or deteriorating job performance.

Refusal to take a drugs test

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If the employee refuses to take a drugs test, the employee will be subject to action under the company's disciplinary procedure up to and including dismissal.

Release of the test result 42

It is a condition of employment that all employees agree to the release of the results of screening for prohibited substances as required.

Right of search The Contractor reserves the right to search the person, his or her possessions and/or immediate work area, who works, visits or performs services on company premises. Where practical, in arranging for the search of the person to be carried out: the police will be contacted in the first instance

(b)

the person to be searched will be entitled to have a colleague present

(c)

the search will be carried out by someone of the same sex.

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(a)

Serious misconduct caused by alcohol, drugs or solvents

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If an employee is known to be, or is strongly suspected of being, intoxicated by alcohol, drugs or solvents during working hours, arrangements will be made for the employee to be escorted from the company premises immediately. The Contractors doctor may also be consulted on the incident. Disciplinary action will take place when the employee has had time to become sober.

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Intoxicated employees

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Consumption of alcohol on the premises

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Employees are expressly forbidden to consume alcohol when at work or to bring alcohol onto company premises under any circumstances. Any breach of this rule will result in disciplinary action being taken which is likely to result in summary dismissal.

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Education and training

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The Contractor will provide training for appropriate staff in recognising and responding to the early stages of alcohol or drugs problems amongst employees. The Contractor will provide health educational initiatives to raise awareness of the policy and the risks associated.

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Construction Site Safety 1.6.4 Appendix 2

How usually taken

Effects sought

Harmful effects include

Heroin(Smack, horse, gear, H, junk, brown, stag, scag, jack)

Injected, snorted or smoked

Drowsiness, sense of warmth and wellbeing

Physical dependence, tolerance, overdose can lead to coma and even death. Sharing injecting equipment brings risk of HIV or hepatitis infection

Snorted in powder form, injected

Sense of well-being, alertness and confidence

Dependence, restlessness, paranoia, depression, damage to nasal membranes

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Commonly misused substances

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Cocaine(coke, charlie, snow, C)

Crack(freebase, rock, wash, stone)

As for cocaine but, because of the intensity of its effects, crack use can be extremely hard to control, damage to lungs

Ecstasy(E, XTC, doves, disco biscuits, echoes, scooby doos)Chemical name MDMA

Swallowed, usually in tablet form, occasionally snorted as a powder

Alertness and energy but with a calmness and sense of well-being towards others. Heightened sense of sound and colours

Possible nausea and panic, overheating and dehydration if dancing, which can be fatal. Use has been linked to liver and kidney problems. Long-term effects not clear but may include mental illness and depression

LSD(acid, trips, tabs, dots, blotters, microdots)

Swallowed on a tiny square of paper

Hallucinations, including distorted or mixed-up sense of vision, hearing and time. An LSD trip can last as long as 812 hours

There is no way of stopping a bad trip which may be a frightening experience. Increased risk of accidents can trigger off long-term mental health problems

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Smokable form of cocaine Similar to those of snorted cocaine but initial feelings are much more intense

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How usually taken

Magic mushrooms(shrooms, mushies)

Eaten raw or dried, Similar effects to those of LSD but the cooked in food or brewed trip is often milder and shorter in tea

As for LSD, with the additional risk of sickness and poisoning

Swallowed as tablets or capsules, injected ampoules

Dependence and tolerance, overdose can lead to coma or even death. Severe withdrawal symptoms

Effects sought

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Barbiturates(barbs, downers)

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Name (street or trade name)

Calm and relaxed state, larger doses taken to produce a drunken effect

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Amphetamines(speed, whizz, uppers, In powder form, dissolved Stimulation of the nervous system, billy, sulph) in drinks, injected, sniffed wakefulness, feeling of energy and or snorted confidence Rolled in tobacco into a Relaxed, talkative state, heightened spliff, joint or reefer and sense of sound and colour smoked; smoked in a pipe or eaten *Also smoked from a 'bong' waterpipe

Tranquillisers(brand names include Valium, Altivan, Mogadon (moggies), Temazapam (wobblies, mazzies, jellies))

Swallowed as tablets or capsules, or injected

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Cannabis(hash, dope, grass, blow, ganja, weed, shit, puff, marijuana, skunk*)

Harmful effects include

Insomnia, mood swings, irritability, panic. The comedown (hangover) can be severe and last for several days Impaired co-ordination and increased risk of accidents, paranoia, poor concentration, anxiety, depression, increased risk of respiratory diseases including lung cancer. Possible risk of developing mental health problems, especially schizophrenic conditions

Prescribed for the relief of anxiety and to Dependency and tolerance, increased risk of treat insomnia. High doses cause accidents, overdose can be fatal, severe drowsiness withdrawal symptoms

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How usually taken

Anabolic steroids(many trade names)

Injected or swallowed as tablets

Effects sought

Harmful effects include

With exercise can help to build up muscle. However, there is some debate about whether drug improves muscle power and athletic performance

For men: erection problems, risk of heart attack or liver problems For women: development of male characteristics Injecting equipment brings risk of HIV or hepatitis infection

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Name (street or trade name)

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Poppers(alkyi nitrates, including arnyl Vapours from a small bottle Brief and intense head-rush caused by Nausea and headaches, fainting, loss of nitrate with trade names such as Ram, of liquid are breathed in sudden surge of blood through the balance, skin problems around the mouth and TNT, Thrust) through mouth or nose brain nose, particularly dangerous for those with glaucoma, anaemia, breathing or heart problems

Solvents(including gas lighter refills, aerosols, glues. Some paint thinners and correcting fluids)

Sniffed or breathed into the Short-lived effects similar to being lungs drunk and disoriented, possible hallucinations

Nausea, thick-headed, dizziness, blackouts, increased risk of accidents. Fatal heart problems can cause instant death

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Construction Site Safety 1.6.5

Safety Critical Communication

1.6.5.1 Key points Good communication is essential for the management of health and safety on construction sites.

2

Contractors are legally required to provide information that is 'comprehensible', i.e. provided in a format that can be understood by the worker.

3

This requirement can result in problems where the recipients of the information have limited or no understanding of Arabic and/or English, particularly during site induction.

4

Communicating using images has the potential to overcome these problems, regardless of the mix of languages spoken on site.

5

A bank of images, each representing a hazard or a simple instruction has been developed.

6

It is likely that it will be necessary to hold separate training sessions to assess the understanding of safety critical words and phrases by those with Arabic and/or English language problems.

7

Confirming that the workers being assessed can associate each image with a spoken short phrase in plain Arabic and/or English, will give supervisors and managers confidence that the workers have an understanding of safety critical words in Arabic and/or English.

8

Due to their simplicity, these phrases aid translation into other languages, if needed.

9

Before using any images, workers' competence, training and language skills must be assessed. This will also indicate the level of supervision required generally.

10

The images can be used to support site inductions, tool box talks or other training, or superimposed on site plans to identify the location of welfare facilities, fire-fighting equipment, and so on.

11

The images also help to fill gaps in translation, as well as improving memory recall of site rules.

12

If appropriate, the images can enhance and complement existing procedures rather than replace them.

13

An understanding of the images should not be solely relied upon to ensure that work of a higher risk nature can be carried out safely.

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1.6.5.2 Introduction 1

Good communication is essential for the management of health and safety on construction sites. The number of workers on sites, where Arabic and/or English is not their first language, has increased over recent years. Some of these workers have excellent skills in spoken and written Arabic and/or English, but there are others for whom understanding Arabic and/or English is a problem. This can be a barrier to effective communication of health and safety information.

1.6.5.3 Relevant health and safety legislation Health and Safety at Work 1

Contractors to provide employees with any necessary information and adequate training to ensure their health and safety at work.

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1.6.5.4 The Management of Health and Safety at Work The requirements of these Regulations: (a)

requires Contractors to provide 'comprehensible' information on the: (i)

risks identified in their risk assessment

(ii)

preventative and protective measures identified as necessary by risk assessments

(iii)

emergency procedures on site

(iv)

risks arising from the work of other contractors

(b)

duties on Contractors to provide 'comprehensible' information to subcontractors and the self-employed

(c)

duty on Contractors to take into account the capabilities of their employees. This includes their capability to understand instructions and training given in Arabic and/or English

(d)

places duties on Contractors regarding the employment of temporary workers or those supplied by a labour agency. Before starting work these workers need to be supplied with 'comprehensible' information on:

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any special occupational qualifications or skills required to enable the worker to work safely

(ii)

the requirement for any health surveillance arising out of the work to be carried out.

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(i)

The word 'comprehensible' can be taken to mean provided in a format that can be understood by the worker. The Contractor can provide information in a form which takes into account any language difficulties and suggests the use of symbols as one way of doing this.

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1.6.5.5 Construction (Design and Management) CDM

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These Regulations place duties on the Contractors to ensure that workers are provided with instruction and training, with specific references made to induction training and site rules.

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1.6.5.6 Managing the situation 1

Contractors who engage workers who cannot speak or understand Arabic and/or English have a few options when deciding how to manage communications. These include hiring a bilingual supervisor who can give information, instruction and training to workers. Alternatively, Arabic and/or English speaking co-workers are often used on site to communicate with non-Arabic and/or English speaking workers. However, their competence (both technically in construction and as a translator) must be assessed first.

2

Another option is for training materials to be translated or to be represented in a pictorial form (images). The effectiveness of images to overcome language barriers has been confirmed through research.

1.6.5.7 Pre-start assessments 1

Before any worker starts on site certain facts must be established. These are the level of: (a)

the worker's competence and training

(b)

the worker's understanding of Arabic and/or English

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(c)

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supervision required.

2

The type of work to be done by the worker will dictate the required level of competence and identify any training needed. Regardless of language issues foreign workers must meet the level of competence and training expected of any worker asked to do the task(s). Therefore, contractors should apply the same criteria for non/low-Arabic and/or English speaking workers as they do for Arabic and/or English speakers, which will require some form of competency assessment.

3

Failure to prove an acceptable level of competence will indicate that further training is required before considering the other pre-start factors.

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END OF DOCUMENT

QCS 2014

Section 11: Health and Safety Page 1 Part 1.07: Fire and Flammable Substances (Regulatory Document)

REGULATORY DOCUMENT........................................................................... 1

1.7

FIRE AND FLAMMABLE SUBSTANCES ........................................................ 1

1.7.1

Fire Prevention and Control in the Office....................................................... 4

1.7.2

Fire Prevention and Control in connection to construction .......................... 25

1.7.3

Dangerous Substances ............................................................................... 35

1.7.4

Liquefied Petroleum Gases ......................................................................... 50

1.7.5

Vehicle Fuels (including Petrol, Diesel and LPG) ........................................ 67

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QCS 2014

Section 11: Health and Safety Page 2 Part 1.07: Fire and Flammable Substances (Regulatory Document)

FORWARD

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This Section of the Regulatory Document (RD) was produced as a project deliverable under Ministry of Municipality and Urban Planning Contract Number P2009/3, entitled “Consultancy Services for the Preparation of Codes and Standards for Safety and Accident Prevention on Construction Sites”. During the latter stages of the project, the Committee responsible for the administration of the project decided that the RD and the associated Safety and Accident Prevention Management/Administration Systems (SAMAS) would be best delivered to stakeholders via the portal provided by the Qatar Construction Standards (QCS). The QCS includes references and certain sections which address occupational health and safety. To ensure that that users of the RD/SAMAS are fully aware of the where occupational health and safety issues are addressed in the QCS, the following table summarises where potential overlaps may occur. For consistency, it is recommended that in matters relating to occupational health and safety reference is made first to the RD/SAMAS. For the purpose of clarity, however, references are made in the relevant section of the RD/SAMAS to their comparable sections in the QCS and vice versa.

QCS 2014

Section 11: Health and Safety Page 3 Part 1.07: Fire and Flammable Substances (Regulatory Document)

Sr. No

QCS 2014 Section No.

Part No.

Part Name

1

1

7

Submittals

8

7.5.2

Health and Safety Organization Chart

2

1

7

Submittals

9

7.6.1

Health and Safety Plan

3

1

10

Health and Safety

All

All

All

4

1

11

Engineer's Site Facilities

10

11.4.6

Safety Equipment and Clothing

5

1

14

Temporary Works and Equipment

3

14.4

Test Certificates for Cranes and Lifting Tackle

6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1

General Requirements for Piling Work

7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

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Item Name

.

Page No. Item No.

Safety and Management

4.9.1.13 Protection of Testing Equipment 1.6

Temporary Fencing

15

7.8.13

Safety Requirements

Works in Relation to Services

4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

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8

1

17

8

8

Painting and Protective Coatings

6

8.1.9

Safety

18

8

9

Trenchless Pipeline Construction

7

9.2.5

Safety Requirements

19

8

10

Pipeline Cleaning and Inspection Survey

4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

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Sewer Rehabilitation

9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16

Noise Levels and Vibration

1

23

m

11

19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1

General Provisions for electrical Installation

7&8

1.1.11

Fire and Safety Precautions

25

21

1

General Provisions for electrical Installation

14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5

Fire Resistance Period

28

29

3

Geotechnical Specifications

4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4

Safety Measures and Systems

32

29

7

Concrete Structures

6

7.1.10

Safety Railing

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1.7.1

Section 11: Health and Safety Page 4 Part 1.07: Fire and Flammable Substances (Regulatory Document)

Fire Prevention and Control in the Office 1.7.1.1 Key points Fires can and do kill, injure and cause serious human suffering and financial loss. The potential dangers are particularly severe on many construction sites, where construction activities such as hot work are frequently combined with circumstances where fires can spread quickly and escape may be difficult.

2

The rate of injury to people and damage to property and environment caused by fire in connection to construction is significant.

3

When construction activities are not adequately controlled, employees and members of the public can also be killed or injured, and property adjacent to construction sites be put at risk – for example, from a site fire large enough to spread off-site. Offices in particular site offices are vulnerable to fire risks and serious fire damage.

4

Particular attention is required regarding sites, premises, temporary accommodation brought onto site to provide offices, canteens and welfare facilities that are occupied by people at work on construction sites. They shall be subjected to a specific fire risk assessment.

5

Temporary accommodation on site must be used for their intended purpose. They shall not be used for storing dangerous substances.

6

These Regulations require a risk based approach for fire prevention and control and places legal obligations on the contractor to carry out a fire risk assessment and put in place appropriate control measures and maintaining them in accordance with any changes that occur.

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1

site-based offices and temporary site accommodation;

(b)

off-site company offices;

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(a)

(c)

any other place of work in connection to construction activities.

These Regulations require the contractor to ensure that:

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1.7.1.2 Introduction

(d)

construction sites, offices, premises and temporary accommodation or part of them are subjected to fire prevention and control measures;

(e)

fire risk assessments are carried out, recorded, reviewed and acted upon;

(f)

fire arrangements are in place for the offices, temporary accommodation and the construction site;

(g)

elimination and reduction of risks from dangerous substances are followed;

(h)

fire detection and fire systems are in place;

(i)

Procedures for serious and imminent danger and for danger areas;

(j)

emergency arrangements are in place including emergency routes and exits;

(k)

liaison is undertaken with the relevant governing body for fire.

1.7.1.3 The fire problem (l)

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Section 11: Health and Safety Page 5 Part 1.07: Fire and Flammable Substances (Regulatory Document)

1.7.1.4 Enforcement of fire safety legislation 1

The Fire safety legislation is enforced by the Civil Defence, Ministry of Interior, the State of Qatar.

1.7.1.5 Duty for fire prevention 1

These Regulations require the contractor to undertake a formal risk assessment in relation to: (a)

site-based offices and temporary site accommodation;

(b)

off-site company offices;

(c)

any other place of work in connection to construction activities and his undertakings;

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so as to determine the appropriate fire safety measures to be implemented.

These measures include a suitable means of escape, fire alarms, emergency lighting and fire-fighting equipment. Suitable records should be maintained.

3

The Contractor must:

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take such general fire precautions as will ensure, so far as is reasonably practicable, the safety of any of their employees; and

(b)

in relation to relevant persons who are not their employees, take such general fire precautions as may reasonably be required to ensure that the premises are safe.

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'General fire precautions' includes:

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(a)

reducing the risk of fire and the spread of fire on the premises

(b)

methods of escape

(c)

measures for securing that the means of escape can be safely and effectively used at all times

(d)

measures in relation to the means for detecting fire on the premises and giving warning in case of fire on the premises

(e)

arrangements for action to be taken in the event of fire, including measures relating to the instruction and training of employees, and measures to mitigate the effects of the fire.

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(f) 5

measures in relation to the means for fighting fires on the premises

The Contractor must: (a)

assess the risks to which relevant persons are exposed

(b)

consider the effects of dangerous substances

(c)

review the risk assessment regularly, particularly if there have been significant changes to the environment

(d)

not employ young persons without making a suitable and sufficient risk assessment of the risks to them.

6

The risk assessment must include the control measures which have been, or will be taken, to reduce the risk of fire and identify any group of persons identified by the assessment as being especially at risk.

7

No new work activity involving a dangerous substance may start unless the risk assessment has been made and the required measures have been implemented.

QCS 2014

Section 11: Health and Safety Page 6 Part 1.07: Fire and Flammable Substances (Regulatory Document)

Elimination or reduction of risks from dangerous substances 8

Where a dangerous substance is present, the Contractor must ensure that risks are either eliminated or reduced so far as is reasonably practicable.

Fire-fighting and fire detection 9

Where necessary, the contractor must ensure that the premises are equipped with appropriate fire-fighting equipment, fire detectors and alarms. Any non-automatic fire-fighting equipment must be easily accessible, simple to use and indicated by signs.

10

The Contractor must, where necessary: take measures for fire-fighting on and in the premises, adapting them to the nature of the activities carried out there and the size of the undertaking and of the premises concerned

(b)

nominate competent persons to implement those measures and ensure that the number of such persons, their training and the equipment available to them are adequate, taking into account the size of the premises concerned and any related hazards. This requirement does not apply to a self-employed person or a partnership where, in either case, there is sufficient knowledge and experience to enable adequate preventative and protective measures to be taken

(c)

arrange any necessary contacts with external emergency services, particularly regarding fire-fighting, rescue work, first aid and emergency medical care.

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In order to safeguard the safety of relevant persons where necessary, the Contractor must ensure that routes to emergency exits from premises and the exits themselves are kept clear at all times. The following requirements must be complied with. Emergency routes and exits must lead as directly as possible to a place of safety.

(b)

People must be able to evacuate the premises quickly and safely.

(c)

The number, distribution and dimensions of emergency routes and exits must be adequate for the maximum number of persons who may be there at any one time.

(d)

Emergency doors must open in the direction of escape. Sliding or revolving doors must not be used for exits specifically intended as emergency exits. Emergency doors must not be locked or fastened in a way that stops them from being easily and immediately opened in an emergency.

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Emergency routes and exits

(e)

Emergency routes and exits must be indicated by signs. Emergency routes and exits requiring illumination must be provided with emergency lighting of adequate intensity in the case of failure of their normal lighting.

Procedures for serious and imminent danger and for danger areas 12

The Contractor must establish and put into effect appropriate procedures, including safety drills, and nominate a sufficient number of competent persons to implement those procedures. The Contractor must also ensure that nobody can access any area to which access has been restricted on grounds of safety, unless the person concerned has received adequate safety instruction.

Additional emergency measures in respect of dangerous substances 13

The Contractor must ensure that: (a)

information on emergency arrangements is available

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(b)

suitable warning and other communication systems are established to enable an appropriate response

(c)

where necessary, before any explosive conditions are reached, visual or audible warnings are given and relevant persons withdrawn

(d)

where the risk assessment indicates it is necessary, escape facilities are provided and maintained to ensure that, in the event of danger, relevant persons can leave endangered places promptly and safely.

14

The Contractor must ensure that the information required is made available to relevant accident and emergency services, and also displayed at the premises, unless the results of the risk assessment make this unnecessary.

Maintenance The Contractor must ensure that the premises and any facilities, equipment and devices provided are subject to a suitable system of maintenance and are maintained in an efficient state, in efficient working order and in good repair.

16

Where the premises form part of a building, the Contractor may make arrangements with other occupiers of the building to ensure that the above requirements are met.

17

Provision of information to employees, self-employed and Contractors from outside the undertaking

18

The Contractor must provide employees and relevant others with understandable and relevant information on the risks identified, the preventative and protective measures, the significant findings of the risk assessment and certain other matters. Such information will usually be communicated by way of safety signs, site induction, written procedures and similar means.

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The Contractor must ensure that employees are provided with adequate safety training that includes suitable and sufficient instruction and training on the appropriate precautions and actions to be taken by employees in order to safeguard themselves and other relevant persons on the premises. It needs to take account of the fire risk assessment and the emergency procedures, and be easily understandable and repeated periodically. The training should cover: discovering a fire

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Training

(b)

how to raise the alarm

(c)

what to do on hearing the alarm

(d)

procedure for alerting visitors and all staff

(e)

calling the fire service

(f)

evacuation procedures, assembly points and fire drills

(g)

location and use of fire-fighting equipment

(h)

location of escape routes

(i)

how to open escape doors

(j)

importance of fire doors

(k)

how to stop equipment and isolate power

(l)

not using lifts

(m)

use and risks of highly flammable and explosive substances

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(n)

good housekeeping

(o)

smoking policy and smoking areas.

Co-operation and co-ordination 20

Where two or more Contractors share, or have duties at, premises, whether on a temporary or a permanent basis, they must co-operate as necessary to enable them to comply with the requirements of these Regulations.

General duties of employees at work

take reasonable care for the safety of themselves and of other relevant persons who may be affected by their work

(q)

co-operate with their employer (the contractor)

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(p)

The employee must inform their employer, or any other employee with specific responsibility for the safety of employees, of any work situation which they would reasonably consider to be a serious and immediate danger to safety. Employees should also report any matter which they consider to be a shortcoming in the employer’s protection arrangements for safety.

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Every employee must, while at work:

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1.7.1.6 The Management of Health and Safety

These Regulations require that risk assessments be carried out for all work activities. These include assessing and controlling the risk of fire on construction sites.

2

Furthermore, these Regulations require that all Contractors have access to competent health and safety advice, which again in the context of this module, includes having access to someone who is competent to:

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accurately assess the risks to the health and safety of any person from the outbreak of a fire, and

(b)

indicate to the Contractor what additional actions, if any, must be taken to adequately control those risks

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1.7.1.7 Construction (Design and Management) CDM In most cases, the requirements for fire and safety in on-site offices and other accommodation will be enforced under these Regulations and the requirements are: (a)

for measures to be taken to prevent the risk from fire, explosion or any substance likely to cause asphyxiation.

(b)

for measures to be taken to detect and fight fires in relation to work carried out on construction sites.

1.7.1.8 Fire risk assessments 1

The stages of a fire risk assessment are:

Identify potential fire hazards on site 2

What flammable materials are present?

3

What sources of ignition are present?

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4

Can anything be done to reduce either?

5

What must be done to keep flammable materials and sources of ignition apart?

Identify who might be harmed How many people are at risk?

7

Are any at an enhanced level of risk because of what they do or where they work?

8

Is the means of raising the alarm effective - can it be heard by all?

9

Are escape routes clearly signed and kept free of obstructions?

10

Does everyone know where their escape route is?

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Determine the level of risk

Having considered the fire hazards and who might be harmed, is the level of risk acceptable - are the existing fire prevention measures adequate?

12

To determine the answer to the above point consider:

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are sources of ignition under adequate control?

(b)

is a hot-works permit system in place and if not, is one necessary?

(c)

are the existing fire detection/warning systems effective?

(d)

is the means of escape (for everyone on site) adequate?

(e)

is the means of fighting fire (for example, portable fire extinguishers) adequate, appropriate for the likely type of fire and well maintained?

(f)

have sufficient site staff been trained in the use of fire extinguishers?

(g)

is it necessary to establish a network of Fire Wardens to oversee any evacuation of the site?

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(a)

Significant findings of the risk assessment, including details of any actions taken to reduce the fire risk, must be recorded in a manner that can be easily retrieved should it be necessary to do so.

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Record the significant findings

Review the fire risk assessment 14

It could be argued that this stage is more important on construction sites, due to the everchanging nature of the site, than it is in many other types of workplace.

15

For example, consider: (a)

what was an escape route last week might be a 'dead-end' today

(b)

the increasing complexity of escape routes as large structures are built

(c)

the start of a "hot-works' process

(d)

the start of a process that necessitates the storage of flammable substances, such as LPG and other gases, in bulk.

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1.7.1.9 The following is a list of some of the factors that should be considered when carrying out a fire risk assessment.

Abrasive cutters

(c)

Heaters

(d)

Heat-producing processes

(e)

Electrical apparatus

(f)

Machinery overheating

(g)

Discarded smoking materials

(h)

Arson or malicious fire-raising

.

(b)

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Hot work

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Storage of combustible materials Flammable gases

(b)

Flammable liquids

(c)

Timber

(d)

Plastics

(e)

Paper, cardboard and similar materials

(f)

Cotton, wool and similar materials

(g)

Flammable waste material

Building features Access, egress

(b)

Floor openings

(c)

Flues

(d)

Doors, windows

(e) (f)

(g)

Floor construction

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(a)

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Wall linings

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Sources of possible ignition

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Maintenance (a)

Cleaning (use of flammable materials)

(b)

Plant maintenance

Fire detection (a)

Automatic detectors

(b)

Fire alarm call points

(c)

Alarm bells

Means of escape in case of fire (a)

Doors

(b)

Staircases

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(c)

Passageways

(d)

Assembly points

(Note that lifts are not recommended as a means of escape.)

10

Fixed fire-fighting equipment

(b)

Hose reels, sprinklers

(c)

Extinguishers

(d)

Position of extinguishers

(e)

Site fire plan

Test regularly

(b)

Service after use

(c)

Maintain in correct position

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Maintenance of fire-fighting equipment

Staff training Raising the alarm

(b)

Emergency procedures

(c)

Appointment of fire wardens

(d)

Fire drills

(e)

Fire-fighting equipment

(f)

End-of-day fire checks

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Provision of fire-fighting equipment

An example fire risk assessment questionnaire is included at Appendix 2.

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1.7.1.10 On-site temporary buildings Temporary buildings on site include site offices, canteens, rest rooms, drying rooms and toilets. They are often of timber construction, although of fire-resisting surface materials. They may be found as a single building, or as a range of single-storey structures, or they may form a multi-floor 'administrative complex'. Ideally all temporary buildings would be easily accessible by the fire and rescue service, should the need arise.

2

Temporary buildings should be separated from the building under construction, other temporary buildings and storage compounds by a fire-break of at least 10 metres where possible. If it is not possible to achieve a 10-metre separation, ideally, the fire break will not be less than 6 metres.

3

Temporary buildings which are located inside the building under construction, or within 6 metres of it, must be equipped with fire-detection systems.

4

Temporary buildings should be designed and constructed:

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(a)

of materials that would not contribute significantly to the growth of a fire or the propagation of smoke or corrosive fumes

(b)

of fire-resisting material to BS 476 with regard to walls, roof, doors and windows, to achieve 30 minutes fire resistance

(c)

where stacked on top of each other, the floor and roof assembly, and members

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5

Where temporary buildings do not sit flush on the floor, measures must be taken to prevent the accumulation of rubbish in the space beneath the floor, whilst still allowing under-floor ventilation.

6

Consideration should be given to fitting automatic fire detection systems and intruder alarms to temporary buildings in which flammable substances are stored.

7

Automatic fire detection systems must be fitted in temporary buildings in which cooking is carried out.

1.7.1.11 The conditions for fire In order to take the measures required to prevent fires starting, it is first necessary to understand the conditions that must be present to enable a fire to start.

2

Three factors are necessary for fires to burn:

3

Fuel or combustible material. Any material or substance, whether liquid, solid or gas, which will burn given sufficient amounts of heat and a supporter of combustion such as air or oxygen.

4

Heat or ignition source. Every fuel has an ignition temperature. All solids and liquids give off vapour when heated, and it is this vapour that ignites.

5

Air (or other supporter of combustion such as oxygen) which is always there to sustain fire, providing the other factors are present.

6

Once a fire has started, if any one of these factors is isolated or removed, the fire will be extinguished. There are three basic ways of achieving this:

7

Removal of the fuel or combustible material, leaving nothing to burn.

8

Removal of the heat by the application of water to cool the burning material.

9

Reduction or exclusion of the air/oxygen by smothering the burning material. Foam, dry powder, carbon dioxide (CO2) and fire blankets are all smothering agents.

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1.7.1.12 How fires can be spread 1

Fire can be spread in four ways: (a)

conduction

(b)

convection

(c)

radiation

(d)

direct burning.

2

Conduction is where heat is transmitted from one place to another along or through solid material, such as along a metal pipe or through a door or wall. The conduction of heat therefore has the potential to start a fire in a location that is remote from the original source of heat.

3

Convection occurs where superheated gases or heat rising from a fire ignites other combustible material or when particles of burning material in the circulating air are deposited

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in another place, causing another fire. 4

Radiation is the transfer of radiated heat from the fire, through the air directly to other flammable materials nearby, which will cause those materials to be raised to their ignition temperature and then burn.

5

Direct burning is a combination of conduction, convection and radiation and is where the fire spreads and reaches other combustible materials and ignites them, adding further fuel to the fire.

1.7.1.13 Classes of fire All fires can be placed into one of the following six categories.

2

Class A - Carbonaceous material, such as paper, cloth, wood, rubber, often referred to as 'solid fuel fires'.

3

Class B - Flammable liquids or liquefiable solids, such as oil, fat, paint and fuel. These can be subdivided into:

4

B1 - Fires involving liquids that are soluble in water, such as methanol. They can be extinguished by carbon dioxide, dry powder and water spray.

5

B2 - Fires involving liquids that are not soluble in water, such as petrol and oil. They can be extinguished using foam, carbon dioxide and dry powder.

6

Class C - Flammable gases or liquefied gases, such as propane, butane, hydrogen or acetylene.

7

Class D - Combustible metals, such as magnesium, sodium and phosphorus.

8

Class E - Electrical fires - Any fire involving electrical apparatus or equipment.

9

Class F - High temperature cooking oils or fats, such as those used in deep fat fryers in large catering establishments or restaurants.

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On the majority of building or construction sites, the following carbonaceous items are freely available sources of fuel:

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Class A - carbonaceous material

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(a)

cardboard, paper and cloth

(b)

wood

(c)

dirty rags, oily rags and clothes

(d)

packaging materials.

If a fire occurs involving carbonaceous material, a hose-reel or a water extinguisher should be used. The jet of water should be aimed at the base of the fire first, and then moved progressively over the whole of the burning area. Always remove the material from the source of heat if possible, but without endangering the person involved or starting a fire in another location.

Class B - flammable liquids or liquefiable solids 12

Fires involving flammable liquids, such as: (a)

petrol or diesel

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(b)

oil

(c)

paraffin

(d)

paint

(e)

resin and adhesive.

This type of fire should be dealt with using foam or dry powder extinguishers, depending on whether the fire is contained or flowing.

14

If the fire is contained, use a foam extinguisher with the jet of foam directed at the back of the container.

15

This allows a blanket of foam to build up and spread across the surface of the burning liquid.

16

If the fire is flowing, a dry powder extinguisher should be directed at the front edge of the fire, in an attempt to separate the flames from the fuel.

17

The aim of using extinguishers in such a way is for the fire to be covered with a blanket of either foam or dry powder. This will cut off the supply of air, and thus the oxygen, to the fire.

18

Once the blanket has been laid, do not disturb it until the liquid has cooled. Any reintroduction of air may cause the fire to re-ignite.

19

NEVER use a water extinguisher or a hose-reel on a fire involving any flammable liquid. The water will react violently with the burning liquid and cause an explosion.

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Class C - flammable gases or liquefied gases

Extreme caution is necessary when dealing with fires involving liquefied gases as there will always be the danger of an explosion.

21

LPG expands to a ratio of 274:1 so a leak of just 1 litre of liquid would produce a cloud of gas, if diluted in air to the right concentration, large enough to fill a room 3m x 2m x 2m. This would cause an explosive atmosphere.

22

If a fire occurs in which a compressed gas cylinder is directly involved: (a)

call the Qatar Administrative Authority and tell them of the location of the cylinders and type of gas involved attempt to turn the gas off at the cylinder, if it is safe to do so

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(c)

attempt to turn off any gas appliances if it is safe to do so

(d)

activate the emergency evacuation procedure and clear the site.

23

Do not try to fight a fire in which a compressed gas cylinder is directly involved; leave it to the Qatar Administrative Authority as an overheated cylinder can explode.

24

If a fire involves other combustible materials, for example timber, that might cause the fire to spread to the location of the cylinders, a decision based upon personal safety will have to be taken upon whether to attempt to fight the fire to prevent an escalation of the situation.

25

Class C fires are best dealt with by the use of dry powder extinguishers.

Class D - combustible metals 26

Fires of this type involve magnesium, sodium, phosphorus, and similar metals, and should only be dealt with by trained fire fighters.

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27

NEVER APPLY WATER TO ANY BURNING METAL FIRE OR A FIRE INVOLVING POWDERED METAL. It would cause an immediate explosive reaction.

28

Specially formulated powders are available for use in controlling fire in metals but, as a last resort, if no proprietary powder is available, dry sand or earth may be applied to smother the burning area.

29

The proprietary powder should be carefully placed and not thrown onto the burning metal. Throwing the powder will cause the burning material to be spread.

30

Be sure either to wear darkened safety glasses whilst attempting to cover the fire, or to look away from the extreme brightness. Failure to take these precautions could damage the eyes.

1.7.1.14 Electrical fires Fires involving electrical equipment can be dealt with using carbon dioxide (CO2) or dry powder.

2

In staff training, the following simple rules for safety should be emphasised:

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do not use water on any fire involving electrical equipment. You may be electrocuted

(b)

switch off the electricity supply, if possible, before fighting the fire. It is then just an ordinary fire

(c)

do not approach closer than 1 metre to any fire where the electrical supply has not been switched off

(d)

carbon dioxide (CO2) is the best extinguishing medium if the concentration of gas can be confined, for example within an electrical distribution cupboard

(e)

in extinguishing electrical fires, direct the discharge from the extinguisher to one edge of the fire and, with a sweeping movement, pass to the far edge until the fire has been extinguished.

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(a)

Electrical equipment used on building and construction or demolition sites sometimes incorporates devices to protect against overheating and fire.

4

Most fires in electrical equipment are due to misuse or neglect, where appliances have not been properly maintained, or are being used for a purpose, or in a manner, for which they were not designed.

5

A fuse larger than the appliance rating will negate the purpose of the fuse and render the appliance potentially unsafe.

6

All employees should be properly trained so that they do not misuse equipment, and ensure that damaged or defective equipment is reported, taken out of use and professionally repaired.

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1.7.1.15 Other types of fire Flammable adhesives and flammable liquid stores 1

Use dry powder or foam.

2

Extreme care must be taken if the adhesive is petroleum- or spirit-based as explosive vapours will be given off.

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Cooking ranges (site canteens) 3

Use foam, dry powder, carbon dioxide (CO2) or a fire blanket. Never move a cooking container, the contents may splash and cause serious burns.

Hot working with cutting or welding equipment, bitumen boilers 4

Use foam, dry powder or carbon dioxide (CO2). Turn off the heater.

5

The correct types of fire extinguisher must be provided and kept close at hand, with a careful watch being maintained for fire breaking out whilst work is in progress.

1.7.1.16 Dealing with fire In the event of a fire, the most important consideration is the safety of occupants such as site visitors and staff.

2

Effective control measures, such as periodically practising emergency evacuations and the routine maintenance and/or testing of fire detection and fire-fighting equipment, can save lives. Everyone must know what they have to do if there is a fire or during a rehearsal of emergency evacuation procedures (a fire drill).

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1.7.1.17 Emergency procedures

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In the event of a fire occurring, it is essential that the alarm is raised as quickly as possible so that workers can quickly and safely reach a place of safety.

2

This can only be achieved by considering the following steps.

3

A means of detecting and warning of fire must be provided in all offices. Hand bells, klaxons, manually or electrically operated sounders may be suitable so long as they are clearly audible above background noise in all areas and can be readily identified as being a fire alarm. Flashing lights or vibrating pagers may be required in certain circumstances.

4

Legible written emergency procedures must be displayed in prominent locations within offices and should include: the location of the notice to enable the location of the fire to be pinpointed, e.g. firstfloor photocopier room

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(b)

instructions for raising the alarm

(c)

instructions for calling the fire and rescue service

(d)

instructions to report to the nearest assembly point

(e)

clear information as to the whereabouts of the assembly point

(f)

a clear instruction not to leave the assembly point until a roll-call has been taken

(g)

an indication of the locations of fire escape routes

(h)

an instruction not to re-enter the building or site until it has been declared safe to do so by someone in authority.

1.7.1.18 Calling the fire and rescue service 1

If a fire is discovered, everyone on site must be made aware of it. The fire and rescue service must be called. Where there is a switchboard, it is usual for the switchboard operator to be nominated as the person who always calls the Civil Defence (Fire Department).

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2

On hearing the alarm, anyone calling the fire and rescue service should give the full postal address of the site, any prominent nearby landmark, and any instruction for entering the site where there is more than one option.

3

If you have a fire alarm which is automatically connected to the Civil Defence (Fire Department) via an alarm company, the Civil Defence (Fire Department) must still be called to confirm that the automatic call has been received.

Location of occupants It will be necessary to appoint fire wardens whose job it is to ensure that offices and other accommodation are completely evacuated in the event of the fire alarm sounding (including practice drills) and to conduct a roll-call at the assembly point.

5

The fire wardens must be trained in their duties and have a clear understanding of the area of the offices for which they are responsible. The number of fire wardens required will depend on several factors, including the area and layout of the office complex and the number of levels on which it is sited.

6

The location of permanent staff can be easily identified by the use of IN/OUT boards that can be removed from their normal location, taken to the assembly point and used for the roll-call.

7

Arrangements must be made for visitors to be logged into and out of offices so that, in the case of an emergency, they can be located quickly and taken to a safe place.

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Means of escape

Adequate means of escape must be provided to enable all visitors and employees to reach a place of safety if a fire occurs. If a fire occurs in the open air, it will usually be obvious to all site staff where the danger lies and the direction they must go to remain safe.

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Means of escape must have regard and consider individuals with disabilities.

10

They should also consider the following points: As part of emergency planning, dedicated escape routes should be decided on, clearly signed and adequately lit.

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Such signs should be positioned where the escape route changes direction or level. The signs must indicate the final exit to a place of safety.

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(c)

All directional signs should be clearly visible and kept unobstructed and should conform to BS 5499.

(d)

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To ensure that all site employees are aware of these escape routes, periodic fire drills should be carried out and should include the full evacuation of all visitors and staff from the building. Records should be kept of all drills and evacuations.

Where construction site offices are located in a multiple-occupancy building, the safety of other occupiers, as well as their visitors and members of the public, must be a consideration. For example, emergency exit routes from the premises may have to be maintained or provided for other occupiers through the construction area or other provisions made for them.

1.7.1.19 Emergency lighting 1

The provision of emergency lighting should always be considered when assessing the fire safety requirements for satisfactory means of escape.

2

This is particularly important where work is dependent on artificial lighting because natural

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light is not available or practical. 3

If the lighting circuits fail, any standby emergency lighting system must switch on automatically and clearly illuminate: (a)

exits and directional signs

(b)

corridors and associated exits

(c)

circulation areas

(d)

changes in levels

(e)

any projections and protrusions, such as temporary partitioning, office equipment and storage

(f)

internal and external staircases.

Emergency lighting, whether by battery or standby generator or a combination of both, should be tested on a regular basis by a competent person in accordance with BS 5266.

5

Records of tests of the emergency lighting equipment should be kept and must be available for inspection when required.

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Automatic or manual fire alarms should be tested weekly, with a different call point being used on each occasion where these are a feature of the system.

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1.7.1.20 Fire alarms

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1.7.1.21 Fire drills

Fire drills in site offices and on site should be held on a regular basis, at not more than sixmonthly intervals. They should take the form of a rehearsal of the evacuation procedures to ensure that everyone knows how to leave the site quickly and safely if a fire occurs.

2

Records of fire alarms, equipment tests and fire drills should be kept.

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1.7.1.22 Fire-fighting equipment

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Portable fire extinguishers

Fire extinguishers do not prevent fires.

2

Fire extinguishers can be used by trained employees in an attempt to minimise loss and damage after a fire has started. However, preventing the fire in the first place is a far better option.

3

Where there is a realistic possibility that staff will have to use a fire extinguisher, they should be trained in their use.

4

In line with the risks identified in a fire risk assessment, adequate numbers of suitable types of portable fire extinguisher must be provided and kept available throughout the premises.

5

Extinguishers must be located in conspicuous positions near exits on each floor. They should be fixed to the wall with their carrying handles approximately 1 metre above the floor level. Where this is not possible, they should be fixed in position (for example, using base plates or stands) at floor level.

6

In the open, they should be situated in red painted boxes which are either sitting on the floor or raised 500 mm above ground level, with a 'FIRE POINT' sign at a height readily seen

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above any obstructions. Care must be taken during winter months to ensure that extinguisher contents do not freeze. To protect electrical distribution panels and items of electrical equipment, appropriate extinguishers (usually carbon dioxide) must be provided near but not dangerously close to the equipment concerned.

8

For large or costly items of equipment, such as computer suites, the installation of automatic fire detection and extinguishing systems should be considered.

9

Fire-fighting equipment should be inspected monthly and maintained and tested at least once a year by a competent person. The maintenance and tests should be carried out in accordance with the manufacturer's instructions.

10

All fire-fighting equipment must be maintained and inspected regularly, and all such inspections recorded in the appropriate register.

11

Extinguishers should be tested by discharge at intervals specified in BS 5306, and should always be recharged immediately after any use.

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Colour of fire extinguishers All fire extinguishers should conform to BS EN 3.

13

Colour-coding by agent or medium (see below) enables a trained person to rapidly identify the type of extinguisher needed in an emergency. Colour of panel

Water Foam

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Red

Cream Blue Black Yellow

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Carbon dioxide

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Powder (all types)

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Other information concerning its use may also be displayed on the body of the extinguisher.

Toxic vapours from fire extinguishers 15

The discharge of a carbon dioxide (CO2) extinguisher in any small, enclosed or confined space will reduce the percentage of oxygen in the air. The dust cloud from a dry powder extinguisher may, in a confined space, produce local and temporary breathing difficulties and poor visibility.

16

Once an extinguisher has been discharged in such circumstances, the user should leave the area immediately. When it is safe to do so, the area should be thoroughly ventilated before allowing anyone to re-enter. If there is a need to re-enter before the air has cleared, suitable breathing apparatus will have to be worn.

Staff training in the use of fire extinguishers 17

The contractor is to ensure that all employees are familiar with fire procedures, and that an appropriate number of them are trained in the use of fire-fighting equipment.

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18

Training in the selection and use of portable extinguishers is essential if they are to be used effectively in fighting small fires.

19

It is also very important that the right type of extinguisher is used on certain types of fire. Details of which one to use with which type of fire are contained in Appendix 2 of this section.

20

Attention should be given to the physical strength of persons who may have to use extinguishers. Some extinguishers weigh up to 20 kg.

21

During staff training on the use of extinguishers, the following points also need to be emphasised:

(b)

only use an extinguisher if it is safe for you to do so

(c)

do not let the fire come between you and your escape route. You may become trapped if the fire develops

(d)

always stay between the fire and your escape route

(e)

if the extinguisher does not appear to be working or is ineffective on the fire, get out immediately

(f)

if the fire starts to increase or gets out of control, get out immediately.

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think of evacuation first

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During induction training or ongoing staff training, the following points should be made to all staff: do not use a fire extinguisher unless you have been trained to do so

(b)

do not misuse fire extinguishers, for example, when messing around or as a joke

(c)

do not move fire extinguishers from their allocated positions

(d)

do not use fire extinguishers as door stops

(e)

immediately report any fire extinguishers that appear to have been used, misused or damaged.

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1.7.1.23 Hose-reels Hose-reels linked to a constant water supply may sometimes be available, and can be an effective means of fire-fighting.

2

Hose-reels work:

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(a)

either, by the user opening a valve adjacent to the hose-reel drum before unreeling the hose and turning on the nozzle

(b)

or, by automatically turning on the supply as the hose-reel is unwound.

3

Training employees in the correct use of hose-reels is essential if fire-fighting is to be effective. Staff need to be fully aware of how the hose-reels work before they use them in an emergency.

4

A HOSE-REEL SHOULD NOT BE USED:

5

(a)

on live electrical apparatus

(b)

on any fire involving fat, oil, paint or other flammable liquids

(c)

on any fire involving burning metal or metal powder.

To do so could lead to electrocution, or a violent explosion of burning liquid or metal.

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1.7.1.24 Fire blankets These are usually sufficient to deal with small, contained fires involving frying pans, teamaking facilities and so on.

2

Before attempting to extinguish such fires, always turn off the gas or electricity supply.

3

Pull the blanket from its container and wrap the corners of the blanket around your hands, making sure that your hands and forearms are completely covered. Hold the blanket at chest level and gently place it over the burning container to exclude the air from the fire. DO NOT THROW the blanket as you may miss the burning container or cause it to spill.

4

Leave the blanket in place until the container has cooled down. Do not lift one corner to check if the fire is out as this may allow enough air in to re-ignite the fire. Do not move the container before it is cold.

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Construction Site Safety 1.7.1 Appendix 1

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Types of portable fire extinguisher and what to use them on Make yourself aware of the instructions on the fire extinguisher before using it. Water (red)

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Class Substances, materials, etc.

Foam (cream)

Carbon dioxide (CO2) (black)

Dry powder (blue)

Wet chemical (yellow)

YES Difficult to use o For small fires

YES outdoors in windy conditions only YES, but not if no water available ideal

Carbonaceous and organic materials, wood, paper, rag, textile, cardboard, common plastics, laminates, foam

YES Excellent YES

B

Flammable liquids, petrol, oil, fats, adhesives, paint, varnish

NO

YES If liquid is YES, but not ideal YES not flowing

YES, but not ideal

C

Flammable gas: LPG, butane, propane, methane, acetylene

YES Will cool the area and put out secondary fires

YES If in liquid YES form

YES

NO

D

Metal, molten metal, reactive metal powder

NO

NO

NO

YES Trained person - if no explosive NO risk Special powders are available, but DRY sand or earth may be used

NO

NO

YES

YES, but not ideal Or switch off NO electricity and deal with as an ordinary fire. Be aware that equipment may retain an electrical charge.

NO See Note

NO

NO

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Electri Electrical installations, computers, cal electric typewriters, VDUs, photocopiers, televisions, etc.

F

Commercial deep fat fryers or oil fryers NO

Notes: Dry powder may not penetrate spaces or behind equipment Light water foam (AFFF) may be used instead of water or foam Extinguishers used to control Class B fires will not work on Class F fires because of the high temperatures generated

YES

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Construction Site Safety 1.7.1 Appendix 2 Fire safety questionnaire 1

This questionnaire has been worded so that the desirable answer is YES. If you answer NO, you may wish to give more thought to the problem.

General Has a fire risk assessment been carried out?

3

Have any shortcomings highlighted by the risk assessment been rectified?

4

Have employees been made aware of the significant findings of the fire risk assessment?

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Flammable materials

Are flammable materials, especially flammable waste materials, cleared away on a daily basis?

6

Is there proper storage for highly flammable liquids?

7

Are LPG bottles being stored properly?

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Smoking materials Is there a non-smoking policy?

9

Are ashtrays provided in places where smoking is permitted?

10

Are there adequate and clear 'No Smoking' signs in areas where smoking is not permitted?

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Heating appliances

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Are heating appliances correctly sited, installed and maintained?

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Are fuel supplies, such as propane and butane, kept outside and piped into the building?

13

Are combustible materials being kept well away from heaters and stoves?

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Electrical appliances 14

Is all electrical work or repairs carried out by competent electricians?

15

Are the correct fuses fitted to electrical appliances?

16

Is only one appliance being used from each socket?

17

Are all electrical appliances being inspected and tested regularly?

Staff training 18

Is everyone on site trained in fire prevention?

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19

Are all staff being properly trained in procedures to be followed in case of fire?

20

Are all staff being trained in the use of fire-fighting equipment?

21

Have fire marshals been appointed and trained?

22

Is the location of the fire assembly point known to everybody?

Fire extinguishers Are all fire extinguishers serviced regularly, checked and recharged as necessary?

24

Are all fire extinguishers of the appropriate type?

25

Are all fire extinguishers clearly identified and easily accessible?

26

Is there an up-to-date fire plan, showing the location of each fire extinguisher and its type, for the premises?

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Fire alarm Is the fire alarm tested weekly?

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Is a different call point used for each test?

29

Can the fire alarm be heard clearly in all parts of the premises?

30

Is someone nominated to call the fire and rescue service in case of fire?

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Fire drills and records

Are fire drills held on a regular basis?

32

Are records kept of all drills and tests of equipment?

33

Are the records readily available for inspection?

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Construction Site Safety 1.7.2

Fire Prevention and Control in connection to construction 1.7.2.1 Key points The risk of fire is greater during the construction- including refurbishment and demolition works.

2

This set of regulations is about preventing fires from starting and ensuring people’s safety if they do.

3

It applies to all construction works, small and large, and aimed at all with a role in developing, managing and applying fire safety prevention and development of standards and arrangements on site.

4

It is essential that fire safety are considered in the planning for construction and implemented effectively during the construction phase. Precautions must be considered at the design stage and before work starts.

5

It needs to address the risks both to the site personnel and neighbouring environment. This may mean rejecting proposals for particular methods and materials in a specific location, based on the potential for serious consequences from any fire during the construction stage, or planning additional, sometimes expensive or difficult, mitigation methods if a specific design or method is not to be changed.

6

Materials, methods of construction and site processes must be selected to minimise fire risk and work planned in an order that is practical but also minimises risk. For example, alternative specifications for materials which are fixed together using mechanical rather than hot means can reduce risk.

7

Sites involving higher risk materials and processes will need higher standards of general fire precautions. Reducing the risks is particularly important when there are constraints which cannot be removed such as location of site and space available.

8

There are specific duties for the responsible person to carry out fire risk assessments for construction and construction related activities. A detailed fire risk assessment and required controls need to be developed from the outset identifying the stages and activities which give rise to critical risk points and which, therefore, will need highest levels of control.

9

Fire risk assessments need to be carried out by a competent person. Projects that are more complex will probably need to be assessed by a person who has had comprehensive training or experience in fire risk assessments.

10

A high degree of communication and co-operation is required between all parties, including main and sub-contractors, to ensure adequate controls are in place at all times. Where construction work takes place in occupied or part-occupied buildings or premises, the responsible person needs to take account of the implications for occupiers including staff. Effective liaison between contractors and occupiers is essential.

11

Coordination with the Civil defence for works, including demolition shall be part of planning of works. The Civil Defence (Fire Department) may wish to be involved in advising on the management of on-site fire risks.

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It should be noted that the Civil Defence (Fire Department) can gain access to site at any time to conduct their fire fighting/prevention duties. Fire extinguishers, emergency lighting, fire alarms and fire signs must comply with current Civil Defence

1.7.2.2 Interpretation 1

“Construction work” means the carrying out of any temporary or permanent building, civil engineering or engineering construction and includes:

Section 11: Health and Safety Page 26 Part 1.07: Fire and Flammable Substances (Regulatory Document)

(a)

the construction, alteration, conversion, fitting out, commissioning, renovation, repair, upkeep, redecoration or other maintenance, (including the use of corrosive, flammable or toxic substances), de-commissioning, demolition or dismantling of a structure;

(b)

the preparation for an intended structure, including site clearance, exploration, investigation and excavation, and the clearance or preparation of the site or structure for use or occupation at its conclusion;

(c)

the assembly on site of prefabricated elements to form a structure or the disassembly on site of prefabricated elements which, immediately before such disassembly, formed a structure;

(d)

the removal of a structure or of any product or waste resulting from demolition or dismantling of a structure or from disassembly of prefabricated elements which immediately before such disassembly formed such a structure; and

(e)

the installation, commissioning, maintenance, repair or removal of mechanical, electrical, gas, compressed air, hydraulic, telecommunications, electronic or similar services which are normally fixed within or to a structure.

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“Dangerous substance” means:

a substance or preparation which meets the labeling guide for classification as a substance or preparation which is explosive, oxidising, extremely flammable, highly flammable or flammable;

(b)

a substance or preparation which because of its physico-chemical or chemical properties and the way it is used or is present in or on site or premises creates a risk; and

(c)

any dust, whether in the form of solid particles or fibrous materials or otherwise, which can form an explosive mixture with air or an explosive atmosphere;

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“Explosive atmosphere” means a mixture, under atmospheric conditions, of air and one or more dangerous substances in the form of gases, vapours, mists or dusts in which, after ignition has occurred, combustion spreads to the entire unburned mixture;

4

“General fire precautions” has the following meaning: measures to reduce the risk of fire on the construction sites and premises and the risk of the spread of fire on them

(e)

measures in relation to the means of escape from the construction sites and premises;

(f)

measures for securing that, at all times, the means of escape can be safely and effectively used; measures in relation to the means for fighting fires on construction sites and premises;

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(h)

measures in relation to the means for detecting fire on the premises and giving warning in case of fire on the construction sites and premises; and

(i)

measures in relation to the arrangements for action to be taken in the event of fire on the construction sites and premises, including— (i) measures relating to the instruction and training of employees; and (ii) measures to mitigate the effects of the fire.

5

“Responsible person” means: (a)

in relation to construction site, the party (normally the contractor) responsible for the site;

(b)

in relation to workplaces other than the above (such as an office building), the owner, if the workplace is under his control;

(c)

in relation to any place of work not falling within (a) or (b) (e.g. site compounds or premises) -

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Section 11: Health and Safety Page 27 Part 1.07: Fire and Flammable Substances (Regulatory Document) (i) the party who has control of the place of work; or (ii) the owner where the party in control of the place of work does not have control in connection with the construction works.

6

“Workplace” means any construction sites, site compounds, site premises or building provided on a permanent or temporary basis in connection with construction used or provided as a place of work and includes: (a)

temporary accommodation units brought onto site to provide offices, canteens and welfare facilities or a part of them;

(b)

any place within the sites or premises to which such employee has access while at work; and

(c)

any room, lobby, corridor, staircase, road, or other place— (i) used as a means of access to or egress from that place of work; or

“Substance” means any natural or artificial substance whether in solid or liquid form or in the form of a gas or vapour;

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(ii) where facilities are provided for use in connection with that place of work.

The responsible person shall:

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1.7.2.3 Duty for general fire precautions

(a) take general fire precautions to ensure, so far as is reasonably practicable, the safety of his employees; and

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(b) in relation to relevant persons who are not his employees, take general fire precautions, as may reasonably be required to ensure their safety and that of the construction site.

1.7.2.4 Duty for prevention of risk from fire form construction works

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The responsible person shall take suitable and sufficient steps to prevent, so far as is reasonably practicable, the risk of injury to any person during the carrying out of construction work arising from fire or explosion

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1.7.2.5 Duty for fire risk assessment The responsible person shall make a suitable and sufficient assessment of the risks to which relevant persons are exposed for the purpose of identifying the general fire precautions he needs to take to comply with the requirements of the Regulatory Document.

4

Any such assessment must be reviewed by the responsible person regularly so as to keep it up to date and particularly if:

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(a) there is reason to suspect that it is no longer valid; or (b) there has been a significant change in the matters to which it relates including when the site, special, technical and organisational measures, or organisation of the work undergo significant changes, change in scope or extensions; or 5

Where changes to an assessment are required as a result of any such review, the responsible person must make them.

6

The responsible person must not employ a young person unless he has, in relation to risks to young persons, made or reviewed an assessment in accordance with the above duties.

7

As soon as practicable after the assessment is made or reviewed, the responsible person must record the following: (a) the significant findings of the assessment, including the measures which have been or will be taken by the responsible person; and (b) any persons or group of persons identified by the assessment as being especially at risk.

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No new work activity involving a dangerous substance may commence unless: (a) the risk assessment has been made; and (b) the measures required have been implemented

1.7.2.6 Duty for Fire Safety arrangement 9

The responsible person must make and give effect to such arrangements as are appropriate, having regard to the size of his undertaking and the nature of its activities, for the effective planning, organisation, control, monitoring and review of the preventive and protective measures.

1.7.2.7 Duty for elimination and reduction of risks from dangerous substances Where a dangerous substance is or is liable to be present in or on site and premises, the responsible person shall ensure that risk to relevant persons related to the presence of the substance is either eliminated or reduced so far as is reasonably practicable:

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(a) replace a dangerous substance, or the use of a dangerous substance, with a substance or process which either eliminates or reduces the risk to relevant persons.

(c) mitigate the detrimental effects of a fire. The responsible person must:

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(b) Where it is not reasonably practicable to eliminate risk, apply control measures consistent with the risk assessment and appropriate to the nature of the activity or operation

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(a) arrange for the safe handling, storage and transport of dangerous substances and waste containing dangerous substances; and

Temporary accommodation on site must be used for their intended purpose. They shall not be used for storing dangerous substances.

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(b) ensure that any conditions necessary for ensuring the elimination or reduction of risk are maintained.

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1.7.2.8 Duty for fire detection and fire fighting In order to safeguard the safety of relevant persons, the responsible person must ensure that:

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(a) the site is, to the extent that it is appropriate, equipped with appropriate firefighting equipment and with fire detectors and alarms; and (b) any non-automatic fire-fighting equipment so provided is easily accessible, simple to use and indicated by signs. 14

For the purposes of the above, what is ‘appropriate’ is to be determined having regard to: (a) the dimensions; (b) Use of the site and work activities; (c) the equipment contained on the site; (d) the physical and chemical properties of the substances likely to be present; and (e) the maximum number of persons who may be present at any one time.

15

The responsible person must, where necessary: (a) take measures for fire-fighting in the site, adapted to the nature of the activities carried on there and the size of the undertaking and of the environment concerned; (b) nominate competent persons to undertaken and implement those duties and measures

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(c) arrange any necessary contacts with external emergency services, particularly as regards fire-fighting, rescue work, first-aid and emergency medical care. (d) A person is to be regarded as competent for the purposes of the above shall have sufficient training, experience and knowledge and other qualities to enable him properly to undertake the duties in relation to Fire prevention and control.

1.7.2.9 Emergency procedures Where necessary in order to safeguard the safety of any person on a construction site, the responsible person shall prepare and implemented suitable and sufficient arrangements for dealing with emergency, including procedures for any necessary evacuation.

17

The procedures shall take account of:

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(a) the type of work for which the construction site is being used;

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(b) the characteristics and size of the construction site and the number and location of places of work on that site;

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(c) the work equipment being used;

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(d) the number of persons likely to be present on the site at any one time; and (e) the physical and chemical properties of any substances or materials on or likely to be on the site.

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(f) The procedures shall ensure that steps are taken to ensure that every person to whom the procedures extend is familiar with its arrangements and that they are tested and put in effect at suitable intervals.

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1.7.2.10 Emergency routes and exits Where necessary in order to safeguard the safety of relevant persons, the responsible person must ensure that routes to emergency exits from premises and the exits themselves are kept clear at all times.

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The following requirements must be complied with in respect of sites where necessary (whether due to the features of the site, the activity carried on there, any hazard present or any other relevant circumstances) in order to safeguard the safety of relevant persons—

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(a) emergency routes and exits must lead as directly as possible to a place of safety; (b) in the event of danger, it must be possible for persons to evacuate the site as quickly and as safely as possible; (c) the number, distribution and dimensions of emergency routes and exits must be adequate having regard to the use, equipment and dimensions of the premises and the maximum number of persons who may be present there at any one time; (d) emergency doors must open in the direction of escape; (e) sliding or revolving doors must not be used for exits specifically intended as emergency exits; (f) emergency doors must not be so locked or fastened that they cannot be easily and immediately opened by any person who may require to use them in an emergency; (g) emergency routes and exits must be indicated by signs; and (h) emergency routes and exits requiring illumination must be provided with emergency lighting of adequate intensity in the case of failure of their normal lighting.

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1.7.2.11 Liaison with the emergency services

access for emergency service vehicles

(b)

fire-fighting shafts

(c)

fire lifts and temporary hoist facilities

(d)

dedicated emergency escape routes and staircases

(e)

sprinkler installations

(f)

floor-load limitations

(g)

positions of dry riser inlets and wet risers

(h)

fire points

(i)

temporary buildings and accommodation

(j)

hazardous items such as gas cylinders, gas mains, electrical risers, temporary holes in floor slabs etc.

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(a)

Liaison with the local fire and rescue service should also include the arranging of site inspections and familiarisation tours for fire and rescue service crews.

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Liaison with the emergency services is essential. In particular, on large or complex developments, the fire and rescue service should be provided with site plans detailing the following:

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1.7.2.12 Fire protection during construction

Construction works should be designed and planned to allow the earliest possible installation of fixed fire protection features. These will aid the protection of the building and improve the means of escape of those working within the structure.

37

Such measures include:

fire-protective materials on structural steelwork

(b)

automatic fire detection systems

(c)

automatic sprinklers and other fixed fire-fighting installations

(d) (e) (f)

fire doors

(g)

fire stopping to lift shafts, service ducts and voids.

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fire escape staircases

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Wet or dry rising mains, where planned, should be progressively commissioned as the project progresses.

1.7.2.13 Water supplies for fire fighting 39

Adequate water for fire fighting must always be available. Whether this is achieved by utilising the fire hydrants fixed to existing street mains or by providing a fixed dam, the amount of water likely to be required should be discussed with the fire authority as part of the liaison process.

40

All fire hydrants must be clear of obstructions and suitably marked. Particular care should be taken to ensure that site plant, delivery lorries or workers' cars are not parked close to or over hydrants.

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Construction Site Safety 1.7.2 Appendix Safety questionnaire 1

This questionnaire has been worded so that the correct answer is YES. If you answer NO, you may wish to give more thought to the problem.

Assessing fire risk Has a suitable and sufficient fire risk assessment been carried out?

3

Have any shortcomings highlighted by the risk assessment been rectified?

4

Have employees been made aware of the significant findings of the fire risk assessment?

5

Has a competent person been appointed to continually assess the fire risk and to develop and update the fire safety plan?

6

Is it necessary to appoint Fire Wardens to oversee any site evacuation?

7

If so, have they been appointed and their duties and areas of responsibility made clear?

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Flammable materials

Are flammable materials, especially flammable waste materials, cleared away on a daily basis?

9

Is there safe, secure storage for highly flammable liquids?

10

Are LPG bottles securely stored in a facility which enables any leakage of gas to safely disperse?

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Bonfires

If bonfires are allowed on site and are really necessary, are they properly supervised?

12

Are bonfires lit during working hours?

13

Are bonfires properly extinguished well before the end of the working day?

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Smoking 14

Is smoking prohibited in all site accommodation and enclosed work areas?

15

Is there a non-smoking policy on site?

16

Is a means of safely disposing of smoking materials provided in places where smoking is permitted?

17

Are there adequate and clear official 'No Smoking' signs at each entrance to all site accommodation and in other areas where smoking is not permitted?

18

Is any total or partial smoking ban actively enforced?

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Hot work 19

Where required, has a Hot Work Permit been issued?

20

If so, does it specify that hot work must cease a specified period (e.g. 1 hour) before the end of the working day?

21

When hot work takes place is the correct type of fire extinguisher provided?

22

Are the correct precautions being taken where flame-cutting and welding takes place?

23

Are checks being made at the end of work to see that nothing is left smouldering?

24

Are cavities, eaves and other voids checked at the end of work?

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Heating appliances Are heating appliances correctly sited, installed and maintained?

26

Are fuel supplies, such as propane and butane, kept outside and piped into the building?

27

Are combustible materials being kept well away from heaters and stoves?

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Electrical appliances

Are all electrical work or repairs carried out by competent electricians?

29

Are the correct fuses fitted to electrical appliances?

30

Is only one appliance being used from each socket?

31

Are all electrical appliances being inspected and tested regularly?

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Staff training

Is everyone on site trained in fire prevention?

33

Are all staff properly trained in the procedures to be followed in case of fire?

34

Are all (or sufficient) staff trained in the selection and use of fire-fighting equipment?

35

Have fire marshals been appointed and trained?

36

Is the location of the fire assembly point known to everybody?

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Fire extinguishers 37

Are all fire extinguishers serviced regularly, checked and recharged as necessary?

38

Are all fire extinguishers of the appropriate type?

39

Are all fire extinguishers clearly identified and easily accessible?

40

Is there an up-to-date fire plan for the site?

41

Is the fire plan updated as necessary?

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Fire alarm 42

Is the fire alarm tested weekly?

43

Is a different call point used for each test?

44

Can the fire alarm be heard clearly in all parts of the premises?

45

Is someone nominated to call the fire and rescue service in case of fire?

Fire drills and records Are fire drills held on a regular basis?

47

Are records kept of all drills and tests of equipment?

48

Are the records readily available for inspection?

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Construction Site Safety 1.7.3

Dangerous Substances 1.7.3.1 Key points A risk assessment must be carried out before dangerous substances are stored, transported or used. In some cases, a method statement and/or a Permit To Work will also be required.

2

These Regulations cover the flammable or explosive properties of dangerous substances used in the workplace.

3

People who use dangerous substances must be fully aware of their hazardous properties, adopt methods of controlling the risks and be trained in the use of portable fire extinguishers.

4

Electrical apparatus and naked flames should not be used near dangerous substances, particularly if they are being sprayed.

5

Good ventilation is essential wherever dangerous substances are used or stored.

6

Smoking policies and waste disposal policies must be established and diligently monitored.

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1.7.3.2 Introduction

Dangerous substances are widely used on building and construction sites. The main hazards are fire and explosion, and everything possible must be done to lessen the risks.

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Safety is divided into three areas:

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the storage of substances

(b)

the safe handling and transport of substances

(c)

the uses to which substances are put.

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1.7.3.3 The Management of Health and Safety at Work These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity to identify any hazard that employees or any other person might encounter as a result of the work being carried out.

2

When hazards are identified, it is the Contractor's duty to either eliminate the hazard or to put control measures in place to reduce the risks to health and safety arising out of the hazards, as far as is reasonably practicable.

3

If an identified hazard requires health surveillance, the Contractor must make it available to employees. The surveillance must be appropriate, taking into account the risks to their health and safety that have been identified.

4

The Contractor must provide employees with clear and relevant information on any risks that exist in the workplace and of control measures that are in place to reduce those risks.

5

Employees, in turn, have a duty under these Regulations to tell their Contractor of any work situation which presents a risk to the health and safety of themselves or of any other person.

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1.7.3.4 Dangerous Substances and Explosive Atmospheres 1

Contractors must control the risks to safety from fire and explosions. These Regulations apply at all places of work where: (a)

a dangerous substance is present (or is liable to be present) at the workplace

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(b)

the dangerous substance could be a risk to the safety of people as a result of fires, explosions or similar energetic events.

2

A definition of a 'dangerous substance' is:

3

'any substance or mixture of substances that can put people's health or safety at risk from fire and explosion.'

4

Dangerous substances are: (a)

any substance or mixture of substances that is classified as explosive, oxidising, extremely flammable, highly flammable or flammable

(b)

any dust, whether in the form of solid particles or fibrous materials, which can form an explosive mixture in air.

A definition of 'explosive atmosphere' is:

6

'a mixture of air and one or more hazardous substances in the form of a gas, vapour, mist or dust, which will explode after ignition has occurred.'

7

In the construction industry, many dangerous substances are used, or created by, work activities, for example:

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the storage and use of solvents, adhesives and paints

(b)

the storage and use of flammable gases such as oxygen and acetylene during cutting and welding

(c)

the storage and use of LPG for work processes, heating or cooking

(d)

the creation of large quantities of airborne dust, for example as a result of woodmachining or sanding, and the handling and storage of bulk waste dust

(e)

the storage and decanting of vehicle fuels and lubricants

(f)

the storage and handling of liquid flammable wastes such as fuel oils

(g)

many 'hot work' activities such as the hot-cutting of tanks and drums that have contained flammable materials.

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1.7.3.5 Contractors' duties Contractors must assess and eliminate or reduce risks from dangerous substances.

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Complying involves:

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Assessing risks 3

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Before work is carried out, Contractors must assess the fire and explosion risks that may be caused by dangerous substances. This should be an identification and careful examination of: (a)

dangerous substances in the workplace

(b)

work activities involving those substances

(c)

ways in which those substances and work activities could harm people.

The purpose is to help Contractors to decide what they need to do to eliminate or reduce the risks from dangerous substances. If there is no risk to safety from fires and explosions, or the risk is low, no further action is needed. If there are risks then Contractors must consider what else needs to be done.

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Preventing or controlling risks Contractors must put control measures in place to eliminate risks from dangerous substances, or reduce them as far as is reasonably practicable. Where it is not possible to eliminate the risk completely Contractors must take measures to control risks and reduce the severity of the effects of fire or explosion.

6

The best solution is to eliminate the risk by replacing the dangerous substance with another substance, or using a different work process.

7

This is called substitution.

8

In practice, this may be difficult to achieve. However, it may be possible to reduce the risk by using a less dangerous substance, e.g. by replacing a low flashpoint liquid with a high flashpoint one. In other situations, it may not be possible to replace the dangerous substance. For example, it would not be practical to replace petrol with another substance at a filling station.

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(b)

avoid or minimise releases of dangerous substances

(c)

control releases of dangerous substances at source

(d)

prevent the formation of a dangerous atmosphere

(e)

collect, contain and remove any releases to a safe place (for example, through ventilation)

(f)

avoid ignition sources

(g)

avoid adverse conditions, e.g. exceeding the limits of temperature or control settings, that could lead to danger

(h)

keep incompatible substances apart.

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These control measures should be proportionate to the degree of risk as highlighted in the risk assessment and be appropriate to the nature of the activity or operation.

Mitigation 11

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reduce the quantity of dangerous substances to a minimum

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Where the risk cannot be eliminated, these Regulations require control measures to be applied in the following priority order:

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Control measures

In addition to control measures, Contractors must subsequently put in place mitigation measures. These measures should be consistent with the risk assessment and appropriate to the nature of the activity or operation, and include: (a)

reducing the number of employees exposed to the risk

(b)

providing explosion-resistant plant

(c)

providing explosion suppression or explosion relief equipment

(d)

taking measures to control or minimise the spread of fires or explosions

(e)

providing suitable personal protective equipment.

Preparing emergency plans and procedures 12

Arrangements must be made to deal with emergencies. These plans and procedures should cover safety drills and suitable communication and warning systems, and should be in

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proportion to the risks. If an emergency occurs, workers tasked with carrying out repairs or other necessary work must be provided with the appropriate equipment to allow them to carry out this work safely. 13

The information in the emergency plans and procedures must be made available to the emergency services to allow them to develop their own plans if necessary.

Providing information, instruction and training for employees 14

Employees must be provided with relevant information, instructions and training.

15

This includes: the dangerous substances present in the workplace and the risks they present, including access to any relevant safety data sheets and information that applies to the dangerous substance

(b)

the findings of the risk assessment and the control measures put in place as a result (including their purpose and how to follow and use them)

(c)

emergency procedures.

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(a)

Information, instruction and training need only be provided to other people (non-employees) where it is required to ensure their safety. It should be in proportion to the level and type of risk.

17

The contents of pipes and containers must be identifiable to alert employees and others to the presence of dangerous substances.

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In relation to construction site activities, this could include bottled gas/petrol storage areas. These duties include: identifying and classifying (zoning) areas where potentially explosive atmospheres may occur

(b)

avoiding ignition sources in zoned areas, in particular those from electrical and mechanical equipment

(c)

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Places where explosive atmospheres may occur

providing appropriate anti-static clothing for employees

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(d)

where necessary, identifying the entrances to zoned areas by the display of signs

(e)

19

before they come into operation, verifying the overall explosion-protection safety of areas where explosive atmospheres may occur.

Decisions on the zoning of areas and the appropriate actions to take must be made by someone who has been trained and is competent to do so.

1.7.3.6 Personal Protective Equipment 1

These Regulations require that where a risk has been identified by a risk assessment and it cannot be adequately controlled by other means that are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment is used by employees. In essence, personal protective equipment (PPE) may only be used as a last resort. In deciding which type of PPE to issue, the Contractor must take into account the risk that the PPE is being used to protect against, and ensure that the PPE will fit the wearer and allow them to work safely.

2

If more than one item of PPE is being used, the Contractor must make sure that individual items of PPE are compatible so that each item does not adversely affect the performance of

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another. 3

Whilst the Contractor must, as far as possible, ensure that any personal protective equipment supplied must be worn, the employee in turn must ensure that they wear the equipment provided and know the procedures for reporting loss or defect to the Contractor.

4

Dangerous substances and explosive atmospheres require the prevention of: (a)

inhalation of fumes and vapour given off by dangerous substances

(b)

skin contact with dangerous substances

(c)

eye injuries resulting from splashes of dangerous substances.

1.7.3.7 Provision and Use of Work Equipment These Regulations require that a Contractor only supplies work equipment that is correct and suitable for the job and ensures that the equipment is maintained and kept in good working order.

2

Where the use of the equipment involves a specific risk to the health and safety of employees, it must be restricted to competent specified workers.

3

In the context of this module, these Regulations apply to the provision and use of work equipment that allows dangerous substances to be handled (including decanting), transported, used and disposed of in a safe manner.

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The Control of Substances Hazardous to Health does not apply to dangerous substances by virtue of their explosive or flammable nature. However, they may apply if these substances also possess certain other hazardous properties. This would be identified as part of the COSHH assessment carried out on the substance.

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1.7.3.8 Control of Substances Hazardous to Health

1.7.3.9 Construction (Design and Management) CDM These Regulations specify the measures to be taken to prevent the risk from fire, explosion or any substance likely to cause asphyxiation.

2

These Regulations specify the measures to be taken to detect and fight fires in relation to work carried out on construction sites.

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1.7.3.10 Competence and training 1

In most cases it will be necessary for the Contractor to provide employees with adequate information, instruction, training and supervision to enable them to carry out any work task safely and without risk to their health.

1.7.3.11 Storage of dangerous substances 1

2

On most building or construction sites, dangerous substances will be used at some time during the construction phase. Depending upon the nature of the work to be undertaken it may be necessary to store bulk quantities of dangerous substances, either: (a)

in an external, secure, purpose-built compound, where site conditions allow

(b)

in a suitable, secure internal storeroom if, because of the nature of the site, external storage is not possible.

Alternatively, small quantities, from, say, 200 ml containers upwards will often be taken to

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the place of work by the person doing the job. Where small quantities of dangerous substances for daily use are required in the workplace, metal lockable bins may be used.

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on a concrete sloping pad with a sump to catch any leaks or spillage

(b)

with a low sill all around, sufficient to contain the contents of the largest can or drum stored + 10%, i.e. bunded

(c)

surrounded by a 1.8 metre high wire fence

(d)

so that it is protected against direct sunlight

(e)

at least 2 metres away from nearby buildings or boundaries, except that, where the boundary of the store forms part of a solid wall, cans or drums may be stacked up against that wall up to 1 metre from the top.

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(a)

Cans or drums should be stored: (a)

so that their contents can be easily identified and removed in the event of any leak or damage on their sides and chocked to prevent movement.

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Where it is necessary to store dangerous substances in bulk, a store should be built:

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Storage in the open air

6

Stores or bins must be kept locked and only sufficient amounts for each day's requirements should be removed, as and when needed.

7

They may be marked with suitable signs such as 'Flammable Liquid' or 'Flammable Gas'.

8

Additionally, if an assessment shows that an explosive atmosphere may be present in a particular area, appropriate numbers of the sign below must be displayed.

9

The sign comprises a yellow background and black graphics. Signs must conform to BS 5499 Safety signs and colours.

10

Naked flames, smoking, matches or lighters must not be allowed in the area of the store, and proper prohibition signs must be clearly displayed as well as other signs already indicated.

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Any lighting within a store must be flameproof to the appropriate standard, and under no circumstances should electrical sockets be permitted.

12

Where there is a need for electrical apparatus (other than lighting) within a store, the supply must be permanently wired in using intrinsically safe equipment.

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Other points to be noted.

Stores should not be built below ground level, because the vapours from spillages and leaks will not be able to disperse.

14

Adequate cross-ventilation at both high and low level is necessary.

15

The store should always be kept locked when unattended.

16

A door sill of approximately 150 mm in height should be provided to catch any leaks or spillages in order to retain the liquids inside the building.

17

A quantity of absorbent material, to soak up any spilt liquids, and a suitable container for the collection and safe disposal of the contaminated absorbent, should be provided at the store.

18

The use of mobile phones in or immediately adjacent to the store should be prohibited. Notices to this effect should be provided and prominently displayed.

19

Any shelves or racking in the store should be of a non-ferrous metal or other noncombustible construction.

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Storage inside a building 20

A separate building should be provided, if possible, solely for the storage of dangerous substances where protection from the weather or security is required. Ideally, it will be constructed from fire-resisting materials and it should be at least 2 metres away from other buildings or boundaries.

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21

A risk assessment should be carried out to determine whether the risks of storing dangerous substances in such a location are acceptable. If not, either additional control measures must be put in place or alternative arrangements made for storing the substances.

22

Where a separate building cannot be provided, and the store forms part of an existing structure, the surrounding walls and roof of the store must be fire-resisting and the door should be of the fire-resisting type and open outwards.

23

It is recommended that the maximum quantities that may be stored in cabinets and bins are no more than 50 litres for highly flammable liquids (and flammable liquids with a flashpoint below the maximum ambient temperature of the workroom/working area) and no more than 250 litres for other flammable liquids with a higher flashpoint of up to 55°C.

Other points to be noted. Stores should not be built below ground level, because the vapours from spillages and leaks will not be able to disperse.

25

Adequate cross-ventilation at both high and low level is necessary.

26

The store should always be kept locked when unattended.

27

When not in use, containers of flammable liquids needed for current work activities should be kept closed and stored in suitable cabinets or bins of fire-resisting construction and which are designed to retain spills (110% volume of the largest vessel normally stored in it).

28

A quantity of absorbent material, to soak up any spilt liquids, and a suitable container for the collection and safe disposal of the contaminated absorbent should be provided at the store.

29

Signs should be positioned on or near the store stating, for example 'Highly Flammable' or 'Flashpoint below 32°C'. All signs should conform to BS 5499 Safety signs and colours.

30

Naked flames, smoking, matches or lighters must not be allowed in the store, and signs stating this must be clearly displayed.

31

The use of mobile phones in or adjacent to the store should be prohibited. Notices to this effect should be provided and prominently displayed.

32

Any lighting or other electrical apparatus must conform to BS EN 60079-14.

33

Any shelves or racking in the store should be of a non-ferrous metal or other noncombustible construction.

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1.7.3.12 Handling and use of dangerous substances likely to cause an explosive atmosphere 1

The use of any dangerous substance, including decanting small quantities for daily use from bulk containers, must be the subject of a risk assessment.

2

The findings of the risk assessment will indicate the maximum quantity of the dangerous substance that can be taken to the place of work and the safe working practices to be observed once it is there and being used.

3

Generally, only enough of the dangerous substance to enable the work-in-hand to be carried out should be taken to the place where it is to be used. Clearly, actual quantities will depend on the work activity and also the organisational arrangements for controlling the fire risks in the workroom/ working area.

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Decanting, mixing or sampling should not be carried out in a store. It should be done in the open air or in a separate room constructed of fire-resisting materials.

5

Funnels should be used to prevent spillage whilst decanting is taking place and drip trays should be used to catch any spillage that may inadvertently occur.

6

Any spillage should be soaked up using proprietary absorbents, dry earth or dry sand.

7

Metal bins with lids should be provided for any used absorbents to be placed in and these should be emptied regularly and carefully.

8

Consideration must be given to the disposal of any waste as it may well be classified as hazardous waste.

9

In general, where work involves the use of a dangerous substance that has the potential to create an explosive atmosphere inside a room, all electrical power should be turned off unless all electrical fittings are intrinsically safe by design. If space heating is needed, it should be flameproof and incapable of causing the ignition of any vapours present in the atmosphere.

10

The build-up of concentrations of vapours must be avoided and dispersed, if necessary, by natural or mechanical ventilation. If mechanical ventilation is necessary, a flameproof motor, not in the ventilation trunking, should be used.

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Other points to be considered

Naked flames, welding and heating torches, and smoking materials should be prohibited in any area where an explosive atmosphere may be present.

12

Metal bins with lids must be provided for offcuts, waste or rags. They should be emptied regularly.

13

A suitable container with a lid should be used for any brushes or scrapers which require soaking, to remove residues of dangerous substances. This should be placed in a safe area well away from any possible source of ignition.

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1.7.3.13 Spraying of dangerous substances New covering materials, such as paints, varnishes and lacquers, and the techniques for applying them, have been developed and extensive use of spray painting equipment can now be seen on construction sites,

2

Using a spray gun for spraying dangerous substances is most likely to introduce an airborne explosive mist into the workplace, creating a hazard both to the user and to other workers in the area. Such work must only be undertaken by fully trained and competent employees and in a situation where all appropriate precautionary measures are in place. A risk assessment must be carried out and other controls such as 'permits to work' and 'permits to enter' (for those people involved in the job, by implication, excluding all others), implemented as necessary.

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Points to be noted 3

Identify the material carefully and always follow the manufacturer's instructions on preparation, use and application.

4

Always use the correct type of spraying equipment. Never make do, just because the proper equipment is not immediately to hand.

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If alternative control measures are not available or adequate, protective clothing and respiratory protective equipment must be used.

6

Always use the hygiene and washing facilities provided.

7

Do not introduce ignition sources into the working area.

8

Do not smoke or use naked flames in the working area.

9

Always place warning signs in approaches to the area where the work is being carried out, and at entrance points to areas in which dangerous substances are being used. Use physical barriers, if necessary, to stop unauthorised persons entering the area.

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1.7.3.14 Empty tanks and containers Bulk tanks and drums Do not cut or heat any empty tanks, containers or drums unless they have been certificated as being free of flammable vapours that could explode. Current opinion recommends reducing the length of time that such certification is valid for. Under most circumstances, the cutting work should be planned to start immediately the 'gas-free' certificate is issued.

2

Special care is necessary when demolishing or dismantling disused bulk-tanks. By disturbing the tank or heating the residues left inside, you may cause an explosive concentration of vapours.

3

Entry into any disused tank or vessel that may be regarded as a confined space should be avoided by doing the work from outside, if possible. Often, there will be a need to clean residues and if entry to a confined space is unavoidable, a safe system of work must be followed and the work carried out under a Permit to Work system.

4

There are a number of factors to consider when the work involves large tanks. The first would be what the contents were. Oil storage tanks may have held so called 'heavy fuel oil' and these will undoubtedly have been insulated. It is quite likely that the insulation system will have been asbestos. If the tanks once held petrol, it may have been leaded fuel. This means that the exposure to lead fumes during cutting should be considered.

5

It is normal for large tanks, whether above or below ground, to be emptied and cleaned by a specialist contractor before dismantling. The contents are generally removed by a large vacuum tanker and then the inside of the tank is steam cleaned. Most of this work can be carried out from the outside and it is only to carry out the final clean that entry is required. Operatives carrying out this final clean must be trained in confined space working and provided with all the normal gas detector, rescue equipment and PPE that would be expected for confined space working.

6

Having been cleaned, the tank is tested and a 'gas-free' certificate issued. It should then be cut up as soon as possible. The implication of not doing so is that it is practically impossible to completely clean a tank, particularly where its construction incorporates internal ribs, welds and other internal features which could harbour residue of the content. These may well become fume and if the concentration becomes high enough then the atmosphere inside the tank may become explosive if ignited.

7

It is important to be aware that even so called cold cutting techniques such as hydraulic shears may cause sparks and so leaving the cutting even until the next day is simply not an option.

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1.7.3.15 Fire 1

Fires involving flammable liquids usually fall into one of two categories: (a)

flowing liquid fires

(b)

contained liquid fires.

2

Powder extinguishers are the most suitable type for tackling a flowing liquid fire. The use of foam or carbon dioxide extinguishers may be effective on a small, flowing liquid fire.

3

Foam extinguishers are the most suitable type for use on contained liquid fires. Powder or carbon dioxide extinguishers may also be used, but operators should be aware of the short duration of small carbon dioxide extinguishers and the possibility of reignition of any residual vapours being given off when an ignition source is still present.

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4

DO NOT USE A WATER EXTINGUISHER FOR ANY FIRE INVOLVING HIGHLY FLAMMABLE LIQUIDS, BECAUSE THE WATER WILL CAUSE A VIOLENT REACTION AND MAKE THE LIQUID OVERFLOW.

5

Suitable portable fire extinguishers should, wherever possible, be sited in pairs (so as to minimise the risk of failure) and in strategic positions adjacent to the store.

Colour of fire extinguishers 6

Colour-coding by agent or medium (see below) enables a trained person to rapidly identify the type of extinguisher needed in an emergency. Colour of panel

Water

Red

Foam

Cream

Powder (all types)

Blue

Carbon dioxide

Black

Wet chemical

Yellow

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Extinguishing medium

Other information concerning its use may also be displayed on the body of the extinguisher.

8

Training in the correct type of extinguisher to use and the safe way to operate fire-fighting equipment is essential and should be undertaken by all staff who work with dangerous substances. The use of the wrong extinguisher in the wrong way would have serious consequences.

9

Advice on training can be obtained from extinguisher manufacturers or the local fire station.

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Construction Site Safety 1.7.3 Appendix 1 Safety questionnaire 1

This questionnaire has been worded so that all the correct answers are YES. If you answer 'NO' to any question perhaps you need to give the matter more attention.

Dangerous substances General Has a risk assessment been carried out?

3

Does it indicate that other methods of managing the situation are required, such as a method statement or Permit to Work system?

4

Have employees been made aware of the significant findings of the risk assessment?

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Storage in the open air Is the base of the store built of concrete and sloped?

6

Is there a low level sill surrounding the base?

7

Is there a ramp for access to the store over the sill?

8

Is a sump provided to catch any leakages or spillages and is the capacity large enough to contain any leakages or spillages?

9

Is there a roof or cover over the store to protect the contents from direct sunlight?

10

Is there an adequate separation distance between the store and adjacent buildings or boundaries?

11

Are appropriate signs displayed, for example 'Highly Flammable' or 'Flashpoint Below 32°C'?

12

Are the correct fire extinguishers provided and positioned adjacent to the store?

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Storage in buildings 13

Is the storage building used exclusively for the storage of dangerous substances?

14

If the store is part of a multi-purpose building, is there adequate fire separation from the rest of the building?

15

Are appropriate signs displayed, for example 'Highly Flammable' or 'Flashpoint Below 32°C'?

16

Is there a sill across the doorway to prevent leakages or spillages reaching the open air and is the capacity large enough to contain any leakages or spillages?

17

Is there adequate cross-ventilation at both high and low level?

18

Is there the required separation distance between the store and adjacent buildings or boundaries?

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Storage at the place of work 19

Is there a lockable metal cabinet available to store small quantities for daily use?

20

Is it marked with appropriate safety signs?

Decanting Is decanting done only in the open air or in a fire-resisting building?

22

Is the decanting located away from any source of heat or ignition?

23

Are dangerous substances only decanted into small, correctly marked containers with effective closures?

24

Are funnels correctly used to assist decanting?

25

Are drip trays positioned to catch any leakages or spillages?

26

Are suitable absorbents or spill kits available to contain any spillage?

27

Are metal bins available for used absorbents to be placed in?

28

Are these bins emptied regularly?

29

Is contaminated absorbent safely, carefully and properly disposed of?

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Use of dangerous substances

Where dangerous substances are used, is adequate ventilation provided?

31

If there is a need for mechanical extraction, is the electric motor out of the line of discharge of the fumes?

32

Are there signs stating 'No Smoking' or 'Naked Lights'?

33

Are metal waste bins with lids provided for dangerous substances that are no longer required?

34

Are the correct warning notices provided?

35

Are serviceable fire extinguishers of the correct type provided and positioned adjacent to the workplace?

36

Are containers with lids provided for cleaning brushes?

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Spraying 37

Have the materials in use been clearly identified?

38

Are the correct precautions in relation to use and storage being observed?

39

Is the correct spraying equipment being used?

40

Is the correct protective clothing and equipment, including RPE, being worn?

41

Are the necessary precautions being taken to avoid all ignition risks?

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42

Are warning notices correctly displayed?

43

Are barriers in use if necessary?

44

Are serviceable fire extinguishers of the correct type provided and positioned adjacent to the workplace?

Empty tanks and containers Are the necessary precautions being taken against the risk of explosion in storage tanks awaiting demolition or dismantling?

46

Has an explosive gas-free certificate been obtained prior to any hot work? (NB Check how long the certificate is valid for.)

47

Is a Permit to Work system used when work is being carried out on disused or redundant tanks?

48

Are authorising Permits to Work to deal with all the confined space issues being obtained before any entry into a tank is made?

49

Has thought been given to the possibility of contamination around the tank from leakage or spillage?

50

Has advice been sought from a competent person before work begins?

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Fire

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Emergency procedures

Are the correct types of fire extinguisher provided and suitably positioned adjacent to the store or workplace?

52

Have the staff been correctly trained to use them?

53

Are there procedures to call the fire and rescue service?

54

Is there a telephone available to call the fire and rescue service?

55

Is the address of the site displayed on prominent notices conveniently located in offices and near telephones?

56

Are suitable absorbents or spill kits available to contain any spillage?

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Construction Site Safety 1.7.4

Liquefied Petroleum Gases 1.7.4.1 Key points A risk assessment must be carried out before dangerous substances are stored, transported or used. In some cases a method statement and/or a permit to work will also be required.

2

Liquefied petroleum gases (LPG) are normally found as compressed liquids, usually of commercial butane or propane.

3

LPG is a colourless odourless liquid that floats on water but vaporises to form a gas which is heavier than air. A stenching agent is normally added.

4

A release or spillage of LPG can form a large vapour cloud of flammable gas capable of ignition from some distance.

5

LPG is stored on site in fixed tanks, refillable cylinders or non-refillable disposable cylinders (cartridges).

6

Storage should be in secure, non-combustible, well ventilated areas away from other risks and sources of ignition.

7

All LPG cylinders and regulators for use with fixed heaters, cookers and lighting in site huts must be kept outside and piped in using rigid copper piping.

8

Staff who work with LPG must be suitably trained in the hazards and use of LPG, such as not rolling cylinders. .

9

In the event of a leak, do not attempt to operate electrical apparatus or switches.

10

If a fire breaks out that involves LPG cylinders:

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immediately inform the fire and rescue service of the whereabouts of all cylinders on site, including details of whether they are full or empty

(b)

if in any doubt as to the safety of the overall situation, evacuate the site and put a security cordon in place.

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1.7.4.2 Introduction

LPG is a mixture of hydrocarbons that are a gas or vapour under normal conditions of temperature and pressure, but can be turned into a liquid by either the application of pressure or the reduction of temperature.

2

LPG can be found in numerous locations, in various sizes of cylinder and can be put to a variety of uses on building and construction sites. Uses range from the heating of bitumen boilers, site huts and offices to providing a fuel for hand tools and cutting equipment.

3

If used properly and safely, LPG is a convenient and valuable source of energy. Misuse or carelessness can cause serious accidents.

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Legislative requirements

1.7.4.3 Dangerous Substances and Explosive Atmospheres 1

The nature of LPG, particularly in its gaseous form, will result in areas where it is used or stored coming within the requirements of these Regulations.

1.7.4.4 The Management of Health and Safety at Work 1

All work activities must be the subject of a risk assessment, including those that involve the

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use of LPG and other flammable substances. These Regulations place a requirement on every Contractor to make a suitable and sufficient assessment of every work activity in order to identify any hazard that employees or any other person might encounter as a result of the work being carried out. 2

Once those hazards have been identified, it is the Contractor's duty to put control measures into place in order to remove or reduce those hazards as far as is reasonably practicable.

1.7.4.5 Construction (Design and Management) CDM These Regulations specify the measures to be taken to prevent the risks of fire, explosion or exposure to any substance likely to cause asphyxiation on construction sites.

2

These Regulations specify the measures to be taken to detect and fight fires in relation to work carried out on construction sites.

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1.7.4.6 Provision and Use of Work Equipment

Any equipment used in conjunction with the use, handling or storage of LPG is classified as work equipment under these Regulations. Every Contractor must ensure that all persons who work with or supervise others in the use of LPG or LPG equipment have available to them adequate health and safety information and, where appropriate, written instructions regarding the use of that equipment.

2

Equipment that is used in conjunction with LPG which is hired-in or purchased second-hand must also comply with the requirements of the Regulations.

3

Every Contractor must ensure that all persons who work with, or supervise others in the use of LPG equipment, have received adequate training for the purposes of health and safety, and be aware of any risks in the use and precautions to be taken in the case of an accident.

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1.7.4.7 Personal Protective Equipment These Regulations require that, where a risk has been identified by a risk assessment and it cannot be adequately controlled by other means which are equally or more effective, then the Contractor must provide and ensure that suitable personal protective equipment is used by employees. In essence, personal protective equipment (PPE) may only be used as a last resort. In deciding which type of PPE to issue, the Contractor must take into account the risk that the PPE is being used to protect against, and ensure that the PPE will fit the wearer and allow them to work safely.

2

If more than one item of PPE is being used, the Contractor must make sure that individual items of PPE are compatible so that each item does not adversely affect the performance of another.

3

While the Contractor must, as far as reasonably practicable, ensure that any personal protective equipment supplied is worn, employees must ensure that they wear the equipment provided and know the procedures for reporting loss or defects to the Contractor.

4

In the context of these Regulations they are preventing:

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(a)

skin contact with LPG in its liquid form

(b)

jets of gaseous LPG entering the eyes or impacting on the skin

(c)

the inhalation of gaseous LPG when a released cloud of LPG is confined. Entry into such areas should only be undertaken by trained persons when absolutely necessary.

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1.7.4.8 Manual Handling Operations 1

Every Contractor should, as far as is reasonably practicable, avoid the need for employees to undertake any manual handling operations at work which may involve a risk of injury.

1.7.4.9 The Control of Substances Hazardous to Health 1

These Regulations do not apply to LPG by virtue of its flammable nature, but they will apply by virtue of its other hazardous properties.

Definitions Liquefied petroleum gas means any commercial butane, commercial propane or a mixture of the two.

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Commercial butane

This is usually stored in blue cylinders and is generally known as Camping Gaz or Calor Gas.

4

It consists mainly of butane and butane isomers. The remaining components are predominantly propane and propane isomers, pentane and pentane isomers.

5

Because of the low vapour pressure, butane cylinders are not generally used outside.

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Commercial propane

This is usually stored in vessels or in red cylinders.

7

It consists mainly of propane and propane isomers. The remaining components are predominantly butane and butane isomers, ethane and ethane isomers.

LPG properties

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LPG is a colourless, odourless liquid or gas which normally has a smell or 'stench' added before distribution.

9

As a liquid, it is lighter than water and will float before evaporating.

10

As a gas, it is approximately twice as heavy as air and will sink and flow into sumps and underground excavations or workings. It will also sink into drains but, because its density is approximately half that of water, it will not flow through drains which are water trapped.

11

It is capable of ignition at some distance from the original leak. The resulting flame can travel back to the source of the leak.

12

Any release of liquid under pressure to the atmosphere results in its rapid conversion to gas. This gas has a volume of about 230 (butane) and 270 (propane) times that of the liquid.

13

The expansion during a rapid release of pressure results in a rapid drop of temperature, which for propane can approach its boiling point of 45°C. Leakage of liquid LPG will result in the release of large volumes of highly flammable gases.

14

For example, 1 litre of liquid propane spilt in a workplace will evaporate to make approximately 270 litres of gas. If it is diluted with air to 2%, this will give 13,750 cubic litres of an explosive gas/air mixture - enough to fill a room 3 m x 2.3 m x 2 m.

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Properties of liquefied petroleum gases

Property

Commercial butane 0.57

Commercial propane 0.5

2

1.5

Litres per tonne

1745

1995

Boiling point

-2°C

-45°C

1.5 bar

7.0 bar

1:230

1:270

1.9%-8.5%

2.0%-10.9%

Density in comparison to water Density in comparison to air

Pressure at 15°C Expansion ratio Levels of flammability

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The use of LPG equipment in confined spaces, and small, poorly ventilated spaces (such as basement and sub-basement boiler houses, toilets and kitchens) can give rise to a highly flammable or explosive atmosphere, if the equipment should leak.

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Flammability

Following mechanical failure of LPG equipment, or any other event which causes the release of LPG, the resulting gas will form a flammable mixture with air at gas concentrations between approximately 2% and 10%.

17

Ignition of released LPG, where the concentration exceeds 2%, can result in fire or, if confined, an explosion. If a leak does not ignite immediately, and the LPG and air mixture drifts from the point of release, it will gradually become more diluted.

18

However, should the concentration still exceed 2% and ignition occur, this could cause a flash or cloud fire-back to the point of release.

19

A leak of LPG may be noticed either by the smell or the noise of the gas escaping. There may also be condensation or frosting on the outside of the cylinder.

20

Leaks must not be traced with a lighted match or naked flame as this would almost certainly cause an explosion. Only soapy water or a proprietary leak-finding fluid should be used.

21

If it is suspected that LPG has leaked inside a building, no attempt should be made to touch any electrical apparatus.

22

DO NOT turn light switches or sockets or any other electrical appliance either ON or OFF.

23

Open all doors and windows, if it is safe to do so, and leave immediately. Do not re-enter the building until advice has been sought and you are told it is safe to do so.

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Workplace exposure limits 24

25

The maximum levels of exposure for LPG, are: (a)

1,000 ppm (0.1 %) for long-term exposure (reference period: 8 hours)

(b)

1,250 ppm (0.125%) for short-term exposure (reference period: 15 minutes).

During any maintenance work involving release of pressure, especially in confined spaces, care must be taken that these exposure limits are not exceeded.

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Inhalation 26

LPG gas is not toxic, but at concentration levels above about 10,000 ppm (1%) in air, propane becomes a slight narcotic. At higher levels, it becomes an asphyxiant by displacing oxygen.

27

In a sufficiently high concentration, a person will suffocate and die.

Cold burns The release of liquid propane onto unprotected skin will cause cold burns. This is due to the rapid vaporisation of the liquid, withdrawing heat from the affected area of the body.

29

The release of liquid, or significant amounts of gas at vessel pressure, can also cause the adjacent fittings to cool. This may be sufficient to cause cold burns if the fittings are subsequently touched by unprotected hands.

30

Suitable skin and eye protection must be worn whenever there is the possibility of a release of liquid LPG.

31

In the event of a cold burn, treat as for a bum from a hot object. Flush with copious amounts of cold water and seek medical help.

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Environmental hazards

A small unignited release of LPG would not pose a serious danger to the environment.

33

The gas, being heavier than air, will 'roll' and sink to the lowest point, such as basements or excavations. This may result, if in the flammable range, in a fire or explosion, even if a naked source of flame is a considerable distance from the original leak.

34

A fire and explosion would be instantaneous on ignition and would be limited to immediate damage. The fire might devour only escaping LPG and then the danger will have passed with no lasting environmental damage.

35

The fire will bum fast and the explosion will be intense, but both may be over very quickly.

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1.7.4.10 Storage

LPG can be stored on construction sites in one of three ways:

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(a)

in fixed storage tanks

(b)

in refillable cylinders

(c)

in non-refillable cylinders (i.e. disposable cylinders).

Fixed storage tanks 2

Whilst most LPG used on construction sites can be found in cylinders, on some larger sites there may be a need for bulk storage. In view of the large capacity, it is essential that the positioning of any storage tank is carefully planned and discussed with the local Fire Prevention Officer.

3

LPG tanks should be positioned on a level concrete base to provide a stable foundation. For short-term installations it may be satisfactory to stand the tank on concrete slabs, but advice must be sought from the tank or gas suppliers.

4

Tanks should not be sited close to any ditches, cellars or drains, and delivery and

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emergency vehicles must easily reach them. 5

All access roads must be clear of obstruction and the entire area kept free from weeds and other vegetation.

6

Tanks over 2,250 litres liquid capacity should be electrically bonded and earthed.

7

All bulk storage tanks must have good all-round ventilation. On non-secure sites, tanks should be protected against vandalism by a chain link fence at least 2 m high.

8

Motorway type crash barriers should surround the installation to minimise damage by motor vehicles. Installations must be clearly labelled:

HIGHLY FLAMMABLE LPG: NO SMOKING OR NAKED LIGHTS

.

Signs must conform to BS 5499 Safety Signs and Colours.

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Separation

Adequate separation must be maintained between bulk storage tanks and adjacent buildings or boundaries.

11

As a guide, the distances detailed in the table should be followed:

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Separation distances of bulk LPG tanks Gas capacity

litres

gallons

metres

450

99

2.5

451-2,250

100-495

3

2,251-9,000

496-1,980

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0.2-1

Minimum distance*

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Water capacity

tonnes Under 0.2

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"Minimum distance from boundaries, buildings or sources of ignition Where possible, LPG storage areas should not be positioned under power cables.

13

Where this is unavoidable, the minimum distances between the extremity of the vessel or cylinders to the nearest cable should be:

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(a)

up to 1 kV - 1.5 m

(b)

1 kV or above- 10 m.

1.7.4.11 Cylinders Handling 1

Care must be taken when moving cylinders around the site, especially by hand or on rough ground. A full 47 kg cylinder has a total mass of about 90 kg and, before moving by hand, requires a manual handling assessment. Cylinders must not be rolled, even when empty.

2

Cylinders should be handled with care and, wherever reasonably practicable, moved using suitable equipment. They should not be moved unprotected in dumper trucks or on forklift trucks. The valve on a cylinder should not be used for lifting or to lever the cylinder into position. Damage to the valve can result in a non-controllable release of LPG under high

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pressure. Throwing cylinders from any height or dropping them is prohibited, as in such circumstances damage to the valve, shroud and cylinders is even more likely. Damaged cylinders Before use, cylinders should be examined. Any damaged or faulty cylinder should not be used. The cylinder should be labelled and put in a safe place for return to the supplier.

4

If a cylinder is found to be leaking (usually from the valve) and the leak cannot be stopped, the cylinder should be carefully removed to a well-ventilated open space free from sources of ignition. It should be left with the leak uppermost, marked faulty, and notices displayed prohibiting smoking or other naked lights. General access should be prevented by barriers or otherwise. The supplier of the cylinder and, if necessary, the fire and rescue service, should be informed immediately.

5

Under no circumstances should attempts be made to dismantle or repair defective cylinders.

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Refillable cylinders

A level base of compacted earth, concrete or paving slabs should be provided and surrounded by a secure chain link fence at least 2 m high. A hard standing should be provided for the delivery and dispatch of cylinders. The area should be kept weed and vegetation free. If the compound is more than 12 m square, two exits should be provided in opposite corners of the compound. If less than 12 m square, one gate will suffice. Gates should open outwards and always be left unlocked when someone is in the compound. There should be sufficient shelter to prevent cylinders from being exposed to extremes of weather.

7

Signs must be clearly displayed indicating the presence of LPG, and prohibiting smoking and the use of any naked flame in the area of the store.

8

LPG cylinders must be stored with their valves uppermost. They must be stored away from oxygen, highly flammable liquids, oxidisers, toxic or corrosive gases or substances. A distance of at least 3 m must be kept between LPG cylinders and other such substances, although they may be kept in the same compound.

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Separation 9

Any store for refillable LPG cylinders must be located away from boundaries, buildings, fixed sources of ignition or electrical equipment by at least the distances detailed in the table below. LPG storage (including empties) Separation from building/boundary under 1,000kg

3m

10

1,001-4,000 kg 4m The store must be sited at least 3 m away from any cellars, drains or other excavations into which a leak of gas would collect.

11

No cylinder should be stored within 1.5 m of any compound fencing.

12

If only a small compound is used, 3 m x 3 m for example, cylinders may be stored against

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the inside of the compound fencing, providing this fence is not within 3 m of any boundary. 13

Empty cylinders must be stored with their valves securely closed to prevent any residue of gas escaping, or air being drawn into the cylinder.

14

Stocks should be grouped in batches of not more than 1000 kg and batches separated by a minimum 1.5 m gangway.

15

Where lighting is necessary, it should be mounted well above ground level and not less than 2 m above the cylinders.

16

Any equipment not in use, such as portable hand equipment, should be isolated so as not to be accessible to trespassers. Any cylinders not required should be returned to the storage compound or other secure position.

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Non-refillable cylinders

Non-refillable LPG cylinders for use with small portable equipment such as blowlamps may be stored in a lockable metal container.

18

Care should be taken when changing cylinders to ensure that connections are correctly made and that there are no leaks.

19

Always dispose of empty containers safely and in accordance with the manufacturer's recommendations. Do not, under any circumstances, puncture or throw 'empty' cylinders onto a fire.

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Additional storage details for small LPG containers

These are often non-refillable (e.g. cartridges) but small refillable cylinders (e.g. Primus) should also be stored in the same way.

21

Although only containing small quantities of gas, they must not be stored in occupied site huts.

22

They should be kept in a secure, non-combustible, well-ventilated external enclosure. The store should have warning signs: 'Highly Flammable - LPG' and prohibition signs: 'No smoking/naked lights'.

23

The disposal of cartridges after use requires care as they still contain gas. Under no circumstances should cartridges be thrown on fires. Small numbers of empty cartridges may be disposed of by including them in normal refuse.

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General transportation of LPG cylinders 24

When loaded onto vehicles, cylinders must be kept upright and secured. Vehicles must be equipped with a dry powder extinguisher and a first-aid kit. They must also display warning notices.

25

Do not overload the vehicle and, if using a closed vehicle, ensure that any cylinders are removed from the vehicle at the end of each journey.

26

If a cylinder leaks during a journey, close the valve immediately. If this is not possible, move the vehicle to open ground away from buildings and people, and inform the emergency services.

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Use of LPG in cylinders 27

Everyone with any responsibility for the storage and transportation of LPG must understand the characteristics and hazards of the LPG product they are using.

28

They should understand the fundamentals of fire fighting and control of leakages. They should also have knowledge of the procedures for dealing with emergencies.

29

It is not possible to cover all aspects of the use and application of LPG, but the following checklist gives the main points for its safe use and handling. Please note that this list should not be regarded as exhaustive. Never use or store a gas cylinder on its side, unless it is a special cylinder for use on LPG-fuelled plant and vehicles. Liquefied gas may escape, causing concentrations of gas, and operatives may suffer frostbite because of the very low temperature of the escaping liquid.

(b)

Propane cylinders must never be stored indoors because any leak will lead to large concentrations of explosive mixtures.

(c)

Only hoses suitable for use with LPG installations or appliances should be used and these should be inspected frequently for wear.

(d)

Cylinders must not be dropped during handling, nor brought into violent contact with other cylinders or adjacent objects.

(e)

Before and after use, valve protection caps and plastic thread caps or plugs should be fitted to prevent accidental leakage.

(f)

LPG cylinders should not be used below ground level as any leakage of gas will collect at the lowest point and will not disperse.

(g)

Regulators must be handled with care. Damaged regulators should not be used, but should be replaced or sent for specialist repair.

(h)

Hoses and fittings should be examined before use. Damaged items must be replaced.

(i)

LPG cylinders are fitted with a left-hand thread or push-on connection. Union nuts and couplers have grooves on the outside corners of the nuts confirming this. Always use the correct size spanner to tighten or loosen connections. Hand tight connections will permit leaks.

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(a)

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Left-hand threaded nut showing grooves on face corners

30

Over-tightening will damage threads and cause leaks. Checks for leaks should be carried out using soapy water or other proprietary detector.

31

NEVER USE A MATCH OR OTHER NAKED FLAME.

32

Before connecting any cylinder of LPG to equipment, it is essential that all fires, flames or other potential sources of ignition, including any smoking materials, are extinguished. Where it is reasonably practicable to do so, cylinders should be changed in the open air.

33

If a leak is found, the gas supply must be turned off at the cylinder immediately.

34

Flexible hoses should be in good condition and be protected or steel braided if they are likely to be subjected to damage by abrasion. Hoses must conform to BS 3212 (Specification for

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flexible rubber tubing, rubber hose and rubber hose assemblies for use in LPG vapour phase and LPG air installations). 35

Before use, inspections should be carried out on all LPG appliances and equipment. The inspection should cover testing for leaks, cleaning, adjusting, checking hoses, hose clips and ferrules.

36

Empty cylinders should always be treated as new ones and returned to a properly designated central storage area for collection. Under no circumstances should an LPG cylinder, either full or empty, be left around the site or buried during site operations.

Regulators LPG regulators should be suitable for the equipment with which they are to be used. They should be suitable for either propane or butane and be set to the correct pressure. They should be capable of passing the correct flow capacity.

38

It is dangerous to use regulators set at the incorrect pressure.

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1.7.4.12 Bitumen boilers and cauldrons

The majority of, if not all, bitumen boilers or cauldrons are fuelled by LPG to melt the block bitumen. Such a boiler or cauldron must be sited on a level non-flammable base, away from areas where site traffic may damage hoses or gas cylinders.

2

Ensure that any LPG cylinder is at least 3 m away from the boiler or cauldron to which it is attached.

3

Full cylinders, not attached, should be kept at least 6 m away from the boiler or cauldron and protected from heat.

4

Supply hoses should be checked for crushing, damage to the metal braiding or impregnation with bitumen. Any unserviceable hose must be replaced.

5

The sequence for lighting is as follows:

(b)

Have the source of ignition ready before turning on the gas. Light the burner, ensuring that the gas is turned on slowly.

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(c)

Remove the burner from the boiler or cauldron.

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(a)

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(d)

Replace the burner beneath the boiler or cauldron.

6

If frost forms on the outside of the cylinder, the gas flow rate is too high. Either use a smaller burner or couple two or more cylinders together by means of a manifold.

7

Never leave a bitumen boiler or cauldron unattended when the burner is alight.

8

Never move a bitumen boiler or cauldron with the burner alight.

9

If a bitumen boiler or cauldron is overfilled, overflows or boils over, the LPG cylinder valves must be turned off immediately. Any spillage should be contained using dry sand or earth and then left until cool. No attempt should be made to remove or recover any spillage of hot bitumen.

10

A dry powder extinguisher, of a minimum 4.5 kg in size, should be provided whenever a bitumen boiler or cauldron is used.

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1.7.4.13 Gas-operated hand tools 1

(a)

disposable

(b)

refillable.

These cylinders come in various shapes, sizes and colours, depending on the manufacturer. They range in size from the very small (0.5 kg) to the very large (47 kg).

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2

There are two types of LPG cylinder available for use with portable tools:

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Range of LPG cylinder sizes

All LPG cylinders used with portable equipment should be positioned upright and secured (if possible). Cylinders used with cutting equipment should always be placed on purpose-made trolleys.

4

Before changing a cylinder, always make sure that all valves are closed.

5

Hoses must never be kinked to try to shut off gas when changing torches. It does not work and can lead to a gas escape.

6

Always replace valve protection caps and plastic thread caps.

7

Flames from portable tools must not be allowed to play on LPG cylinders.

8

When work has been completed, turn off the cylinder valves and allow the flame from the portable torch to burn out.

9

Closure of torch valves rather than cylinder valves will retain gas in hoses which, if damaged, will allow gas to escape.

10

Hoses and torches must never be put into site toolboxes while still attached to the cylinder.

11

Manufacturers' operating pressures must be strictly observed and must NEVER be exceeded.

12

Do not interfere with preset pressure regulators.

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1.7.4.14 LPG for use in site huts and other small buildings 1

All LPG cylinders and regulators for use with fixed heaters, cookers and lighting within site

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huts, must be kept outside and the gas supply piped in using rigid copper piping. The use of flexible hosing is permitted only between the cylinders and change-over valves or manifolds, and for the final connection to appliances, but this must be kept as short as possible. All pipework should be exposed and easily accessible for inspection, but located to prevent accidental damage. Any work on LPG pipework or other parts of a fixed installation, including testing, must only be carried out by appropriately trained persons.

3

Ventilation for heaters and cookers must be permanent and adequate. It should be divided equally between vents at high and low level.

4

A two-burner cooker in a site hut needs approximately 150 mm x 150 mm ventilation. A 3 kW convector heater needs approximately 225 mm x 225 mm ventilation.

5

Inspections of all appliances must be carried out before use. If soot forms or smells occur, do not use or allow the appliance to be used. Find out the reasons for the problem and have it put right.

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Enclosed spaces

Before using LPG equipment in an enclosed space, it is essential to carry out a risk assessment. It is essential to ensure that there is adequate ventilation, which may have to be forced. This is necessary to ensure full combustion and also to make certain that the products of combustion, other fumes and excess oxygen from any cutting apparatus are removed. Proper safety precautions and atmospheric monitoring should be considered.

7

Wherever practicable, cylinders used with operations in confined spaces should be located in a safe area, preferably in the open air. The supply pressure should be reduced to the lowest practicable level on leaving the source of supply.

8

Where cylinders are used below ground level, the number must be kept as small as possible. All cylinders and hoses should be removed as soon as work has finished or if it is interrupted for a substantial period, e.g. overnight.

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Fire

Instructions for dealing with incidents involving LPG will vary for each situation. The most important thing is to avoid endangering anyone's life. The following actions should be taken by anyone discovering a fire.

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Action in an emergency

(a)

In case of fire, no matter how small, call the Civil Defence (Fire Department).

(b)

Whilst waiting for the fire and rescue service to arrive (if it can be done safely), turn off all cylinder valves to cut off the fuel supply and remove the cylinders from the area.

(c)

If the actions in 2 above cannot be completed safely, and thereby starve the fire of further LPG, evacuate the site and impose a cordon to stop anyone inadvertently entering the area.

(d)

Never attempt to use a water extinguisher to put out an LPG fire. Dry powder extinguishers are the most suitable type to use. The use of the wrong extinguisher in the wrong way could have serious consequences.

(e)

Training in the correct type of fire-fighting equipment to use, and the safe way to operate it, should be undertaken by all staff who work with LPG. These staff must be trained to recognise when the situation is getting out of control and they should also evacuate the area.

(f)

When the fire and rescue service arrives, inform the Fire Officer of the situation

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the location and contents of all the cylinders

(i)

details of any security cordon that you have implemented

(ii)

confirmation that all people who were known to be in the area have been accounted for or details of anyone that is unaccounted for, and

(iii)

if possible and required, offer them the data information sheet relating to the cylinder(s) involved.

Remember that cylinders fitted with pressure relief valves can produce gas jets which will extend a considerable distance.

(h)

if cylinders are exposed to a severe fire or are engulfed in flames, no attempt should be made to fight the fire. Evacuate everyone from the area.

(i)

where a flame from a leaking gas cylinder is extinguished but the valve is still open, gas will continue to escape and there will be a danger of a gas cloud forming and the risk of an explosion.

(j)

any cylinder involved in a fire should be clearly labeled that it has been involved in a fire and removed from the area to a safe place. Contact the suppliers -they will give advice and arrange for the cylinder(s) to be collected,

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(g)

Instructions concerning emergency procedures should be clearly displayed and all employees should be made aware of them.

11

Data information sheets are available from product manufacturers giving advice in case of an accident involving LPG cylinders. A copy of each sheet should be available for inspection and those sheets relating to the cylinders involved should be given to upon request the Civil Defence (Fire Department).

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1.7.4.15 Fire-fighting equipment Selected and suitable employees should be trained in the use of fire-fighting equipment.

2

Advice on the training of staff can be obtained from the LPG supplier or fire and rescue service.

3

Portable fire extinguishers, sited in pairs to minimise the risk of failure, should be positioned at strategic points wherever LPG is stored or used. As a general guide, no fewer than two 4.5 kg dry powder extinguishers or equivalent should be provided for every 20 large cylinders (47 kg) stored.

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1.7.4.16 Training 1

Most accidents involving LPG are due to ignorance of basic safety precautions.

2

All persons using LPG cylinders, tools or equipment should be suitably instructed in the hazards associated with LPG, and the precautions to be taken in its use.

3

An LPG safety questionnaire is attached at Appendix 1.

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Construction Site Safety 1.7.4 Appendix 1 LPG safety questionnaire 1

This questionnaire has been worded so that all the correct answers are YES. If you answer 'NO' to any question you may need to give the matter more attention.

Storage Has a risk assessment been carried out?

3

Has specialist advice been sought prior to the location of fixed or moveable storage tanks?

4

Is there the required separation distance between the storage tanks and adjacent buildings or boundaries?

5

Is the base supporting the tanks level?

6

Is the base paved or concrete?

7

Is there a chain link fence surrounding the tank?

8

Are there barriers to prevent collision?

9

Are the correct warning signs displayed?

10

Are there outward opening exits from the cylinder storage compound?

11

Are the exits non-self locking?

12

Is the area kept weed free?

13

Are all access areas being kept clear?

14

Are the correct type of fire extinguishers provided?

15

Are all cylinders stored upright?

16

Are the LPG cylinders 3 m from cylinders containing any other products?

17

Are cylinders being handled safely?

18

Is the LPG being grouped in not more than 1,000kg?

19

Are there 1.5 m wide gangways?

20

Is lighting provided?

21

Is lighting at least 2 m above the tallest stack?

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Transportation 22

Have drivers received adequate training?

23

Are cylinders transported upright and secured?

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24

Is the vehicle equipped with the correct type of fire extinguisher?

25

Is the vehicle equipped with a first-aid kit?

26

Does the vehicle carry suitable warning notices?

27

If using a closed van, are all gas cylinders offloaded at the end of each journey?

Use of LPG cylinders and appliances Are valve caps and protectors replaced after every use?

29

Are regulators being handled carefully?

30

Is the correct size of spanner being used to tighten connections?

31

Is all equipment, such as hoses and clips, being inspected regularly for leaks?

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Bitumen boilers and cauldrons

Is there a fire extinguisher of the correct type readily available?

33

Is the boiler or cauldron standing on a non-flammable level base?

34

Is the cylinder in use with the bitumen boiler or cauldron, a minimum of 3 m away?

35

Are any cylinders not in use a minimum of 6 m away?

36

Are hoses inspected regularly for damage or bitumen impregnation?

37

Are cylinders ice-free when the boiler or cauldron is alight?

38

Should manifolds coupling two or more cylinders be used?

39

Are bitumen boilers always attended when alight?

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Hand tools

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Are cylinders being used in the upright position?

41

Are purpose-made trolleys being used for cylinders used in conjunction with cutting equipment?

42

Are hand tools being used at the manufacturer's recommended operating pressures?

43

Are connecting hoses being regularly checked for wear and damage?

44

Are cylinder valves being turned off on the completion of work?

45

Is there a fire extinguisher of the correct type readily available?

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Site huts and other buildings 46

Are LPG cylinders, supplying heaters and other appliances, fixed outside the building?

47

Is the gas fed into the building by the provision of fixed copper piping?

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48

Are fixed installations only installed, modified and by competent engineer?

49

Is the final, short flexible hose as short as possible?

50

Are all pipes in use readily accessible for inspection?

51

Is there plenty of ventilation at high and low levels?

52

Are weekly inspections being carried out on all appliances?

53

Is there a fire extinguisher of the correct type readily available?

Fire precautions Are written procedures provided and displayed prominently?

55

Is there a telephone available to summon the fire and rescue service?

56

Are the correct types of fire extinguishers provided?

57

Are your staff trained in the use of fire extinguishers?

58

Are your staff and visitors aware of the site emergency evacuation alarm and procedure?

59

Are personnel aware of pressure relief valves?

60

Are product data sheets available?

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Construction Site Safety 1.7.4 Appendix 2 Retrieval of orphaned compressed gas cylinders The cylinder retrieval arrangements in place for the major national companies are listed below. Collection company

Contact numbers

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Notes

If a cylinder is no longer needed, it should be returned to the local dealer of the company owning the cylinder.

2

Until such time as they are collected, 'orphaned' cylinders should be stored in a safe and secure manner.

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Construction Site Safety 1.7.5

Vehicle Fuels (including Petrol, Diesel and LPG) 1.7.5.1 Key points A risk assessment must be carried out before dangerous substances are stored transported or used; in some cases a method statement and/or a permit to work will also be required.

2

Petrol is a flammable liquid that can be used for equipment such as generators and stored on site in small quantities in containers designed for the purpose. It has a flashpoint below 21 °C.

3

Diesel is a heavy mineral oil with a flashpoint much higher than that of petrol and is normally used as fuel for large commercial vehicles and construction plant.

4

Liquefied petroleum gas (LPG) is a compressed liquid, usually propane or butane, stored in cylinders. It is commonly used for heating, cooking or powering small vehicles such as dumper trucks or forklifts. It is heavier than air and has a flashpoint much lower than that of petrol.

5

Sources and safe storage of fuels should be recorded and carefully monitored.

6

Staff who work with flammable fuels must receive training in their safe handling and use prior to beginning work and must receive regular training in the use of fire extinguishers. Water must not be used on any liquid fuel fires.

7

The disposal of waste fuel is likely to be hazardous waste and should be managed accordingly.

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Vehicle fuels are classified as 'dangerous substances'. As such, there will be a risk of fire involved in their transportation, storage and use.

2

Wherever flammable liquids are stored or used a list of the substances present should be maintained, along with details of their quantities and location, which should be readily available for use by the fire and rescue service.

3

When used correctly and safely, petrol, diesel and LPG are useful fuels for the engines of vehicles and plant. When abused, they can cause explosions which can severely burn or even kill.

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1.7.5.3 Legislative requirements 1

Contractors are strongly advised to familiarise themselves with the content of Sections G1, G3 and G4 with regard to: (a)

the practical aspects of safe transportation, storage and use of dangerous substances (diesel and petrol) and LPG in the workplace

(b)

general advice on fire fighting, including the selection and use of hand-held fire extinguishers.

1.7.5.4 Petrol 1

Whilst the majority of construction plant will run on diesel oil, some small items of plant will have petrol-fuelled engines, for example: (a)

chainsaws

(b)

small portable generators

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Section 11: Health and Safety Page 68 Part 1.07: Fire and Flammable Substances (Regulatory Document)

(c)

disc cutters.

(d)

there will, therefore, be a need on occasions for petrol to be stored on site. This assumes that only small quantities of petrol will be stored on site.

Petrol, like many other flammable liquids, can give off large volumes of flammable vapours at room temperature. These vapours, when mixed with air, can ignite with violent and devastating consequences. Spilled petrol, if not contained, can flow to a source of ignition and then flash back to the source of the spillage. It is a dangerous substance to have on site unless adequate controls are implemented.

3

Petrol should ideally be stored outdoors to permit the dispersal of fumes from leakage. However, it is acknowledged that in some circumstances, for example the refurbishment of a city-centre building which has no open land, it may be necessary to store small quantities of petrol inside the building.

4

Petrol should be stored in suitable containers that enable the safe filling of petrol-powered machinery without spillage. Where necessary a funnel should be made available.

5

Containers must be robust, have tight fitting lids to prevent the leakage of liquid and vapour and be otherwise suitable for the purpose. Ideally containers will be of metal construction as these are more resistant to fire. These are usually of 5 litres capacity and the convention is that green containers are used for unleaded petrol.

6

All containers should be clearly labeled "Petroleum Spirit' or 'Highly Flammable' so that people on site are aware of the contents and any precautions that they must take.

7

Containers should, where reasonably practicable, be stored in the open air at ground level (singularly or in stacks). This enables leaks to be quickly seen and any vapours to be easily dispersed. They should not be stored on the roof of a building.

8

Where the best option of storing containers outside is not reasonably practicable they may be kept in suitable storerooms, preferably separate buildings, specifically designed for the purpose.

9

Other activities, including filling and emptying containers, must not be carried out in the designated storage area. This is to prevent other activities that are a higher risk causing a fire, which then spreads to involve the larger quantities in storage.

10

Any lighting equipment in any installation must conform to BS EN 60079-14 Explosive atmospheres - electrical installation design, selection and erection.

11

Electrical socket outlets are not permitted within any store where petrol or other flammable materials are stored.

12

Suitable fire-fighting equipment, such as a foam or dry powder extinguisher conforming to BS EN 3, must be positioned in close proximity to the store.

13

The store should not be sited under a staircase or other means of escape. A sill should be provided (not less than 150 mm in height) across the doorway of the store to prevent any leakage of petrol flowing out, along with measures to prevent any leakage of petrol into the drains or sewers.

14

The height of the sill should be adequate to contain a spillage of 110% of the volume of the largest container in the store or 25% of the aggregate capacity, whichever is the greater.

15

All reasonable precautions must be taken to prevent fire or means of ignition being brought close to any container.

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Outdoor storage 16

Petrol must be stored away from other storage areas and processes. There must be a minimum distance of 2 metres between a petrol storage area and any: (a)

occupied building

(b)

site boundary

(c)

process area

(d)

fixed sources of ignition

(e)

flammable liquid storage tanks.

Where higher risk activities (processes) are taking place, such as oxyacetylene cutting, the safety distance should be increased to a minimum of 4 metres.

18

The above distances may be reduced if fire walls to specific dimensions and standards of fire resistance are built.

19

Any outdoor petrol storage area should be secure both during working hours and at night. It might be considered that the normal site security arrangements are sufficient or that a dedicated secure store is required, in which case a welded mesh, palisade or chain-link fence of 1.8 metres high is the minimum requirement.

20

The features of any petrol storage area should not limit the means of escape in a fire.

21

Storage areas and a space of 1 metre around them will be classified as a Zone 2 hazard area and as such:

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any electrical fittings must be of the appropriate standard

(b)

there must be no sources of ignition

(c)

there must be no accumulation of combustible materials such as rubbish or vegetation.

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Where petrol is stored indoors at a place of work, a maximum of 50 litres may be stored. A risk assessment must be carried out and measures implemented to ensure that so far as is reasonably practicable, storage is carried out so as to:

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(a)

minimise the risks of fire and explosion

(b)

mitigate the effects of any fire and explosion that may occur.

In doing so, the risk assessment must consider the storage area with respect to: (a)

the absence of any sources of ignition

(b)

effective ventilation

(c)

adequate security

(d)

prohibition of filling equipment inside the storage area

(e)

avoiding spills and dealing with any spills that do occur

(f)

keeping containers closed when not in use.

Section 11: Health and Safety Page 70 Part 1.07: Fire and Flammable Substances (Regulatory Document)

Where significant amounts of petrol will be stored indoors a specially designed storage building must be constructed. However, given the small quantities of petrol that will be stored indoors on most construction sites, it is not envisaged that such a structure will be required.

Bulk petrol storage tanks

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QCS 2014

Demolition or rebuilding work on a site may involve the removal of old petrol storage tanks. Before any work can be started to demolish or remove any tanks, they must be certified gasfree and cleaned. This is a hazardous operation and should only be done by skilled specialist contractors.

26

No attempt must be made by anyone other than a specialist contractor to enter a disused petrol tank.

27

Note; Lead which has settled into any remaining sludge can be a major health hazard in old petrol tanks. It may also be present in rust and scale.

28

Where any tank is to be left in temporary disuse, it must be sealed below the pump by disconnection, and then by stopping the suction pipe. The vent pipe should be left open to the air.

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Vehicle petrol tanks 29

No welding, soldering or brazing operations should be performed on any vehicle fuel tank until it has been properly freed from gas or the contents made inert. This prohibition applies whether the tank is on or off the vehicle. A competent person should then authorise 'hot work' on the tank, preferably under a Permit to Work system.

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1.7.5.5 Diesel oil General requirements 1

The tank must have sufficient strength so that in normal circumstances it will not leak.

2

Appropriately designed and constructed supports for the tank must be used.

3

The tank must be so positioned to minimise the risk of impact damage by other vehicles and should not be placed within 10 metres of a watercourse or within 50 metres of a spring, well or borehole. The tank should also be positioned with consideration for future maintenance.

4

The tank must be situated within a secondary containment system (bund wall) which: has a capacity of 110% or more of the tank's capacity - or, if more than one container is stored, 110% of the largest container's storage capacity or 25% of the aggregate capacity, whichever is the greater

(b)

is so constructed that its base and walls are impermeable to oil and water

(c)

is strong enough to withstand being filled with either water or oil

(d)

has walls which cannot be penetrated in any form by tank drainage

(e)

if penetrated by a fill pipe or draw-off pipe, is adequately sealed to prevent leakage

(f)

has valves, sight gauges and vents sited within it.

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(a)

External fill pipes and draw-off pipes to the tank(s) should be positioned to minimise impact damage and, if above ground, should be properly supported. If underground, they should have no mechanical joints except where accessible.

6

They should be laid in a duct or sleeve to protect them from physical damage, and be protected against corrosion.

7

The whole system should have a leak detection system which should be tested regularly.

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Fill pipes

All fill pipes should be fitted with an automatic overfill prevention device if filling takes place where the tank cannot be kept under constant observation.

9

All fittings should either be screw type or other fixed type coupling.

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Where fuel oil is to be dispensed into containers or vehicles, the outlet must be fitted with a valve or nozzle which closes automatically when not in use, and which cannot be fixed in the open position unless an automatic cut-off nozzle is used on the end of the hose.

11

The hose and nozzle should be housed in an enclosed secure cabinet with a drip tray when not in use, or have a lockable valve where the feed leaves the tank. Hoses should be kept locked or kept within the bund when not in use.

12

Any permanent valve or tap which opens directly from the tank must: (a)

be located within the secondary containment system (bund wall)

(b)

discharge vertically downwards

(c)

be locked off when not in use.

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Section 11: Health and Safety Page 72 Part 1.07: Fire and Flammable Substances (Regulatory Document)

Finally, no vent must discharge outside of the bund in the event of an overfill.

Bulk diesel storage tanks The following points should be noted: the storage tank should be of mild steel

(b)

all bulk storage tanks should be placed on concrete or brick cradles

(c)

storage tanks should be protected from impact damage by delivery vehicles or site traffic

(d)

the tank should be in the open air, on level ground well clear of any openings, windows or doors

(e)

the tank should be vented at the top

(f)

protective gloves should always be worn when handling diesel oil. Skin contact may cause irritation leading to dermatitis and infection

(g)

metal storage cans should be kept in a lockable store, which has a sill to prevent any spillage flowing out. Appropriate warning labels should be displayed prominently on the store

(h)

a minimum distance of 750 mm between the tank and walls and 600 mm from the base is recommended to facilitate inspection

(i)

the tank should be marked with its capacity and the type of material stored within it

(j)

ensure that surfaces where deliveries are to be made and oil dispensed are protected by a surface impermeable to the oil stored and isolated from any drainage system

(k)

protective gloves should always be worn to protect any exposed skin. Contact can lead to irritation and dermatitis

(l)

metal storage cans should be kept in a lockable store with a sill to prevent spillage flowing out.

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Mobile bowsers

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Any mobile bowser should be fitted with a lock to any tap, valve or pipe through which oil is discharged and all pipes and valves should be locked shut within the bunded area of the bowser when not in use.

16

Where the oil is delivered through a permanently attached flexible pipe:

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(a)

the pipe must be fitted with a hand pump or with a valve at the end which closes automatically when not in use

(b)

the pump or valve must be fitted with a lock and locked shut when not in use

(c)

the pipe must be fitted with a lockable valve at the end where it is connected to the bowser and kept locked shut when not in use

(d)

any sight gauge must be fitted with a lockable valve which is locked shut when not in use.

1.7.5.6 Liquefied petroleum gas (LPG) 1

Every Contractor must ensure that all persons who work with or supervise others in the use of LPG equipment have available to them adequate health and safety information and, where appropriate, written instructions relating to the use of that equipment.

2

Containers of LPG are liable to explode if involved in a fire; pieces of the container may be projected over considerable distances.

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Every Contractor must ensure that all persons who work with, or supervise others in the use of, LPG equipment, have received adequate training for the purposes of health and safety, and be aware of any risks in the use and precautions to be taken in the case of an accident.

4

LPG is used in the building and construction industry as a fuel for small plant vehicles, such as dumper trucks and forklift trucks.

5

Only the correct type of cylinder should be used as these are of special construction and designed specifically to be laid on their side for fitting to the truck and for operation.

6

The following safety points should be strictly observed: make sure you have the correct type of cylinder

(b)

make certain it is correctly connected using the correct size of spanner to tighten the connection

(c) (d) (e)

never interfere with preset reducing valves

(f)

manufacturers' recommended operating pressures should never be exceeded

(g)

store additional cylinders safely

(h)

only keep on site the minimum quantity of LPG that is needed for effective operations.

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if you suspect a leak, do not use a lighted match or other naked flame. Only use soapy water or other proprietary leak detection fluid

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7

LPG cylinders are fitted with a left-hand thread or push-on connection. Union nuts and couplers have grooves on the outside corners of the nuts confirming this. Always use the correct size spanner to tighten or loosen connections. Hand-tight connections will permit leaks.

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Left-hand threaded nut showing grooves on corners

Storage of LPG cylinders All LPG cylinders not in use, empty cylinders awaiting return to the supplier and spare cylinders should be kept securely.

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LPG cylinders should be stored above ground level well away from drains and other low lying areas.

(b)

Stores in the open air should be sited as far from buildings as possible.

(c)

LPG stores in buildings should be accessible directly from the outside and be well ventilated.

(d)

LPG cylinder stores should not be used for the storage of petrol or other fuels (including acetylene).

(e)

Full cylinders should be stored separately from empty cylinders; all cylinders being stored with their valves uppermost.

(f)

Cylinders should be protected from direct sunlight.

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Fire fighting

Fires involving petrol and other vehicle fuels are usually severe, may cause explosions and are generally best left to the fire and rescue service. Knowledge of what to do in the event of a fire is essential if injuries and deaths are to be avoided.

10

In most cases where vehicle fuels are involved in a fire, or are being heated by it, a rapid evacuation of the site and a call to the fire and rescue service will be the only sensible and safe courses of action.

11

However, where other, less hazardous materials such as timber are involved in a fire, which could spread to a fuel storage area or an area where construction plant is located, a decision based upon the risks to personal safety will have to be taken as to whether or not to attempt to fight the fire to prevent the situation escalating.

12

Generally, the fire and rescue service will not enter any structure that is on fire in which LPG cylinders are known to be present. They are more likely to create an exclusion zone around the structure. It is of great assistance to them if the location of any LPG storage area is such that it can be cooled by a water spray from a distance.

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Disposal of Fuels 13

Other materials contaminated by fuels such as PPE, rags, used spill kit materials, etc. should also be regarded as hazardous waste and should be segregated from other non-hazardous wastes.

14

LPG cylinders that are no longer required should be returned to a local dealer of the company owning the cylinder. Under no circumstances should the LPG cylinder be disposed of in a waste skip or metal recycling skip. END OF DOCUMENT

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Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Page 1

REGULATORY DOCUMENT........................................................................... 1

1.8

MISCELLANEOUS .......................................................................................... 1

1.8.1

Sources of Health and Safety Information ....................................................... 4

1.8.2

Safety Signs .................................................................................................. 12

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Page 2

FORWARD

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This Section of the Regulatory Document (RD) was produced as a project deliverable under Ministry of Municipality and Urban Planning Contract Number P2009/3, entitled “Consultancy Services for the Preparation of Codes and Standards for Safety and Accident Prevention on Construction Sites”. During the latter stages of the project, the Committee responsible for the administration of the project decided that the RD and the associated Safety and Accident Prevention Management/Administration Systems (SAMAS) would be best delivered to stakeholders via the portal provided by the Qatar Construction Standards (QCS). The QCS includes references and certain sections which address occupational health and safety. To ensure that that users of the RD/SAMAS are fully aware of the where occupational health and safety issues are addressed in the QCS, the following table summarises where potential overlaps may occur. For consistency, it is recommended that in matters relating to occupational health and safety reference is made first to the RD/SAMAS. For the purpose of clarity, however, references are made in the relevant section of the RD/SAMAS to their comparable sections in the QCS and vice versa.

QCS 2014

Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Page 3

Sr. No

QCS 2014 Section No.

Part No.

Part Name

1

1

7

Submittals

8

7.5.2

Health and Safety Organization Chart

2

1

7

Submittals

9

7.6.1

Health and Safety Plan

3

1

10

Health and Safety

All

All

All

4

1

11

Engineer's Site Facilities

10

11.4.6

Safety Equipment and Clothing

5

1

14

Temporary Works and Equipment

3

14.4

Test Certificates for Cranes and Lifting Tackle

6

1

15

Temporary Controls

All

All

All

7

1

16

Traffic Diversions

2

16.1.3

Safety

8

1

8

General

3

8.1.6

Safety

9

3

1

General

8&9

1.4.12

10

4

1

General Requirements for Piling Work

7

1.6

Safety

11

4

4

Deep Foundations

37 & 38

4.9.1.7

Safety Precautions

12

4

4

Deep Foundations

13

6

1

General

14

6

7

Asphalt Plants

15

6

14

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Item Name

.

Page No. Item No.

Safety and Management

4.9.1.13 Protection of Testing Equipment 1.6

Temporary Fencing

15

7.8.13

Safety Requirements

Works in Relation to Services

4

14.2.2

Safety

General

7,8, 9 & 10

1.3.2

Health and Safety

se

as

4&5

8

1

17

8

8

Painting and Protective Coatings

6

8.1.9

Safety

18

8

9

Trenchless Pipeline Construction

7

9.2.5

Safety Requirements

19

8

10

Pipeline Cleaning and Inspection Survey

4,5&6

10.1.7

Safety Requirements

20

8

21

9

22

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16

Sewer Rehabilitation

9

11.2.2

Safety

1

General

16

1.2.8

Safety Guards

General

19

1.2.16

Noise Levels and Vibration

1

23

m

11

19

5

Hot Water Storage

4

5.1.6

Safety

24

21

1

General Provisions for electrical Installation

7&8

1.1.11

Fire and Safety Precautions

25

21

1

General Provisions for electrical Installation

14

1.1.23

Safety Interlocks

26

24

1

General

5

1.1.4

Scaffolding

27

29

1

Design Aspects

4

1.1.5

Fire Resistance Period

28

29

3

Geotechnical Specifications

4

2.3.1.5

Safety

29

29

4

Tunnel

18

4.5.8

Safety Regulations

30

29

4

Tunnel

19

4.5.9

Fire Prevention

31

29

4

Tunnel

21

4.6.4

Safety Measures and Systems

32

29

7

Concrete Structures

6

7.1.10

Safety Railing

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Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Page 4

Construction Site Safety 1.8.1

Sources of Health and Safety Information

British Standards Institute (BSI) BSI publications, including all British, European and ISO standards and other reference material, can be obtained direct from: British Standards Institution

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Customer Services 389 Chiswick High Road London W4 4AL Tel: 020 8996 9001 Fax: 020 8996 7001 Email: [email protected] Alternatively, they can be ordered: online from www.bsonline.bsi-global.com



from most branches of good quality bookshops; details on the above website.

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Page 5

Construction Standards British and European Standards

Sections British and European Standards 1.1

1.3

1.4

1.6

1.7

X

BS 1139-3 Metal scaffolding. Specification for prefabricated mobile access and working

X

.

X

BS 1129 Specifications for portable timber ladders, steps, trestles and lightweight staging

BS 1377 Methods of test for soils for civil engineering purposes

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X

BS 1710 Specification for identification of pipelines and services

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X

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X

BS 2037 Specification for portable aluminium ladders, steps, trestles and lightweight stagings BS 2482:2009 Specification for timber scaffold boards

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X

BS 2830 Specification for suspended access equipment for use in the building, engineering construction, steeplejack and cleaning industries

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BS 3212 Specification for flexible rubber tubing, rubber hose and rubber hose assemblies for use in LPG vapour phase and LPG air installations

1.5

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BS 598 Sampling and examination of bituminous mixtures for roads and other paved areas

1.2

X

BS 4078-2 Powder actuated fixing systems. Specification for tools

X

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BS 4078-1 Powder actuated fixing systems. Code of practice for safe use

X

BS 4250 Commercial butane and propane X

BS 4363 Specification for distribution assemblies for reduced low voltage electricity supplies for construction and building sites

X

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BS 4293 Specification for residual current operated circuit breakers

BS 4465 Specification for design and construction of electric hoists for both passengers and materials

X

BS 4481 Part 2 Bonded abrasive products

X

BS 5228:2009-1 CoP for noise and vibration control on construction and open sites - Noise

X

BS 5228:2009-2 CoP for noise and vibration control on construction and open sites - Vibration

X

BS 5266 Part 1 Emergency lighting

X

BS 5266-10 Guide to design and provision of emergency lighting

X

BS 5306 Fire extinguishing installations and equipment on premises

X

1.8

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Page 6

Sections British and European Standards 1.1

1.2

1.3

1.4

1.5

1.6

BS 5306-3 CoP for maintenance of portable fire extinguishers

X

BS 5499 Fire safety signs, notices and graphic symbols

X

BS 5531 CoP for safety in erecting structural frames

X

BS 5534 CoP for slating and tiling

X

X

BS 5588 Fire precautions in the design, construction and use of buildings

X

BS 5607 CoP for safe use of explosives in the construction industry

.

X

BS 5972 Specification for photoelectric control units for road lighting

X

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BS 5975 CoP for Falsework

X

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BS 6187 CoP for demolition (under review)

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BS 7071 Specification for portable residual current devices BS 7121-1 Code of Practice for safe use of cranes. General

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BS 7121-2 Inspecting, testing and examination

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BS 7121-3 Mobile cranes

X X X

X X X X

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BS 7121-4 Lorry loaders

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BS 7212 CoP for safe use of construction hoists

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BS 5974 CoP for temporarily installed suspended scaffolds and access equipment

BS 7121-5 Tower cranes

BS 7273 CoP for the operation of fire protection measures

X

BS 7375 CoP for the distribution of electricity on construction and building sites

X

BS 7430 CoP for earthing

X

BS 7671 2008 IEE wiring regulations 17th edition

X

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BS 7288 Specifications for socket outlets incorporating residual current devices (SRCDs)

BS 7863 Recommendations for colour coding to indicate the extinguishing media contained in portable fire extinguishers

X

BS 7883 CoP and use of anchor devices conforming to BS EN 795

X

BS 8411 Code of practice in the use of safety nets on construction sites and other works

X

BS 8454 Code of practice for the delivery of training and education for work at height and rescue

X

BS 8476 Code of practice for the safe use of concrete pumps BS 8800 Guide to occupational health and safety management systems

1.7

X X

1.8

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Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Page 7

Sections British and European Standards 1.1 BS 18004 Guide to achieving effective occupational health and safety performance

1.2

BS EN 143 Respiratory protective devices. Particle filters. Requirements, testing, marking

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BS EN 166 Personal eye protection. Specifications BS EN 169 Personal eye protection. Filters for welding and similar operations BS EN 170 Personal eye protection. Ultraviolet filters BS EN 171 Personal eye protection. Infrared filters BS EN 172 Personal eye protection. Sunglare filters for industrial use BS EN 175 Equipment for eye and face protection during welding and allied processes BS EN 280 Mobile elevating work platforms. Design calculations. Stability criteria. Construction. Safety. Examinations and tests BS EN 340 Protective clothing. General requirements BS EN 341 Personal protective equipment against falls from a height. Descender devices BS EN 352-1 Hearing protection. Safety requirements and testing. Ear muffs BS EN 352-2 Hearing protection. Safety requirements and testing. Ear plugs

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BS EN 149 Respiratory protective devices. Filtering half masks to protect against particles. Requirements, testing, marking

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BS EN 140 Respiratory protective devices. Half masks and quarter masks. Requirements, testing, marking

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.

X

BS EN 138 Respiratory protective devices. Specification for fresh air hose breathing apparatus for use with full face mask, half mask or mouth piece assembly

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1.5

1.7

1.8

X

,

X

BS EN 137 Specification for respiratory protective devices: self-contained opencircuit compressed air breathing apparatus

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X

BS 31100 Code of practice for risk management BS EN 3 Portable fire extinguishers Parts 3, 6 and 7 BS EN 131-3 Ladders - user instructions BS EN 136 Respiratory protective devices. Full face masks. Requirements, testing, marking

BS EN 165 Personal eye protection. Vocabulary

1.3

X

X X

X

X X X X X

X

X

X X X X

QCS 2014

Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Page 8

Sections British and European Standards 1.1

1.2

1.3

1.4

BS EN 353-1 Personal protective equipment against falls from a height. Guided type fall-arresters including a rigid anchor line

X

BS EN 353-2 Personal protective equipment against falls from a height. Guided type fall-arresters including a flexible anchor line

X

BS EN 354 Personal protective equipment against falls from a height. Lanyards

X

X

X

X

X

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BS EN 393 Lifejackets and personal buoyancy aids. Buoyancy aid 50 BS EN 397 Specification for industrial safety helmets BS EN 420 Protective gloves. General requirements BS EN 474 Earth moving machinery. Safety BS EN 529 RPE - Recommendations for selection, use, care and maintenance BS EN 671 Fixed fire fighting systems. Hose systems BS EN 752 Drain and sewer systems outside buildings BS EN 792-13 Hand-held non-electric power tools. Safety requirements. Fastener driving tools BS EN 795 Protection against falls from a height. Anchor devices. Requirements and testing BS EN 1146 Respiratory protective devices Self-contained open-circuit compressed air breathing apparatus incorporating a hood for escape

1.8

X

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BS EN 365 Personal protective equipment against falls from a height. General requirements for instructions for use, maintenance, periodic examination, repair, marking and packaging BS EN 388 Protective gloves against mechanical risks

X

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X

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X

BS EN 362 Personal protective equipment against falls from a height. Connectors

BS EN 364 Personal protective equipment against falls from a height. Test methods

1.7

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BS EN 360 Personal protective equipment against falls from a height. Retractable type fall-arresters BS EN 361 Personal protective equipment against falls from a height. Full body harness

BS EN 363 Personal protective equipment against falls from a height. Fall-arrest systems

1.6

.

BS EN 355 Personal protective equipment against falls from a height. Energy absorbers BS EN 358 Personal protective equipment against falls from a height. Belts for work positioning systems and restraint and work positioning lanyards

1.5

X

X

X

X X X

X

X X X

X X

X

X

X

QCS 2014

Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Page 9

Sections British and European Standards 1.1

1.2

BS EN 1261 Fibre ropes for general service. Hemp BS EN 1263-1 Safety nets. Safety requirements, test methods BS EN 1263-2 Safety nets. Safety requirements for the positioning limits

1.3

1.4

X

X

BS EN 1492-4 Textile slings. Safety. Lifting slings for general service made from natural and man-made fibre ropes

X

X

BS EN 1827 Respiratory protective devices. Half masks without inhalation valves with separable filters for gases and particles. Requirements, testing, marking

X

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BS EN 1869 Fire Blankets

X X

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BS EN 1870 Safety at woodworking machines - circular saws and vertical panel saws

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BS EN 1498 Personal fall protection equipment - rescue loops

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X

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BS EN 1496 Personal fall protection equipment - rescue lifting devices

X X

BS EN 12158-2: Builders hoists for goods. Part 2: Inclined hoists with non-accessible load carrying devices

X

BS EN 12159: Builders hoists for persons and materials with vertical guided cages

X

BS EN 12385-2 Steel wire ropes. Safety. Definitions, designation and classification

X

BS EN 12385-4 Steel wire ropes. Safety. Stranded ropes for general lifting applications

X

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BS EN 12158-1: Builders hoists for goods Part 1: Hoists with accessible platforms

BS EN 12810-2 Facade scaffolds made of prefabricated components. Particulars of structural design

X

BS EN 12811-1 Temporary works equipment. Part I Scaffolds. Performance requirements and general design

X

BS EN 12811-2 Temporary works equipment. Information on materials

X

BS EN 12841 Personal fall protection equipment - rope access - rope adjustment devices

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BS EN 1492-2:2000 Textile slings. Safety. Roundslings, made of man-made fibres, for general purpose use

BS EN 12899-1: Fixed, vertical road traffic signs. Fixed signs

1.7

X

X

BS EN ISO 6103 Bonded adhesive products. Permissible unbalances of grinding wheels as delivered. Testing

1.6

X

BS EN 1492-1:2000 Textile slings. Safety. Flat woven webbing slings, made of manmade fibres, for general purpose use

BS EN ISO 5349-1 Mechanical vibration. Measurement and assessment of human exposure to hand transmitted vibration

1.5

1.8

QCS 2014

Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Page 10

Sections British and European Standards 1.1 BS EN 13794 Respiratory protective devices. Self-contained close-circuit breathing apparatus for escape

1.2

1.3

X

1.5

1.6

1.7

X

BS EN 13411-5 Terminations for steel wire rope. Safety. U-bolt wire rope grips

X

BS EN 14439 Cranes - safety - tower cranes

X

BS EN 14502-1 Cranes - equipment for lifting persons - suspended baskets BS EN 14593-1 Respiratory protective devices. Compressed air line breathing apparatus with demand valve. Apparatus with a full mask. Requirements, testing, marking BS EN 14593-2 Respiratory protective devices. Compressed air line breathing apparatus with demand valve. Apparatus with a half mask at positive pressure. Requirements, testing, marking BS BS EN 14686 Fibre ropes of polyester/polyolefin dual fibres BS EN 50144-1 Safety of hand-held electric motor operated tools. General requirements BS EN 60079-14:2008 Explosive atmospheres - electrical installations design, selection and erection BS EN 60309 Plugs, socket-outlets and couplers for industrial purposes BS EN 60825 Safety of laser products

X

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BS EN 61557 Electrical safety in low voltage distribution systems

1.4

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BS EN ISO 12402-2:2006 Personal flotation devices. Lifejackets, performance level 275. Safety requirements

X

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BS EN ISO 12402-3 Personal flotation devices. Lifejackets, performance level 150. Safety requirements BS EN ISO 12402-4 Personal flotation devices. Lifejackets, performance level 100. Safety requirements BS EN ISO 12402-5 Personal flotation devices. Buoyancy aids (level 50). Safety requirements BS EN ISO 12402-8 Personal flotation devices. Accessories. Safety requirements and test methods BS EN ISO 14001:2004 Environmental management systems. Requirements with guidance for use BS ISO 525 Bonded abrasive products. General requirements. Pt1: Specification for general features of abrasive wheels, segments, bricks and sticks BS OHSAS 18001 Occupational health and safety management systems. Requirements BS OHSAS 18002 Occupational health and safety management systems -guidelines for the implementation of OHSAS 18001:2007

X

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X

X

X

X

1.8

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Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Page 11

Sections British and European Standards 1.1

1.2

1.3

1.4

PD 2754-2: IEC 60536-2:1992 Classification of electrical and electronic equipment with regard to protection against electric shock. Guide to requirements for protection against electric shock

1.5

1.6

X

X

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PD 5304 Safe use of machinery

1.7

1.8

QCS 2014

Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Page 12

Construction Site Safety 1.8.2

Safety Signs

1.8.1.1 Introduction 1

The colours used and their meanings are outlined on the following pages, together with example signs.

1.8.1.2 Prohibition signs

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These signs are red and white with a black image. The signs inform people of things they must not do, for example 'No pedestrians' or 'No smoking'.

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No pedestrians

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No smoking

Children must not play

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Page 13

1.8.1.3 Mandatory signs

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These signs are blue with a white image and inform people of things that they must do, for example 'Wear ear protection' or 'Use crawling boards'.

Wear a respirator

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Wear a hard hat

Wear eye protection

Wear safety gloves

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Wear ear protection

Wear work boots

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QCS 2014

Ear protection zone

Use crawling boards

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These signs are either yellow or amber with a black image and warn people of potentially dangerous situations, for example 'Forklift trucks operating' or 'Fragile roof.

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1.8.1.4 Warning signs/signs on hazardous substances

General warning

Flammable

Corrosive

QCS 2014

Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Radioactive

Page 15

Toxic

Explosive

Danger of electrocution

Laser beams

Highly flammable

Forklift trucks operating

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Fragile roof

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Irritant

Falling objects

Hazardous to the environment

Suspended loads

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Page 16

1.8.1.5 Safe condition signs

Emergency eye wash

First aid

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Assembly point

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These signs are green with a white image and inform people of features of the site that are associated with a safe condition, for example 'First aid' or 'Fire exit'.

Emergency shower

Wash hands

Drinking water

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Line-throwing appliance

Lifebuoy with line

Stretcher location

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Section 11: Health and Safety Part 1.08: Miscellaneous (Regulatory Document)

Page 17

Fire exit

1.8.1.6 Fire safety These signs are also red and white, but predominantly red with a white image. They indicate the location of facilities associated with fire safety such as 'Call point' or 'Fire point'.

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Call point

Fire point

an 'Unauthorised access strictly prohibited' sign - red and white = must not do

(b)

an 'All visitors must report to the site office' sign - blue and white = must do a 'Beware open excavations' sign - yellow and black = beware of danger an 'Assembly point' sign - green and white = safe condition.

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Often 'mixed signs' will be displayed, which are a combination of the four main types of sign. For example, a sign at the site entrance might include:

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1.8.1.7 Mixed signs

Hose reel

Similar signs that indicate, for example, the location of a dangerous substance storage area will also usually comprise a combination of signs, such as a 'Flammable' (warning) sign, a 'No smoking' (prohibition) sign, and additional appropriate wording.

END OF DOCUMENT

QCS 2014

Section 11: Health and Safety Page 1 Part 2.1.01: Safety, Health and Environment Management System

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ..........................................................1

2.1

SAFETY, HEALTH AND ENVIRONMENT (SHE) MANAGEMENT SYSTEM .1

2.1.1 Amendment Schedule .................................................................................................. 3 2.1.2 Safety, Health and Environmental (SHE) Management Framework ............................. 4

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2.1.3 Statement of Intent ......................................................................................................10 2.1.4 Policy and Responsibilities - Example .........................................................................12

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2.1.5 Organisation Charts ....................................................................................................22

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2.1.6 Index of Key Process ..................................................................................................22

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2.1.7 Author .........................................................................................................................22

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2.1.8 Approvals ....................................................................................................................22

QCS 2014

Section 11: Health and Safety Page 2 Part 2.1.01: Safety, Health and Environment Management System

Purpose 1

The purpose of this document is to provide guidance for development of a clear policy, responsibilities and an example of a management framework that reflects the COMPANY commitment, core values, standards and expectations for both the organisation and those working with COMPANY.

Scope This policy covers all COMPANY operating areas, projects and activities.

2

This policy is intended to assist appointed consultants, sub-contractor and suppliers etc., to meet legislative and other requirements not intended to replace these. The policy should always be read in conjunction with QCS Part 1 (RD) requirements and any other legislative requirements as advised and may be introduced.

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QCS 2014

2.1.1

Section 11: Health and Safety Page 3 Part 2.1.01: Safety, Health and Environment Management System

Amendment Schedule Details of change

Date

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Revision No.

QCS 2014

2.1.2

Section 11: Health and Safety Page 4 Part 2.1.01: Safety, Health and Environment Management System

Safety, Health and Environmental (SHE) Management Framework

2.1.2.1 Introduction 1

This document sets out a framework for the management of Safety, Health and Environmental (SHE) issues across COMPANY’s operations, projects and activities.

2.1.2.2 SHE Management System The management system, and this framework, is based on recognised standards i.e. ISO 9001 ‘Quality Systems’, BSI OHSAS 18001 ‘Occupational Health and Safety Management Systems’ and ISO 14001 ‘Environmental Management Systems’.

2

In summary, the key requirements of the system are:

Procedures for hazard identification, risk assessment, control and management of change.

(c)

Documented, measurable SHE objectives and plans.

(d)

Clear management responsibilities.

(e)

Competence assurance identification and delivery.

(f)

Arrangements for communication, consultation and engagement with the appropriate stakeholders.

(g)

Operating procedures and processes.

(h)

Arrangements for SHE document control and retention.

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Consistent SHE policy statements throughout COMPANY’s operations.

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training

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(k)

Systems for capturing learning events and best practice.

(l)

An audit and monitoring system.

(m)

Regular management reports on SHE performance, including improvement reports.

(n)

Regular management reviews.

Active performance indicators. System for notification, investigation and recording of accidents, learning events and environmental incidents including standardised statistics.

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In order to achieve the consistency desired, along with compliance, with the OHSAS 18001 and ISO 14001 standards, these management system elements are mandatory.

2.1.2.3 Background 1

To ensure core values and expected behaviors set out in the SHE policy namely, commitments to: (a)

Continuously improve SHE performance towards our overall goal of protecting both people and the environment.

QCS 2014

Section 11: Health and Safety Page 5 Part 2.1.01: Safety, Health and Environment Management System

(b)

Ensure that business decisions take proper account of SHE matters and their implications.

(c)

Comply with all legislative requirements pertaining to SHE as the minimum standard.

2

Our overall goal is to protect both people and the environment. Our principles require us to have an effective SHE management system that will deliver consistency in approach and good management information on performance throughout our operations.

3

Good corporate governance also requires SHE performance to be properly reviewed and in addition COMPANY is committed to review and publish this information.

2.1.2.4 Purpose The purpose of this document is to set out an enabling framework for the management of Safety, Health and Environmental (SHE) issues across COMPANY’s operations wherever they are carried out. It deals with the management systems to be adopted, and does not prescribe actual systems of work which it is recognised will be affected by stakeholder, legislative, cultural and working practice requirements.

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2.1.2.5 Scope GENERAL

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Throughout this document reference is made to ‘COMPANY’. This term means any region, operational area or project wherever it is based and wherever it carries out work.

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Continuously improve SHE performance towards our overall goal of protecting both people and the environment.

(b)

Ensure that business decisions take proper account of SHE matters and their implications.

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(a)

Comply with all legislative requirements pertaining to SHE as the minimum standard.

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Joint shall ensure that the SHE management system is consistent with the international best practice principles set out within QCS commitments to:

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JOINT VENTURES (JV’S) AND PARTNERING AGREEMENTS

When entering into a Joint Venture or partnering arrangement the business concerned will ensure that: (a)

A clear and unambiguous policy is developed, put in place and communicated.

(b)

The relevant parties will agree/develop a SHE Management System that takes cognizance of best practice and standards.

(c)

Key processes put in place include planning, competence, operational control, emergency preparedness, change management, performance measuring and monitoring, accident and incident investigation and review.

(d)

Arrangements must also be in place for reporting on SHE performance to relevant parties (including incident reporting), SHE management review by the board and if appropriate the formation of an independent SHE board to provide advice etc

(e)

Within the policy and defined roles and responsibilities, a board member must be identified who has specific responsibility for SHE matters.

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Section 11: Health and Safety Page 6 Part 2.1.01: Safety, Health and Environment Management System

2.1.2.6 Policy POLICY STATEMENTS 1

The COMPANY SHE policy statement and responsibilities applies to all COMPANY’s operations wherever they are carried out. They are included in Section 3 and Section 4 of this document.

2

A template format for the SHE policy statement is included in Section 3 of this document. All Joint Ventures or partnering agreements must use this template as a basis for developing any specific policy. COMMUNICATION

.

The developed policy, including personal responsibilities and those of direct reports, must be communicated to each employee. Examples of those responsibilities are outlined within this section.

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The policy statement will be reviewed at least annually.

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REVIEW

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PLANNING FOR HAZARDS, ENVIRONMENTAL IMPACT IDENTIFICATION, RISK ASSESSMENT AND RISK CONTROL COMPANY will have and maintain procedures for the identification of hazards, environmental impacts, the assessment of risks, and the implementation of necessary control measures. Procedures must include the provision of suitable management and operational levels to ensure work is carried out safely and with consideration of the environment.

2

The procedures will address the activities of: COMPANY employees

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(b)

COMPANY contractors (including any further sub-contractors)

(c)

Other contractors performing work under COMPANY’s control

(d)

Other persons affected by COMPANY’s undertakings, i.e. members of the public

In respect of environmental impact the procedures will also address the supply of goods and materials for use by the COMPANY business. LEGAL AND OTHER REQUIREMENTS

4

Establish and maintain a procedure for identifying and accessing the legal SHE requirements that apply and have an impact on our activities. Impact may also include the effect of any material change that may be brought about by organizational re-structure or senior management appointments. Information on any relevant new SHE requirements that must be communicated to employees and other interested parties as appropriate.

QCS 2014

Section 11: Health and Safety Page 7 Part 2.1.01: Safety, Health and Environment Management System

OBJECTIVE 5

6

COMPANY will set documented, measurable, annual SHE objectives and targets. The objectives must be consistent with the SHE policy and the commitment to continuous improvement. A management programme will be produced for achieving the objectives setting out: (a)

The designated responsibility for achievement of the objectives

(b)

The means and time-scale by which the objectives are to be achieved

(c)

Any appropriate improvement targets and associated improvement plans

The programme will be reviewed at regular intervals to ensure it is up to date and that it addresses any changes that may have occurred in COMPANY.

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2.1.2.8 Implementation and Operation STRUCTURE AND RESPONSIBILITIES

This document recognises that SHE is everybody’s responsibility and will be managed through the organisation in a systematic and structured manner.

2

Regional businesses must develop an effective management structure, including individual responsibilities in SHE matters at all levels. The structure will recognise line management responsibility and allow for access to competent advice on SHE matters.

3

Statements of individual and collective responsibilities are included in Section 4 of this document.

4

A SHE organisational structure chart for the COMPANY business is included in Section 5 of this document. The chart shows operational and functional responsibilities for SHE and visible to all, for example displayed on site.

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COMPETENCE AND TRAINING COMPANY will have processes in place to ensure that those working for, or on behalf of, COMPANY are competent to perform any tasks they are given that may have an impact on SHE performance.

6

COMPANY will also identify the training necessary to meet our SHE policy commitments at each level and function within the business.

7

Plans will be developed to deliver the required training.

8

Training records will be kept and achievement of the required training will be monitored.

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COMMUNICATION AND INVOLVEMENT 9

COMPANY will establish and maintain appropriate arrangements and strategies for: (a)

The communication

(b)

The communication of relevant SHE information to employees and those working on our behalf.

(c)

Consultation with and engagement of employees, those working on our behalf and those affected by the activities of the business.

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(d)

Section 11: Health and Safety Page 8 Part 2.1.01: Safety, Health and Environment Management System Receiving and responding to relevant communication from external interested parties.

OPERATIONAL CONTROL

Project Management Plans

(c)

SHE Management Plans

(d)

Method/Task Statements

(e)

Permit Controls

(f)

Work Instructions

(g)

SHE Performance Reports

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In addition, establish arrangements for the control of SHE documentation and data. The arrangements will ensure that documentation and data is: Retrievable

(b)

Current

(c)

Appropriately authorised, and where necessary

(d)

Periodically reviewed

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Records retention schedule will be prepared, which will identify all SHE records and their associated retention periods. These records will be stored appropriately such that they are readily retrievable and protected against damage, deterioration or loss throughout the retention period.

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Prepare operating procedures and plans for the planning and control of activities associated with identified risks. These may include provision for:

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EMERGENCY PREPAREDNESS

COMPANY will assess the potential for emergency situations and, where appropriate, establish emergency preparedness and response arrangements.

14

There arrangements will be periodically reviewed and tested and, where necessary, revised. Reviews will be undertaken to a pre-determined programme and after the occurrence of accidents or emergency situations.

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2.1.2.9 Checking and Corrective Action PERFORMANCE MEASUREMENT AND MONITORING 1

COMPANY will establish and maintain procedures to monitor and measure SHE performance on a regular basis. This will include: (a)

Active systems which monitor the achievement of objectives and compliance with standards.

(b)

Reactive systems which monitor accidents, ill-health and incidents.

ACTIVE PERFORMANCE INDICATORS 2

Active performance indicators will at least include:

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(a)

Performance results against our short, medium and long term SHE strategy

(b)

Achievement of objectives

(c)

SHE training achievement

(d)

Audit results and surveys

(e)

Assessment against SHE performance standards

(f)

Statistical analysis

(g)

Cases of good working practices

(h)

Learning event reports

ACCIDENTS, INCIDENTS AND CASES OF ILL HEALTH

COMPANY employees

(b)

Employees of sub-contractors where

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COMPANY will establish procedures for notification, investigation and recording of accidents, incidents, cases of ill health, learning events (near misses) and environmental incidents involving:

COMPANY has direct sub-contractors (and any further sub-contractors) performing work under its control, or

(ii)

Has general supervisory authority over the worksite

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(i)

Others affected by COMPANY work such as visitors or members of the public

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Accident and cases of ill health statistics will be compiled and included in management reports. The standard statistics to be used across COMPANY are based on RIDDOR record keeping guidelines for occupational injuries and illnesses. In particular, accident frequency rates, accident incident rates, lost time incident frequency rate and total recordable case frequency rate will be used.

5

Investigation procedures will ensure that incidents that have, or could have, led to serious harm to the individual or the environment are investigated and reported on. Investigations will establish what happened, any corrective or preventive actions required and allocate responsibility for taking such action.

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ENFORCEMENT ACTION Details of any enforcement action taken by the Administrative Authority in the form of prosecutions, enforcement notices, orders, etc will be recorded and included in management reports and communicated as soon as is reasonably practicable, to the senior management team. AUDIT 7

COMPANY Regional businesses will undertake regular audits to monitor the operation of the SHE management system and measure its adequacy and performance.

8

Significant findings of the audits must be acted upon. Close-out reports detailing the action taken will be produced.

9

Details of audits undertaken and their results will be included in management reports.

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2.1.2.10 Management Review MANAGEMENT REPORTS ON SHE PERFORMANCE 1

Prepare regular reports on SHE performance for review by its senior management board. These reports should be prepared at least monthly.

2

Management reports on SHE performance will be produced at corporate, operational area and project levels. A consistent structure will ensure that the key information contained in the reports can be meaningfully compiled and used at a higher level.

3

Report on SHE performance on a monthly basis.

Executive summary

(b)

SHE performance

(c)

Site visit feedback (by exception)

(d)

Learning Events

(e)

Occupational Health

(f)

Environmental

(g)

Stakeholder involvement

(h)

Training

(i)

Best Practice

(j)

Progress against action plans

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Senior management teams of each COMPANY Regional businesses must regularly review SHE performance. Review of SHE performance should be a standard agenda item for management team meetings, and should be high on the agenda. The review should at least consist of presentation and consideration of the relevant SHE report. Headings within the report include:

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MANAGEMENT REVIEW MEETINGS

Actions arising from the review should be documented, responsibility clearly allocated with appropriate timescales.

2.1.3

Statement of Intent

1

COMPANY, (The Contractor) will comply with its legal duties in order to provide a safe and healthy working environment for its employees and others affected by its activities. It will take positive action to ensure that other contractors' employees, occupiers of premises, and members of the public do not have their health and safety adversely affected by the work operations of the company. The only acceptable standard of health and safety, and for welfare facilities, will be full and proper compliance with the requirements of legislation. Where it is possible and practical to do so, the company will exceed the minimum requirements of the Qatar Regulatory Document (Construction).

2

The company will seek to ensure that each company with whom it contracts or subcontracts aspires to a similar high standard of health and safety management.

3

In recognition of the importance that this company places on the engagement and wellbeing of its employees, the company will:

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(a)

consult, on health and safety matters, with its employees and others who may work under its control to ensure that the arrangements for health and safety management are practical to implement and effective

(b)

as far as is reasonably practicable, fully and effectively control the health and safety risks arising from its work activities, in co-operation with employees, other contractors, clients and other relevant parties

(c)

ensure that accident and ill health prevention is provided the highest priority, commensurate with business objectives, within all company operations

(d)

investigate lapses in health and/or safety performance and implement remedial actions to prevent, so far as is reasonably practicable, their recurrence

(e)

provide and ensure that all plant and equipment owned, used or hired by the company is appropriate, safe to use and properly maintained, inspected and tested

(f)

ensure that all equipment, materials and substances used by the company are appropriate for their intended use and used, handled and stored safely

(g)

ensure that all employees are provided with adequate supervisory training, information and instructions to competently carry out their work activities

(h)

ensure that all working places are maintained in a safe and healthy condition

(i)

provide adequate resources, including sufficient finance, and access to competent health and safety advice, to achieve the aims of this policy

(j)

review and revise this policy statement at regular intervals and also where necessary due to changes in the company activities.

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Signed:........................................................ Designation: ............................................

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2.1.4

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Policy and Responsibilities - Example

2.1.4.1 Senior Management Board Collective responsibilities in safety, health and environmental (SHE) matters Provide positive individual and collective leadership on SHE issues.

(b)

Promote an enthusiastic SHE culture that delivers positive commitment to and engages all employees in continuous improvement in SHE performance.

(c)

Ensure a SHE management system is implemented within their sphere of responsibilities. Monitor and review its effectiveness and take necessary improvement action.

(d)

Monitor that personnel under their control comply with their individual responsibilities in SHE matters.

(e)

Challenges areas or instances of performance.

(f)

Ensure that disciplinary processes are in place to address breaches of the SHE policy or management system.

(g)

Establish a framework for the management of SHE.

(h)

Monitor and review the overall SHE performance and where appropriate take necessary actions to minimize and negate.

(i)

Ensure board discussions and decisions take proper account of SHE policy commitments.

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2.1.4.2 Managing Director

(b) (c)

Provide positive leadership on SHE issues for COMPANY

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Individual responsibilities in safety, health and environmental (SHE) matters

Set a clear vision and values for SHE expectations for COMPANY. Promote an enthusiastic SHE culture that delivers positive commitment to and engages all employees in continuous improvement in SHE performance.

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(d)

Ensure that business decisions take proper account of SHE policy commitments.

(e)

Keep abreast of developments in SHE legislation and industry standards.

(f)

Ensure the implementation of an appropriate SHE management system, in compliance with a developed SHE Management Framework, within the business(es) for which responsibility is held. .

(g)

Appoint a responsible person for SHE responsibility.

(h)

Review SHE performance at management team meetings and take appropriate improvement action.

(i)

Monitor that members of the management team comply with their individual responsibilities in SHE matters.

(k)

Consult regarding on decisions affecting SHE management.

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Section 11: Health and Safety Page 13 Part 2.1.01: Safety, Health and Environment Management System

(m)

Ensure that arrangements are in place to ensure everyone is aware of their own individual responsibilities under SHE policies and those of any personnel under their control.

(n)

Ensure appropriate action is taken to address breaches of the SHE policy

2.1.4.3 Directors/Members of the Senior Management Team Individual responsibilities in safety, health and environmental (SHE) matters Provide positive leadership on SHE issues.

(b)

Promote a SHE culture that delivers positive commitment to and engages all employees in continuous improvement in SHE performance.

(c)

Keep abreast of developments in all Qatar SHE legislation and industry standards.

(d)

Ensure that the SHE management system is implemented within their sphere of responsibility. Monitor and review its effectiveness and take necessary improvement action.

(e)

Monitor that personnel under their control comply with their individual responsibilities in SHE matters.

(f)

Ensure appropriate action is taken to address breaches of the SHE policy.

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Provide positive leadership of SHE issues and promote the adoption of SHE best practice.

(b)

Promote an positive SHE culture of that engages all employees.

(c)

Monitor and report on the implementation of the COMPANY SHE Management Framework and progress against the COMPANY SHE Performance Standards.

(d)

Lead and provide functional management for the SHE personnel within COMPANY.

(e) (f)

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Provide assistance and advice to ensure compliance. Develop and recommend annual SHE objectives and targets. Monitor and report against these.

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2.1.4.4 SHE Director

(g)

Produce reports monthly and annually on SHE performance in COMPANY.

(h)

Involved and lead in investigations to ensure that they are adequately reported.

(i)

Review reports of accident and incident investigations identify any trends and ensure that there is an appropriate response to prevent future recurrence.

(j)

Regularly meet with all SHE personnel in COMPANY to monitor and review management of the function as well as development.

(k)

Keep abreast of developments in SHE legislation.

(l)

Represent COMPANY through involvement with appropriate external SHE forums, networks, industry and regulatory bodies.

(m)

Develop and monitor the implementation of processes for the development of SHE personnel in COMPANY.

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Section 11: Health and Safety Page 14 Part 2.1.01: Safety, Health and Environment Management System

2.1.4.5 SHE Managers/Advisers* Individual responsibilities in safety, health and environmental (SHE) matters (a)

Provide positive leadership within your area of operation and promote the adoption of best practice.

(b)

Promote an enthusiastic SHE culture that delivers positive commitment to and engages all employees in continuous improvement in SHE performance.

(c)

Keep abreast of developments in SHE legislation and industry standards.

(d)

Monitor and report on the effectiveness of the SHE management system and progress against the COMPANY SHE Performance Standards. Make recommendations for improvement as appropriate.

(e)

Monitor and report on operational SHE performance and make recommendations for improvement. Monitor to ensure that effective action is taken.

(f)

Lead and provide functional management for any SHE personnel under their control.

(g)

Assist with the identification of SHE training needs, and monitor delivery and recording.

(h)

Monitor and report on the implementation of the approved SHE objectives.

(i)

Produce SHE performance reports as required.

(j)

Promptly alert line and functional management to significant accidents and incidents. Where appropriate be involved in the investigation and ensure that the findings are reported.

(k)

Review accident and incident reports and investigation reports, identify any trends and ensure that there is an appropriate response to prevent future recurrence.

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* The term “SHE Adviser” includes dedicated health and safety or environmental advisers .

Individual responsibilities in safety, health and environmental (SHE) matters. In so far as they are applicable to the role

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(a)

Provide positive leadership on SHE issues within your area of operation.

(b)

Promote an enthusiastic SHE culture that delivers positive commitment to and engages all employees in continuous improvement in SHE performance.

(c)

Implement the business unit SHE management system. In particular: (i)

Identify SHE training needs and have the necessary training arranged. When arranged, release those who require training;

(ii)

Make arrangements for SHE induction training for all new starters at the workplace under their control

(iii)

Implement operating procedures, including risk assessment procedures, for the planning and control of activities associated with identified risks;

(iv)

Ensure that written method statements, risk assessments and/or SHE rules are brought to the attention of those affected;

(v)

Appoint appropriate personnel to undertake SHE duties;

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Section 11: Health and Safety Page 15 Part 2.1.01: Safety, Health and Environment Management System (vi)

Ensure that suitable arrangements are in place for the effective control of changes to planned methods of work.

(d)

Keep abreast of developments in Qatar SHE legislation and industry standards.

(e)

Monitor and review the effectiveness of the SHE management system and report deficiencies.

(f)

Monitor that personnel under their control comply with their individual responsibilities in SHE matters.

(g

Give personnel under their control, including contractors, clear instructions as to their responsibilities to ensure correct working methods.

(h)

Make adequate provision for dealing with safety, health or environmental emergencies.

(i)

Promptly alert line and SHE management to Significant injury to employees or those working under our control;

(ii)

Reportable dangerous occurrences and learning events;

(iii)

Incidents that could lead to enforcement action;

(iv)

Enforcement notices served;

(v)

Injury to a member of the public or a visitor;

(vi)

Serious environmental incidents.

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Where appropriate, be involved in the investigation and ensure that the findings are reported.

(k)

Report visits by members of relevant administrative authorities e.g. Civil Defence (Fire Department)

(l)

Ensure that the SHE manager/adviser is accompanied on workplace inspections. Following such inspections take action agreed as necessary. Thereafter report as requested on the action taken.

(m)

Act immediately on any breach of SHE rules or procedures, unsafe situation or potential threat to the environment that comes to their attention and, where necessary, report such breaches.

(n)

Ensure that the disciplinary process to address breaches of the SHE policy or management system is applied where necessary.

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*Managers people in the organisation at any level above supervisor and below director

2.1.4.7 Supervisors* 1

Individual responsibilities in safety, health and environmental (SHE) matters (a)

Provide positive leadership on SHE issues for the members of the work team for which they are responsible.

(b)

Promote a positive attitude in the workforce and encourage behaviours that protect both people and the environment.

(c)

Organise work to be carried out in accordance with relevant SHE risk assessments/ method statements.

(d)

Monitor that personnel under their control comply with their individual responsibilities in SHE matters.

(e)

Give personnel under their control, including contractors, clear instructions about the required methods of work.

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Section 11: Health and Safety Page 16 Part 2.1.01: Safety, Health and Environment Management System Ensure that all relevant personnel are involved in SHE risk assessments prior to any work activity commencing, and, where appropriate, that method statements are available, understood and that any identified control measures are implemented.

(g)

Where appropriate assess and implement any additional SHE controls required to address the needs of new employees, young persons, non-English speaking workers, disabled persons, pregnant women, etc.

(h)

Monitor that risk assessments/method statements accurately reflect the SHE hazards present and ensure that any required changes are agreed and implemented in accordance with the arrangements for control of changes to planned methods of work.

(i)

Ensure appropriate arrangements are in place for two-way communication and where appropriate deliver tool box talks to the work teams.

(j)

Identify any SHE training requirements of personnel under their control and advise appropriate management accordingly.

(k)

See that accidents and incidents are reported immediately to the relevant manager.

(l)

Ensure that personal protective clothing and equipment is used where identified as required and is properly maintained and stored.

(m)

Ensure that the plant and equipment supplied is appropriate for the work and has any necessary certification. Ensure that plant and equipment is immediately put out of use if unsafe or presents a potential threat to the environment.

(n)

Ensure that only authorised persons operate plant and equipment.

(o)

See that unattended plant, materials and premises are left in a condition that does not present a risk to persons or the environment.

(p)

Ensure that the disciplinary process for breaches of SHE procedures and rules is applied where necessary.

(q)

Develop fire safety procedures, communicate with staff and carry out the necessary training and fire drills with a frequency that is appropriate for the size of the site and the duration of the construction operations.

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*Supervisors people at the first level in the organisation that have responsibilities over the work of others;

Individual responsibilities in safety, health and environmental (SHE) matters. In so far as they are applicable to the role (a)

Set a good personal example on SHE issues within your area of operation.

(b)

Take care of your own health and safety whilst at work; ensure your activities do not adversely affect the health and safety of others or damage the environment.

(c)

Co-operate with the company in all matters of health, safety and environmental protection and make your contribution to reducing accidents and conserving natural resources.

(d)

Ensure you have been fully briefed on, and have a good understanding of, the task at hand. Always work in accordance with the instructions given and any written SHE risk assessments/method statements. Report any conflict.

(e)

Never deviate from an agreed method of working unless the supervisor or relevant manager has been notified and authorisation has been obtained.

(f)

Ensure that you have and use the correct access, tools, equipment and personal protective equipment for the work.

Section 11: Health and Safety Page 17 Part 2.1.01: Safety, Health and Environment Management System

(g)

Never undertake hazardous operations nor operate any items of plant or equipment unless trained and authorised to do so.

(h)

Maintain a tidy workplace with an appropriate level of cleanliness.

(i)

Report to immediate supervisor any defects in plant or equipment or unsafe methods of work and ensure that plant, equipment and premises are left in a safe and secure state and place when unattended. Do not operate any item of plant or equipment that has become defective.

(j)

Report to your immediate supervisor all potential hazards and incidents that have or could have resulted in personal injury or environmental damage.

(k)

Report any work-related personal injury or disease to your immediate supervisor and ensure that an entry is made in the accident book at your place of work.

(l)

If you are asked to undertake a task that you feel is unsafe or for which you feel you do not have the appropriate knowledge or training, report this to your immediate supervisor.

(m)

Ensure you have been fully briefed on the fire safety drill and that you understand your roles and responsibilities. Actively participate in all health and safety drills.

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Individual responsibilities in safety, health and environmental (SHE) matters

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Ensure that arrangements exist to deliver the following: (i)

Orders to suppliers for materials, plant and equipment etc. include relevant SHE requirements notified by the specifier;

(ii)

Suppliers of materials, plant and equipment etc. are requested to provide all necessary information and operating instructions so that their products can be used safely without risk to persons or the environment;

(iii)

Where such information is received by the procurer that it is passed on to the persons who will use the materials, plant and equipment etc;

(iv)

Orders to suppliers for personnel include sufficient detail to adequately describe the work for which they are required;

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(vi)

Contractors and Labour Agencies are assessed as competent and adequately resourced for the work before contracts are placed; Tendering contractors have been provided with the Standard Rules for SubContractors on Safety, Health and the Environment and that compliance with them is a condition of contract;

(b)

No undertakings, either verbal or written, are given to any supplier relieving it of its SHE responsibility.

(c)

Monitor that the above arrangements are effectively implemented.

* Notes 1.

Procurement Managers includes those individuals managing the procurement of personnel.

2.

These responsibilities are specific to this role and are in addition to the other relevant responsibilities contained in this document.

3.

Procurement Managers where they are responsible for placing contracts with suppliers of products and services.

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2.1.4.10 Design, Engineering and Planning Managers* Individual responsibilities in safety, health and environmental (SHE) matters (a)

(i)

Designs which recognise, include and apply safe practice during preparation, construction and subsequent operational use and maintenance, and which consider lifecycle environmental impact including decommissioning and disposal;

(ii)

Design/engineering/planning interfaces are co-ordinated to ensure that the project can be carried out with minimum risk to persons and environment.

Monitor that the above arrangements are effectively implemented.

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Ensure that arrangements exist to deliver the following:

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Ensure that arrangements exist to deliver the following: All plant and equipment is in a safe condition on leaving its depot or store and that relevant, current inspection/thorough examination certificates and licences are carried with that item of plant or equipment;

(ii)

Plant and equipment hired in is from an approved supplier and has current inspection/thorough examination certificates available with it;

(iii)

Inspection, planned preventative maintenance and periodic tests and thorough examinations are carried out and that results are recorded;

(iv)

Repairs and maintenance work are carried out in a proper manner by competent personnel;

(v)

Sufficient information is available regarding the use of all plant, equipment and materials and this information accompanies the item when leaving the depot or store;

(vi)

All plant and equipment defects notified are remedied and plant and equipment is immediately put out of service if it is unsafe or a risk to the environment.

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* These responsibilities are specific to this role and are in addition to the other relevant responsibilities contained in this document

(b)

Monitor that the above arrangements are effectively implemented.

* These responsibilities are specific to this role and are in addition to the other relevant responsibilities contained in this document

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2.1.4.12 Site Engineers/Foremen Individual responsibilities in Safety, Health and Environmental (SHE) matters (a)

Appreciate the responsibility allocated to individuals within the operative and management structure.

(b)

Set a good example and leadership by working safely on the site and wearing the appropriate personal protective equipment.

(c)

Ensure safety arrangements, including fire safety drills, are implemented.

(d)

Ensure that only trained and authorised workers use plant and equipment and that persons undergoing training do not operate plant and equipment unless closely supervised by a competent person.

(d)

Ensure that employees under their control attend induction training before working on the site and that they are correctly supervised at all times.

(e)

Ensure that plant and equipment under their control or brought to site by the subcontractor has any necessary certificates of test, inspection and examination and is safe to use.

(f)

Ensure that clear instruction and information is give to persons under their control.

(g)

Carry out recorded safety inspections of site conditions.

(h)

Ensure that persons under their control wear and use any personal protective equipment correctly, to manufacturer’s instructions and to statutory and company requirements.

(i)

Ensure that employees under their control are given appropriate safety information as required and that details of control measures from risk assessments are fully explained.

(j)

Ensure that any accident/incident is reported and that all accidents are entered in the accident register.

(k)

Ensure that access/egress routes are kept clear from obstruction, particularly escape routes and ensure that good housekeeping is observed at all times.

(l)

Ensure that any plant/equipment for use by employees under their control is checked to ensure any necessary guards or safety devices are checked and fit for use by competent persons prior to use.

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Attend any meeting on safety issues as required and as applicable, co-operate with all personnel on matters of Safety, Health and the Environment.

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2.1.4.13 Office Staff 1

Individual responsibilities in Safety, Health and Environmental (SHE) matters (a)

(b)

Ensure personnel are fully aware of the procedures in the event of an emergency, including: (i)

Any accident, incident or emergency procedure

(ii)

Positions of the fire exits, layout out of escape routes and assembly point location/s

(iii)

Position of the first aid equipment and the identity of the trained first aid personnel

Report any defects in plant or equipment immediately to your supervisor. Ensure plant, equipment and premises are left in a safe and secure state and place when unattended

Section 11: Health and Safety Page 20 Part 2.1.01: Safety, Health and Environment Management System

(c)

Observe good housekeeping at all times and keep corridors, doorways and floor spaces clear and free from obstruction.

(d)

Do not attempt to lift or move articles as heavy as likely to cause injury.

(e)

Do not over-reach for items on high shelves, use the equipment provided.

(f)

Do not misuse or interfere with equipment provided for the safety of you and others.

(g)

Do not try to use, repair or maintain any equipment for which you have received no training or instruction.

(h)

Report any work related personal injury or disease to your immediate supervisor and ensure that an entry is made in the accident book at your place of work.

(i)

Report all potential hazards and incidents that have or could have resulted in personal injury or environmental damage to your immediate supervisor.

(j)

Report any unsafe situation or task you may feel is unsafe and for which you do not have the appropriate knowledge or training, to your supervisor.

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2.1.4.14 Responsibility Matrix

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A responsibility matrix that links the roles in the organisation to the responsibilities under the COMPANY policy is shown on the following page.

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Responsibility Matrix Directors/Managers at all levels a

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Senior Management Board



    

Managing Director



            

Directors/Members of the Senior Management Team



    



           

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SHE Director

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         

Managers at all Levels



           



              

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SHE Managers/Advisers

Supervisors

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Paragraph No.

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All employees

          

All Employees HR Managers





Procurement Managers and Buyers Design Engineering & Planning Managers Plant/Depot/Works/ Stores Manager













Engineers/Foremen



             

Office Staff



        



QCS 2014

2.1.5

Section 11: Health and Safety Page 22 Part 2.1.01: Safety, Health and Environment Management System

Organisation Charts COMPANY plc

TBA

Index of Key Process

1

SHE Mandatory Policy, responsibilities and management framework

2

Safety, Health and Environmental Risk Management

3

COSHH (Control of Substances Hazardous to Health)

4

Guidance on Safe Working in the Vicinity of Buried and Overhead Services

5

Electricity at Work

6

Authorisation of Plant/Equipment Operators

7

Safety, Health and Environmental Information and Training for all Employees, Newly Assigned Employees, Promotees and Subcontractors

8

Contractors Check List for Initial Safety, Health and Environmental Meeting

9

The Reporting of Accidents/Incidents, Diseases and Dangerous Occurrences (RIDDOR), Learning Events and Environmental Incidents

10

Personal Protective Equipment (PPE)

11

The Safe Use of Cranes and Other Lifting Appliances (Excavators, Tele Handlers and Lorry Loaders)

12

Permit to Work Systems

13

Control of Scaffolding and Working at Heights

14

Fire Precautions During Construction Works in Building

15

Asbestos

16

Procedures for Environmental Protection

17

Associated forms for the above.

18

Standards and Guidance

2.1.7

Author

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2.1.6

SECTION

NAME

POSITION IN COMPANY

CONTACT DETAILS

SHE Manager

2.1.8

Approvals NAME

Approved by:

POSITION IN COMPANY

SHEQ Director END OF DOCUMENT

SIGNATURE & DATE

QCS 2014

Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS).............................................................. 1

2.2

SAFETY, HEALTH AND ENVIRONMENT PROCEDURAL AUDIT CHECKLISTS…..……………………………………………………….. ................... 1

2.2.1 EXAMPLE SHE-PRO-002- COSHH.................................................................. 2 2.2.2 EXAMPLE SHE-PRO-003- Safe Working in the Vicinity of Buried and Overhead Services............................................................................................ 5

.

2.2.3 EXAMPLE SHE-PRO-004- Electricity at Work .................................................. 9

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2.2.4 EXAMPLE SHE-PRO-005- SafetyAuthorisation of Plant/Equipment Operators ........................................................................................................................ 12 2.2.5 EXAMPLE SHE-PRO-006- Safety, Health and Environmental Training ......... 14

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2.2.6 EXAMPLE SHE-PRO-008- The Report and Investigation of Accidents and Incidents.......................................................................................................... 18 2.2.7 EXAMPLE SHE-PRO-011- Permit to Work Systems ...................................... 22

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2.2.8 EXAMPLE SHE-PRO-013- Fire Precautions During Construction Works in Buildings ......................................................................................................... 23

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2.2.9 SHE-PRO-014- Asbestos................................................................................ 24

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

2.2.1 EXAMPLE SHE-PRO-002- COSHH

as

qa

The Project /Site Manger must Ensure the procedure is established and reviewed for effectiveness. Appoints a COSHH Coordinator for the project.

ta

rw

QCS 2014

Project Manager

3.i

se

Has the Project Manager appointed a COSHH Coordinator for the project?

1.ii

3.ii

3.ii

et

Has a register of hazardous substances been produced?

m

COSHH Coordinat or

ito

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er

If a substance is supplied or created by COMPANY, the COSHH Coordinator is responsible for ensuring a COSHH assessment has been undertaken. The COSHH Coordinator should ensure that a register of all hazardous substances is maintained, and that each has a valid COSHH assessment, and where applicable a MSDS.

COSHH Have all substances on the register had an Coordinat assessment done? or If a substance is supplied or created by a sub-contractor, it is their responsibility to provide the COSHH assessment along with all other risk assessments submitted for acceptance. These assessments are likely to accompany a method statement, and should be read as part of the method statement acceptance process. Project/Site Managers must ensure that assessments and method statements have been agreed, and monitor work to ensure it is undertaken in line with the method statement. The COSHH Coordinator should ensure that all hazardous substances present on a project have a valid COSHH assessment. For a supplied substance the COSHH assessment should be accompanied by the manufacturers/suppliers MSDS.

3.ii

3.ii

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If there are sub-contractor supplied hazardous materials do they have a valid COSHH assessment?

Project Manager Competent Person Supervisor

Is there evidence that where an activity has changed after the initial Risk Assessment/ Method Statement was carried out, a review has taken place and the documents updated in line with the change?

been

3.ii

3.ii

3.iv

ito

ov

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se

as

Have the COSHH assessments reviewed and agreed?

qa

Contractor s / COSHH Coordinat or Project/Sit e Manager

rw

Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

ta

QCS 2014

3.iv

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et

Where an assessment identifies the likelihood of an adverse health condition or identifiable disease being contracted, then health surveillance may be required. Project Manager / Contractor

Where the health of an individual has been identified as a risk, has health surveillance been arranged?

All activities undertaken under the Risk Assessment (and controls therein) shall be monitored to ensure that the assessment is both suitable and sufficient and is being worked to correctly. Project manager / Supervisor

Is the work being carried out in accordance with the agreed Risk Assessment / Method Statement?

3.iv

Page 3

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

Has a briefing been given to the workforce based on the content of the risk assessment / method statement?

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et

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Supervisor

as

qa

Dependant on the nature of the Risk Assessment and Method Statement, give a briefing to ensure that the detail is communicated to all relevant Operatives and carry out a reality check to confirm understanding of key aspects.

ta

rw

QCS 2014

Total Awarded Total Achievable % Score

12

Page 4

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

Page 5

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ta

2.2.2 EXAMPLE SHE-PRO-003- Safe Working in the Vicinity of Buried and Overhead Services

qa

Project/Site Manager

3.i

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er

Has the Project manager identified the excavations required to carry out the contract works?

ito

Has the Project manager Appointed a Services Coordinator?

et

Are suitable service location equipment available and a competent operator identified / trained?

m

Project Manager

se

as

Evaluate Project Program and the works drawings to identify the requirements for excavation. Appoint a Services Co-ordinator or retain the Services Coordinator’s duties himself. Ensure the availability of suitable service location equipment and a competent operator. Where overhead electrical supply cables are present ensure that controls are in place before authorising any activities on site Agree with Services Co-ordinator the site colour-coding scheme for surface marking of services.

Where overhead electrical supply cables are present have controls been put in place before authorising any activities on site? Is a site colour-coding scheme for surface marking of services in place and communicated?

Services Co-ordinator

3.ii

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

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QCS 2014

Page 6

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Seek out and retain copies of all statutory authority and service drawings relevant to the project’s scope of work. Have transposed onto a master drawing(s), the details of all relevant services. Have recorded on the master drawing(s) the location and depths of services installed during site establishment. Confirm with the Supervisor/Engineer in control of an activity requiring a Permit to Excavate the full extent of the intended activity. Check the activity drawings against the master drawing(s). Produce an activity specific location drawing for reference by the locator of services that includes current landmarks, using SHE-FRM-3-02. Request the locator of services undertake a thorough survey of the area where the activity is to take place with an appropriate service locator, even if it has been established from drawings that there are no recorded services present. Provide an activity specific, location drawing (including any updates identified in the survey) for reference by the Supervisor/Engineer in control of the activity. Update master drawing(s) following receipt of survey information. Ensure information on master drawing(s) is transferred to ‘as-built’ drawings for inclusion in the H&S file. Before any activities start on a site where overhead services are present or adjacent, contact the SHE Adviser for advice. Where overhead electrical supply cables are present the local Electricity Company shall also be contacted for advice on re-routing or clearance and insulation. Have copies of all statutory authority and service drawings relevant to the project’s scope of work been obtained. And details Services transposed onto a Master services Coordinat drawing? or

Has an activity specific location drawing been produced for all activities requiring excavations, that include current landmarks, using SHE-FRM-3-02? Has a thorough survey of the area where the activity is to take place been undertaken with an appropriate service locator, even if it has been established from drawings that there are no recorded services present? Has the master drawing(s) been updated following receipt of survey information or installed services?

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3.iii

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Has the information on the master drawing been transferred to ‘as-built’ drawings for inclusion in the H&S file? Where overhead services are present or adjacent to the works has the local SHE Adviser been contacted for advice? Where overhead electrical supply cables are present has the local Electricity Company been contacted for advice on rerouting or clearance and insulation? Locator of Services

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

ta

QCS 2014

Has the position of services been physically and clearly marked on the ground in accordance with the services marking scheme?

m

Locator of Services

et

ito

Physically and clearly mark the position of services on the ground in accordance with the services marking scheme. Update the activity specific location drawing provided for reference to you by the Services Co-ordinator. .

Have updates been made to the activity specific location drawing?

Supervisors/Engineers

3.iv

Page 7

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

Page 8

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excavation or penetration of the ground (using the information in the guidance); any activity beneath or in the vicinity of overhead electrical supply cables or pipework containing a hazardous substance where there is any possibility, however remote, of plant, equipment, materials or people encroaching into a safety zone; any activity beneath or in the vicinity of any other overhead service where there is a possibility of damage.

se

 

qa

Prepare or arrange for the Sub/Work Package Contractor to prepare for agreement/approval by the Project/Site Manager a specific method statement for activities involving: -

ov

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Ensure persons under their control fully understand they do not commence excavation or penetration of the ground in an area unless the whereabouts of services has been established and a Permit to Excavate has been prepared and approved by the Service Coordinator and obtained, SHE-FRM-3-02.

Has a specific method statement for activities involving: - excavations or work under or near overhead services been prepared?

m

Supervisor s /Engineers

et

ito

Ensure all personnel involved in the activities are instructed in the method statement and Permit to Excavate and sign to confirm their understanding.

Has a Permit to Excavate been prepared and approved by the Service Coordinator? Have all personnel involved in the activities been instructed in the method statement and Permit to Excavate and signed to confirm their understanding?

Total Awarded Total Achievable % Score

17

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

rw

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ta

2.2.3 EXAMPLE SHE-PRO-004- Electricity at Work

qa

Managing Director

3.i

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Has The MD for the Company / Region shall appoint in writing an Electrical Duty Holder for their area of responsibility?

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Managing Director

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The MD for the Company / Region shall appoint in writing an Electrical Duty Holder for their area of responsibility

3.ii

Electrical Duty Holder

et

ito

The Electrical Duty Holder shall Assess and approve all temporary Electrical contractors prior to their appointment In conjunction with the Site / Project Manager appointed coordinator and Authorised Person for each location. Take reasonable steps to ensure that the site electrical coordinator has the competency to undertake the role. Ensure that all projects and appropriate contractors have a copy of the latest Rules for Electrical Safety Undertake independent inspection/audit of site electrical installation / equipment under COMPANY control.

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Electrical Duty Holder

Have all temporary Electrical contractors been Assessed and approve prior to their appointment? Has an authorised person been appointed to for the location? Has the site electrical coordinator been assessed to ensure he has the competency to undertake the role? Is there a copy of the latest Rules for Electrical Safety available on the project? Do the electrical contractors working on the project have a copy of the latest Rules for Electrical Safety? Have inspections / audits been undertaken by the Electrical Duty Holder?

Page 9

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

ta

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QCS 2014

The Site Electrical Coordinator shall     

3.iii

qa

Site Electrical Coordinator

ov

Has the coordinator checked to ensure work is being carried out in accordance with the RES?

ito

Site Electrical Coordinat or

er

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Ensure All work is carried out in accordance with the COMPANY Rules for Electrical Safety. After consultation with the EDH, appoint in writing a competent person for the location he is responsible for. Display the appointment of the site electrical coordinator and competent person on the location notice board and electrical switch gear. Keeps an up to date drawing showing the electrical circuits for the location’s temporary electrical system. Ensure schedule tests are carried out on installations and equipment

m

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Has a competent person been appointed for the project, and the appointment displayed? Is there an up to date drawing of the temporary site electrical circuits? Has the required tests for the electrical system been scheduled? Have the required tests for the electrical system been carried out as scheduled?

Authorised Person

3.iv

The Authorised Person shall control the permit to work system and issue permits as required. Authorise d Person

Is the Authorised person issuing electrical permits as required?

Site / Project Manager

3.v

Page 10

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

ta

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QCS 2014

ito

ov

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Has the Site /Project Manager appointed in writing a permanent works electrical duty holder? Has the specification for the temporary site electrics been communicated to the temporary electrical contractor?

et

Site / project Manager

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After consultation with the EDH appoint in writing a permanent works Electrical Duty Holder. Ensure that the specification for the temporary site electrics is communicated to the temporary electrical contractor.

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 

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The Site / Project Manager shall

Total Awarded Total Achievable % Score

15

Page 11

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

Page 12

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2.2.4 EXAMPLE SHE-PRO-005- SafetyAuthorisation of Plant/Equipment Operators

qa

Project/Site Manager

3.i

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Identify the plant requirements for the project and produce a plant schedule. This should identify COMPANY’s plant requirements. The schedule should be reviewed and revised as the project progresses. Where appropriate appoint a Plant Coordinator or retain the duties. Project Manager

ov

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Has a plant schedule been developed to record the plant requirement of both COMPANY & contractors?

ito

Has a plant schedule been developed reviewed and where necessary revised?

m

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Has a plant Co-ordinator been appointed in writing? Plant Co-ordinator

3.ii

Assess the plant schedule and ensure the plant required is available in line with the contract programme. Advise the Project/Site Manager of any revisions/additions needed to complete the works..

Plant Coordinator

Is the required plant available to carry out the work in accordance with the plant schedule and contract program?

Plant Co-ordinator/Supervisor

3.iii

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

Page 13

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QCS 2014

se

Are copies of the plant operator certificates available in the site register?

er

Plant Coordinat or Supervisor

as

qa

Obtain copies of Plant Operator certificates; forward a copy of the COMPANY direct employed operators certificate to the Regional Training Coordinator. A copy of all Plant Operator certificates should be held on site in the Site Register. Check the operator’s certification for the plant to be operated (see section 4.i and 4.ii) and only allow the use of plant where the certification corresponds to the exact type of plant to be used. Where defects are reported / noted on item of plant, ensure the plant is put out of service and replacement/repair is arranged.

ito

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Are plant operators in possession of the correct certificate for the plant they are using?

m

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Have any defects been noted in the site register and if necessary has the plant with the defect been put out of service?

Total Awarded Total Achievable % Score

7

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

Page 14

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2.2.5 EXAMPLE SHE-PRO-006- Safety, Health and Environmental Training

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SHE training strategy

3.i

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as

. The SHE Department will be responsible for producing and reviewing a SHE training strategy for the whole business. The training strategy and associated training matrix will be available on the intranet*. Line managers are responsible for ensuring that their staff have had the necessary training, or ensuring that appropriate arrangements are made to cover any shortfalls. Requests for SHE training are to be made to the relevant Training Coordinator Has a SHE Training Strategy been produced and is it available to the projects?

Manager

Has a local schedule been produced to identify training requirements for the location in line with the training matrix?

et

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Inductions

ito

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SHE Department

3.ii

All newly assigned employees will receive a SHE induction. In addition a location specific induction will be required to ensure all necessary SHE information is provided. Project inductions will not be given to any person who cannot provide evidence of competency relevant to their role. Projects will provide a full SHE induction for everyone who will be on site. This induction must be provided before an individual is allowed to go onto the site. Project Managers are responsible for ensuring that a site specific induction is in place and provided as required. Visitors to sites, and other locations such as offices, must receive a tailored SHE induction if the full induction is not provided. Visitors must be accompanied by a suitable person who has attended a full site induction. Site inductions will include a short evaluation. Location Have all persons received a SHE induction. Manager / including a location specific induction? Supervisor Are all persons working on the project in possession of relevant qualifications to their role? Where there are Visitors on site have they received a visitor’s induction and are they being accompanied around site?

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

qa

ta

Have all persons on site undertaken an induction evaluation questionnaire specific to the projects?

Page 15

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QCS 2014

3.iii

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Supervisors’ inductions

ov

Have all supervisors received a specific supervisor SHE induction?

ito

Location Manager / Supervisor

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se

Any person on a site who will act in a supervisory capacity must undergo a top up induction. This will identify what COMPANY will expect of them as a supervisor or manager. In particular it will cover expected standards of behaviour on site, and dealing with instances of unsafe behaviour

3.iv

et

Newly assigned COMPANY staff:

 

m

staff shall not commence their duties until they have: received a copy of the SHE policy statement and their SHE responsibilities. If the role involves managing or supervising others they must also receive a copy of the responsibilities of those grades they will be managing or supervising. Responsibilities should be explained to them by their line manager; received general advice and been informed of any significant findings of risk assessments for the work they will undertake;

Location Manager / Supervisor

Have all staff received a copy of their specific SHE Responsibilities, and have they been explained to them by their line manager?

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

Page 16

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er

se

as

qa

Have all staff been informed of the significant findings contained within the risk assessments for the work they will undertake.

3.v

ov

Agency staff

ito

When requesting staff or labour the COMPANY Manager is required to specify to an employment agency:

Project Manager

m

et

 any special occupational qualifications or skills required to do the job, including any specific evidence of competence  specific features of the job that may effect health and safety (e.g. work at heights, heavy manual handling operations, etc). If agency staff are being employed on the project have any specific requirement, with regards to skills, qualifications etc and special features of the job which may effect h & s, been notified to the agency?

SHE training arrangements

3.viii

SHE training will be arranged by the relevant Training Coordinator, who will also maintain SHE training records. The only exception to this will be project specific site Inductions which will be arranged and delivered by site personnel, with records maintained on site. Training Coordinator

Are the SHE training records up to date and available to Managers

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as

qa

ta

Are the SHE Induction records up to date and available on site

m

Project / Site Manager

Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

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QCS 2014

Total Awarded Total Achievable % Score

12

Page 17

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

Page 18

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QCS 2014

ta

2.2.6 EXAMPLE SHE-PRO-008- The Report and Investigation of Accidents and Incidents

as



3.

Investigate cause of accident, record physical evidence and take steps to prevent recurrence. Inform the SHE Department of such incidents. Record and report the accident on the accident book form and send a copy to the SHE Department together with any supporting evidence/documentation Complete the accident book entry report. (Accident Investigation Report Part 1, AIR SHE-FRM-8-02/2)

se

  

qa

For All Accidents on Site

Have all accidents recorded had an element of investigation and steps taken to prevent re-occurrence?

Project / Site Manager Project / Site Manager

Has the SHE Department been informed of all accidents recorded on the project?

ito

ov

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Project / Site Manager

m

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For all accidents reported to COMPANY has the Accident Book been completed?

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

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qa

For All > 3 Day RIDDOR Reportable Accidents

Inform the SHE Department and Contracts Manager as soon as the accident becomes a possible “over 3 day reportable”. Obtain from any contractor a copy of the F100. In the case of an COMPANY emplyee, provide the SHE Adviser / Manager with all relevant detail to allow MIT / SHE to complete the F100. Where appropriate to the potential outcome of the accident / incident, in conjunction with SHE Adviser / Manager, complete/send First Alert form SHE-FRM-8-01 to ensure that relevant persons are informed (see distribution list on First Alert form). Ensure the investigation is undertaken and the report Produced within an appropriate time frame as per QCS requirement.

as

 



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For any RIDDOR Accidents has an F100 been completed and sent to the Enforcing Authority?

Project / Site Manager Project Manager / SHE Advisor

For appropriate accidents / incidents has a First Alert been completed?

et

ito

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Project Manager / Supervisor

m

Has an investigation been carried out and a report been completed?

Reporting and Investigating a Major Accident/Incident (Fatal Accident or Major Injury)

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

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qa

 Contact your SHE Adviser / Manager. The SHE Adviser / Manager will inform the MIT and prior to commencing the investigation and following consultation with the SHE Manager / Director, will advise our legal representatives.

as

 In conjunction with SHE Adviser / Manager, complete/send First Alert form SHE-FRM-8-01 to ensure that relevant persons are informed (see distribution list on First Alert form).

se

 SHE Advisor to ensure that the Labor Ministry has been informed. Where applicable ensure that the Police has also been informed.  SHE Advisor to Inform SHE Director / SHE Manager.

er

 SHE Advisor to carry out an immediate investigation of the accident in conjunction with MIT.

ito

ov

 SHE Advisor to ensure that a copy of the form F100 is completed and sent to the Enforcing Authority within 10 days of the accident, or in the case of a non COMPANY employee, obtain a copy from their employee and ensure that a copy is forwarded to the COMPANY Insurer.

Project Manager

m

et

Was contact made immediately to the SHE Advisor?

Project Manager / SHE Advisor Project Manager / SHE Advisor SHE Advisor

Has a First Alert been completed?

Were the Enforcing Authority has been informed and an F100 been completed and sent to the Enforcing Authority & other relevant parties? Has an investigation been carried out and a report been completed?

Accident Book/Register

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

Page 21

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Site management shall control and verify entries made in the COMPANY accident book and ensure that copies are forwarded as soon as possible after they are made to the SHE Department. All notified accidents shall be entered in the COMPANY accident book including all employees, contractors, visitors to site and accidents to members of the public.

Project manager Project Manager

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se

Is the Accident book available and under secure control? Have all accident book entries been sent to the SHE Department?

The Project / Site Manager is responsible for the completion of the SHE Return and this shall be sent to the SHE Department as soon as possible after the month end but no later than the second working day of the following month.

m

et



ito

Monthly SHE Returns

ov



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QCS 2014

Project Manager / Contractor

Have the monthly returns been completed and sent to the SHE department each month within the time scales set?

Total Awarded Total Achievable % Score

13

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

rw

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qa

ta

2.2.7 EXAMPLE SHE-PRO-011- Permit to Work Systems

1.ii

2.ii 1.iii 3.iii

3iii

et

ito

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Project/Site Manager to ensure this procedure is established and proper application of a permit to work system affecting COMPANY, or employees of sub contractors. Project Has an authorized person been appointed Manager for the implementation of this procedure? Have responsibility for the overall co-ordination and signature for the permit to work system. Authorized Have they co-ordinated the permit to work Person system relating to complexity and detail of the project? Have they satisfied themselves that the precautions required by the permit to work are in place before work commences?

m

Sub contractors to work in accordance with this procedure. Sub Worked in accordance with the permit and contractor associated document?

1.vi 1.vi

Total Awarded Total Achievable % Score

4

Page 22

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been

qa

Has a fire safety coordinator appointed for the project?

ta

EXAMPLE SHE-PRO-013- Fire Precautions During Construction Works in Buildings

Have fire wardens been appointed for the project? Have the appointed duty holders received suitable training? Does the site specific induction include details about fire risks on site and site specific emergency arrangements? Has a fire risk assessment been completed for the project and integrated into a site emergency plan? Have fire emergency drills been completed / planned? Have the requirements of the fire plan been fully implemented on site?

3.iv

3.iv

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ito

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Project Manager / Site Manager

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2.2.8

Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

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3.iv

3.iv 3.iv 3.iv

Total Awarded Total Achievable % Score

7

Page 23

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Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

SHE-PRO-014- Asbestos

qa

2.2.9

ta

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QCS 2014

1.ii

4.ii

5.i

6.i

5.xiii

m

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Project/Site Manager to ensure the procedure is established and that the identification and removal of asbestos containing materials (ACMs), is carried out in accordance with this procedure and relevant information is communicated to interested parties. Project Has a suitable asbestos survey relevant to Manager the works & project been completed and is the report available on site? Have the relevant control measures been implemented and being monitored from the asbestos removal plan/risk assessment? Has the asbestos removal plan/risk assessment/method statement been reviewed and accepted? Does the site specific induction include reference about the Asbestos Containing Materials (ACM’s) on site? Person’s undertaking the work activities are required to carry out the task in accordance with this procedure.

1.vi Competent Person/ Contractor

Has a suitable risk assessment been undertaken for any work which may expose persons to asbestos fibers? Have the findings of the risk assessment been incorporated into planned works? Has a competent supervisor been identified within the planned works? Although COMPANY appoints a specialist contractor for the removal of Asbestos, Project/Site Manager should ensure that they work in line with current legislation and do not put others at risk from their operations.

5.v 5.v 1.iv

5.vi

Page 24

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Is the asbestos removal contractor sufficiently dealing with waste produced during any works. Double bagged with separate disposal as special waste?

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Project Manager Competent Person Supervisor

Section 11: Health and Safety Part 2.2.01: Safety Health and Environment Procedural Audit Checklists

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QCS 2014

5.viii 5.ix

8

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Are viewing panels or CCTV viewing aids incorporate into the enclosure? Are air clearance certificates available for areas reoccupied further to asbestos removal? An effective Management System/ Asbestos Management Plan should be in place to protect staff, operatives and the public when working within a building which contains asbestos Project Are ACM’s clearly labeled with suitable Manager/ warning signs? Site Manager

5.vii

Total Awarded Total Achievable % Score

11

END OF DOCUMENT

Page 25

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ........................... 1

2.3.1

Risk Identification and Management ............................................................... 6

2.3.1.1 Responsibilities ............................................................................................... 6

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2.3.1.2 Definitions ....................................................................................................... 7

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2.3.1.3 Action Required To Implement This Procedure ............................................ 10

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2.3.1.4 Guidance To This Procedure ........................................................................ 12

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2.3.1.5 Appendices ................................................................................................... 14

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2.3.1.6 Reference Documents .................................................................................. 14 2.3.1.7 Author ........................................................................................................... 15

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2.3.1.8 Approvals ...................................................................................................... 15

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 2

PROCESS MAP – COMPANY DIRECT WORK Project/Site Manager

Estimator

Competent Person

Operative

SHE Team

HR

Review tender information for SHE Risk 3.1

3.1

3.2

3.2

Stop work and inform competent person if works significantly change from the agreed RA/MS with agreed RA/MS

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Circulate RA/MS for review 3.

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Review completed RAMS prior to issue

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Where identified prepare MS

Provide advice and monitor works against RA/MS

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Appoint a project competent person to produce Company Risk Assessment and Method Statement 3.2

Undertake activity in line with agreed RA/MS

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Allow for measures to control the Identified risk

Prepare RA in line with RA Schedule

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Review Risk Register and produce a SHE Risk Assessment Schedule 3.2

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Include SHE risk on project Risk Register

Issue Agreed RAMS to relevant supervisor/operat ive

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3.2

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3.2

Brief supervisor/operat ive on content of RA/MS

3.2

3.2

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Monitor works against agreed RA/MS

Maintain up to date Risk Assessment/Method Statement records

Monitor works against issued RA/MS 3.2

3.2 Review and revise RA/MS if circumstances change

Provide advice where works involve young person or expectant mothers 3.2

3.2

Key

Activity Guidance

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

PROCESS MAP – SUBCONTRACT WORKS Estimator

Contractors Responsible Person

Project/Site Manager

Contractors Operatives

Review tender information for SHE Risk

Provide advice and monitor works against RA/MS

3.1 Review Risk Register and update with changes identified by Contractors 3.3

Prepare RA for all activities in the scope of Works 3.3

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Include SHE risk on project Risk Register

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When satisfied the RA/MS is sufficient, return to the S/C for issue 3.3

Brief the Operatives of the content and controls in the agreed RA/MS

Undertake the activity in line with the RA/MS

3.3

Monitor works against agreed RA/MS

Monitor the works against agreed RA/MS

3.5

3.5

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3.3 3.3

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Where identified prepare a Method Statement

Review the RA/MS using Check Sheet System

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3.1

Allow for measured to control the Identified risk 3.1

SHE Team

Stop work and inform the relevant person if works significantly change from the agreed RA/MS 3.3

Maintain up to date Risk Assessment/Method Statement records 3.5

Key

Activity Guidance

Review and revise RA/MS if circumstances change 3.3

Page 3

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

PROCESS MAP – FACILITIES SERVICES AND CUSTOMER ACTIVITIES Area Manager/Customer Care Manager

COMPANY Operative/Tradesman

Line Manager/Customer Care Manager

Produce a Schedule of regular activities undertaken in Property Services and Customer Care operations 3.1

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Complete a full Method Statement where the Risk cannot be controlled by a TRICS form

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Undertake a general Risk Assessment to determine whether the activities require a Method Statement

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Complete task Risk Identification and Control Statement (TRICS) for the activity

Carry out the works in accordance with the completed form

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3.2

Complete task Risk Identification and Control Statement (TRICS) for the activity 3.2

Produce a Schedule of regular activities undertaken in property Services and Customer Care operations 3.

Key

Activity Guidance

Page 4

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 5

PURPOSE 1

The purpose of this procedure is to assign responsibilities and provide a consistent approach to the planning, development and production of suitable and sufficient Risk Assessments and the control of Method Statements for all activities.

SCOPE

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This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site

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QCS 2014

2.3.1

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 6

Risk Identification and Management

2.3.1.1 Responsibilities SHE DIRECTOR 1

Authorises and reviews this procedure.

PROJECT/SITE MANAGER Ensures the procedure is established and used and that Risk Assessments are carried out and, where appropriate, Method Statements are produced.

3

Unless delegated to others, in writing, retain responsibility for monitoring of the works against the relevant control documents.

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2

Prepare Risk Assessments taking account of the task being undertaken and the specific layout and restrictions of the place the work is to be carried out and where identified produce a written Method Statement incorporating a safe system of work.

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COMPETENT PERSON

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Either supervises the work activities or the sub/work package contractor undertaking those work activities in line with relevant control documents required by this procedure. Provide support to the review process for the Risk Assessment and Method Statement, to ensure acceptability SHE-FRM-1-03.

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SUPERVISORS

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SHE MANAGER/ADVISER 6

Provides advice and support in the application of this procedure and monitors effectiveness of the relevant control documents.

7

If the nature of the work is deemed ‘safety critical’, the SHE Manager/Adviser may provide appropriate support for the production of the control documents and the communication to all relevant Operatives.

OPERATIVE/CONTRACTOR EMPLOYEE 8

Carry out the work in accordance with the relevant control documents.

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 7

SUB/WORK PACKAGE CONTRACTOR 9

Prepare Risk Assessments taking account of the work being undertaken and the specific layout and restrictions of the place the works is to be carried out.

HUMAN RESOURCES 10

Provide assistance in cases of new or expectant mothers, young persons or children.

2.3.1.2 Definitions

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Written documents used to manage the risk associated with the work activity including: Risk Assessment

(b)

Method Statement

(c)

Permits

(d)

Plan of Work

(e)

Certification

(f)

Licence

(g)

Skill Card

(h)

or any other supporting documentation

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CONTROL DOCUMENTS

RISK ASSESSMENT The process of hazard, aspect, impact, identification, assessment of the risk, and identification of the controls required to manage the risk to an acceptable level to ensure the health and safety of those affected by the activity and the protection of the environment from harm. In undertaking the Risk Assessment the Qatar Regulatory Document (Construction) principles of prevention must be considered, which are:

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(a)

Eliminate

(b)

Control - In controlling the hazard the following should be considered in order: (i)

Substitution – use a less risky method/material

(ii)

Guarding – place guards, barriers and /or signage to isolate or warn of the hazard

(iii)

PPE – provide personal protection to individuals

(iv)

Decontamination – clear/clean up after exposure

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 8

RISK ASSESSMENT GUIDES 3

Refer to SAMAS 2.4.

METHOD STATEMENT A hazard control measure in the form of a written safe system of work describing the proposed working method and addressing the output from the Risk Assessment process, providing instruction and guidance for those individuals’ carrying out the activities. The purpose of this document is to ensure the proper planning of an element of the works and to detail the overall methodology and associated controls SHE-FRM-1-03. The document must be issued/briefed to management/supervision.

5

For work carried out by COMPANY Facility Services or Customer Care activities, the Method Statement may be substituted with Task Risk Identification and Control Statement (TRICS) SHE-FRM-1-05.

6

Sub/Work Package Contractors are to be encouraged to follow the COMPANY structure as mentioned above. Suggestion to adopt COMPANY safe system will require an element of instruction/training. For guidance contact the SHE Team.

7

Alternatively Risk Assessment and Method Statements prepared by Sub/Work Package Contractors may be prepared as a single document, providing the content is equivalent to that of the RA/MS above.

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This document is specific to Property Services Work and Customer Care activities and eliminates the need to produce a detailed Method Statement in the format described above. It must only be used when the Supervisor has carried out a Risk Assessment which concludes that a Method statement is not required. The Job/Task RA/MS is completed by the operative / supervisor using form SHE-FRM-1-02.

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TASK RISK IDENTIFICATION AND CONTROL STATEMENT (TRICS)

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COMPETENT PERSON 9

Is a person who has sufficient training, experience and knowledge to enable them to properly undertake the task in question or carry out the Risk Assessment.

TECHNICAL ADVISER 10

Dependant on the type of work the Method Statement is being prepared for, the Technical Adviser can be any combination of individuals (i.e. Designer, Materials Engineer, Temporary Works Co-ordinator, etc.)

11

The Technical Adviser provides, where required, support to the review process to ensure suitability of the content of the Risk Assessment/Method Statement. SHE-FRM-1-03.

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

YOUNG PERSON 12

Any person between the age of 16-18 years old.

CHILD

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Any person under 16 years old.

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QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 10

2.3.1.3 Action Required To Implement This Procedure GENERAL At Tender stage the Estimator will review the Pre-Tender Safety Information provided and instigate the production of a Project Specific Risk Register, which will identify Risk including safety risks associated with the proposed works.

2

Details of the risks identified and any measures included on the risk register will be included in the enquiry documents produced for contractor’s works.

3

Allowances should be made in the settled tender for arrangements to control these risks during the Construction Phase of the project.

4

At the start of the Construction Phase, the Project/Site Manager will review the risk register and project program and produce a schedule of activities which will be used as a basis for ensuring that all elements of the construction process are identified and considered for Risk Assessment.

5

Using the schedule the Project/Site Manager will ensure a suitable Risk Assessment is produced which will identify whether a Method Statement is required as part of the control measures.

6

For Facility Service or Customer Care works the Area Manager or Customer Care Manager will produce a schedule of activities undertaken on a regular basis by operatives working on this type of work. A Risk Assessment will be undertaken and where it is identified that the hazards can be controlled without the need of a full Method Statement he will indicate that the operation be subject to a Risk Identification and Control Statement (TRICS) and the procedure in 3.4 will be followed.

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ACTIVITIES UNDERTAKEN BY COMPANY Before carrying out any activity undertaken by direct COMPANY employees, the Project/Area/Site Manager for the workplace/operation/ design concerned shall first produce/review the Risks Assessment Schedule with the intention of identifying where hazard and risk could arise. This should include discussion with the people undertaking the work, if appropriate. It should be remembered that a risk could be seen as minimal but by further work processes could become significant. Such as painting outside to painting in a confined space.

8

Following this review a specific Risk Assessment using SHE-FRM-1-02 shall be undertaken by a Competent Person appointed by the Project/Area/Site Manager.

9

Where young persons or expectant mothers are involved in the activity, additional concerns may be required. Advice should be sought from the HR Team.

10

Where identified in the Risk Assessment the Competent Person in conjunction with any other relevant person will:

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(a)

prepare a Method Statement taking account of the following:

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 11

(i)

The controls identified in the Risk Assessment.

(ii)

All relevant Safety, Health, Environmental (SHE) matters.

(iii)

The headings, as a minimum, indicated in SHE-FRM-1-03 & 1-04.

(iv)

Circulate the Method Statement utilising the tracking and content sheet SHEFRM-1-04.

Take account of comments received from other parties and re-circulate Risk Assessment and Method Statement to those people to ensure issues raised have been dealt with adequately.

(c)

Following agreement of the suitability of the Risk Assessment and Method Statement by the Project/Site Manager, ensure it is issued to relevant management/supervision.

(d)

Monitor performance against the Risk Assessment and Method Statement and identify and make any necessary changes The Risk Assessments produced shall be used, where appropriate, as the basis for COMPANY personnel checking the contents of sub or work package contractors’ safety method statements.

(e)

The Risk Assessment and Method Statement shall be briefed to ensure that the detail is communicated to all relevant Operatives and carry out a reality check to confirm understanding of key aspects.

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(b)

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ACTIVITIES UNDERTAKEN BY CONTRACTORS The Project/Site Manager must ensure contractors have been procured via COMPANY Contractor Assessment procedure.

12

Before carrying out any activity undertaken by sub-contract employees the Contractors Responsible Person shall first undertake a risk assessment taking into account the hazards associated with the work this should include, if appropriate, discussion with the people undertaking the work, and COMPANY Management.

13

The Risk Assessments produced shall be used, where appropriate, as the basis for COMPANY personnel checking the contents of sub or work package contractors’ safety method statements.

14

Where identified in the Risk Assessment the Contractors Responsible Person will prepare a Method Statement taking account of the following:

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(a)

The controls identified in the Risk Assessment.

(b)

All relevant Safety, Health, Environmental (SHE) matters.

(c)

The headings, as a minimum, indicated in SHE-FRM-1-03 & 1-04 (Note: the use of the COMPANY format Risk Assessment and Method Statement templates may be suggested to the Sub-Work Package Contractor for work carried out on projects and locations under COMPANY control).

15

The Project/Site Manager will review the Risk Assessment and Method Statement produced using the tracking and content sheet SHE-FRM-1-04. Circulating to relevant parties as required. Following the review he will take account of comments received from

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 12

other parties and re-circulate Risk Assessment and Method Statement to those people to ensure issues raised have been dealt with adequately. Following agreement of the suitability of the Risk Assessment and Method Statement, the Project/Site Manager will issue it to relevant COMPANY Management/Supervisor who will then ensure that the contractor’s supervisor gives a briefing of the Risk Assessment and Method Statement so that the detail is communicated to all relevant operatives.

17

The Project/Site Manager or Supervisor will monitor performance against the Risk Assessment and Method Statement and identify and communicate any suggested changes. In cases where any significant changes to the system of work are necessary, activities must be stopped so that the changes to be made are re-assessed and approved. Where appropriate, following any revision, the checking process should be repeated.

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TASK RISK IDENTIFICATION AND CONTROL STATEMENT (TRICS)

The TRICS SHE-FRM-1-05 should be completed prior to commencement of works by the Appropriate Line Manager. Where this is not possible or practicable, the individual tradesman undertaking the task should complete the task assessment. The TRICS format is only to be used after an assessment has been made by the relevant Manager and the need to produce a Method Statement for the works has been eliminated.

19

Should the initial TRICS being completed by the tradesman reveal that other assessments (e.g. Manual Handling/Noise) are required the risk assessment guides should be used to develop a safe system of work. Should the safety requirements of the job still not be met then the individual Line Manager shall be contacted immediately.

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RECORDS AND MONITORING OF THE RISK ASSESSMENT The Project/Site Manager should maintain up to date current Risk Assessment records so that any significant change to a activity requiring the Risk Assessment to be re-evaluated can be controlled. The need for review will depend upon the level of risk and the significance of the change.

21

Where appropriate to the activity the SHE Advisor for the project will monitor performance and identify any necessary changes by inspection and/or audit.

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2.3.1.4 Guidance To This Procedure RISK ASSESSMENTS 1

All Contractors and self-employed persons are required to make suitable and sufficient Risk Assessment of work activities to be undertaken. A record of the significant findings of Risk Assessments must be kept. This record shall state the hazards and risks and the controls needed to reduce the risks to an acceptable level. The controls shall then be implemented by management to protect health and safety and the environment.

2

Where Risk Assessments are required to be carried out under particular sections of the Qatar Regulatory Document (Construction), COSHH, Noise, Asbestos and Lead etc. a repeat assessment is not required unless other elements of the work demand assessment in

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 13

their own right (e.g. painting at height may require a COSHH Assessment for the paint as well as an assessment of the risk of working at height or damage to a watercourse due to spillage). 3

Where an assessment identifies the likelihood of an adverse health condition or identifiable disease being contracted, then health surveillance may be required. In all such cases the advice of the SHE Team shall be sought.

4

On completion of a Risk Assessment the record shall then be used to supply the following information to the relevant persons at risk: Hazard/risk/impacts

(b)

Preventative and protective measures

(c)

Emergency procedures

(d)

Name of emergency wardens or incident controllers

(e)

Instruction and training to carry out the work safely

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(a)

All activities undertaken under the Risk Assessment (and controls therein) shall be monitored to ensure that the assessment is both suitable and sufficient and is being worked to.

6

Any changes in work must be notified to the competent person who has developed the Risk Assessment and must result in a review of the assessment and if necessary a revised assessment produced.

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Refer to SAMAS 2.4

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METHOD STATEMENTS

8

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USE OF RISK ASSESSMENT GUIDES Refer to SAMAS 2.4

QCS 2014

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

2.3.1.5 Appendices

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FORMS

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2.3.1.6 Reference Documents

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Appendix 1 – Risk Assessment Process

S,H&E Risk Assessment Form (SHE-FRM-1-01)

2

Job/Task Risk Assessment/Method Statement (SHE-FRM-1-02)

3

Tracking and Content Sheet (SHE-FRM-1-04)

4

Task Risk Identification and Control Statement (TRICS) (SHE-FRM-1-05)

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REFERENCE DOCUMENTS 5

Qatar Regulatory Document (Construction) RD1.1.7

6

Risk Assessment Methodology SAMAS 2.4

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Page 15

2.3.1.7 Author

SECTION

POSITION IN COMPANY

NAME

CONTACT DETAILS

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SHE Manager

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2.3.1.8 Approvals

POSITION IN COMPANY

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NAME

Approved by:

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SHEQ Director

SIGNATURE & DATE

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PUBLIC/VISITORS :

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OTHER WORKERS :

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PERSONS EXPOSED

EMPLOYEES :

Almost no probability A small probability A high probability Almost Certain

Disabled :

YOUNG PERSONS :

Acceptable Risk Level

Action

Insignificant

No action required and no documentary records need to be kept

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Estimated Total No. of Persons at Risk :

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HAZARDS (WHAT MIGHT CAUSE HARM?)

Acceptable

S

H

Unacceptable

Others :

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New or Expectant Mothers :

Date :

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Person Supervising Work :

Date :

Fatality, building loss, catastrophic environment impact

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Person Conducting Assessment :

Risk Quantifying

Major injury, damage or environment impact

Location :

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Activity :

No injury, damage or environment impact

Risk Assessment No :

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Site & Contract No :

Minor injury, damage or environment impact

RISK FACTOR

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SHE-FRM-1-01 - SAFETY, HEALTH & ENVIRONMENTAL RISK ASSESSMENT

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S

H

Unacceptable

E

No further preventative action. Consideration shall be given to more costeffective solutions or improvements that impose no additional cost burden. Monitoring required to ensure that controls in place are properly maintained. Work shall not be started or continued until the risk level has been reduced to an acceptable risk level. While the control measures selected shall be cost-effective, legally there is an absolute duty to reduce the risk, this means that if it is not possible to reduce the risk even with unlimited resources, then the work shall not be started or shall remain prohibited.

NOTES

1

Adverse Weather Conditions

17

Loading/Unloading

2

Cold\Hot

18

Materials

3

Electricity

19

Moving Parts of Machinery

4

Excavation

20

New or Expectant Mothers

5

Fire/Flammable Atmosphere

21

Proximity to Water

6

Floor/Ground Conditions

22

Scaffold

7

Flying Particle/Dust

23

Sharp Objects

8

Hand or Power Tool

24

Stairs/Steps

9

Hazardous Substance

25

Static Equipment/Machinery

10

Heat/Hot Work

26

Structure

11

Lack of Experience

27

Temporary Works

12

Lack of Training

28

Vehicle/Mobile Equipment

13

Lack of/too much Oxygen

29

Working Hours/Fatigue

14

Ladder

30

Workstation Design

15

Lifting Equipment Appliances

31

Young Persons

16

Lighting

32

Other

1.

Physical Hazards are the nature of issues that may cause harm. Tick box for hazard.

2.

Preventative / Control Measures are the actions that will stop it going wrong.

3.

Control measures are to ensure that residual risks are reduced to a minimum. Where controls fail to reduce the risk to a acceptable level then refer assessment to your line manager.

4.

If the operations are likely to affect the public or the safe operation of a public infrastructure or transport system, the control measures must reduce the likelihood of significant harm to the level that existed before our work commenced.

5.

Where young persons or expectant mothers are involved in the activity, ensure that any additional controls are put in place in accordance with local procedures.

6.

In addition to the above, consideration must be given to other individuals’ susceptibility due to pre-existing health conditions, e.g. bad back, poor hearing. Additional ‘human factors’ such as ergonomics, workplace design, etc. should also be considered.

7.

Where a hazard is identified that is not listed in the Physical Hazards list, enter the hazard description followed by Other in brackets i.e. (Other).

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Risk Before Controls U/A

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Nature of Risk What Might Go Wrong?

Control Measures Implemented By (Name)

Perceptive /Control Measures How do you Stop it Going Wrong?

Risk After Controls U/A

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HAZARD No.

Name Person Completing the Assessment Person Reviewing the Assessment

Signature

Date

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Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

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(SHE-FRM-1-02) Job/Task Risk Assessment/Method Statement Section 1 - Job / Task Allocation To be completed by person taking works order/organising task: o

Job / Contract N .: Client:

Contact Name:

Date:

Job / Task Location:

Description of work:

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Proposed work method:

(additional sheets if required)

Signature:

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Completed By (Name):

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Section 2 - Risk Assessment

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To be completed by operative / person undertaking the work/task

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Upon arrival at the work location complete this Risk Assessment before starting work. If the responses mean you cannot complete the job/task safely, discuss your concerns with your Manager. *Delete as required

Yes / No

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Is the proposed work method (above) acceptable? (If No following this risk assessment a method statement must be produced) Are there any client controls e.g. Permits / clearances certificates etc?

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Are barriers and signs needed to separate the work area? Do you know the location emergency procedures / fire exits / muster points / First Aid etc? Do power supplies / fire detection systems need isolating

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Yes No Yes No Yes No Yes No

HEALTH HAZARDS

What personal protective equipment is needed (tick relevant boxes)? Safety Footwear Safety Helmet Hi-Visibility Vests Gloves Eye Protection Hearing Protection Dust Masks Other(state): ……………………………………………. List any items of plant / tools required: (Include drills, saws, compactors, breakers etc…) Are you competent and have you received the training to use them? Yes / No Are all the plant / tools suitable for use, tested and inspected? Yes / No Confirm plant / tools will be visibly inspected by the user prior to use? Yes / No Check labels on materials and substances. If hazardous, has a COSHH Yes / No / NA Assessment been carried out?

EXCAVATION

Have all underground services been located and clearly marked? Are shoring materials on site before starting work?

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PLANT & EQUIPMENT

Yes / No / NA Yes / No / NA

Which is the most appropriate for access (circle as appropriate) Ladder WORK AT HEIGHT

Access Tower

MEWP

Scaffolding If Mobile Elevated Work Platform are you trained and competent to operate? If scaffold / access tower has this been erected by competent person? Will this be inspected by the user prior to use?

Yes / No / NA Yes / No / NA Yes / No / NA

QCS 2014

MANUAL HANDLING SITE TIDINESS ENVIRONMEN T

Completed by (Name):

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

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Can heavy/awkward items be moved and stacked securely? Is lifting apparatus required? Is a separate Manual Handling assessment required? Are materials in safe area and stacked securely? Are all materials segregated from building users and members of the public? Are there facilities for the disposal of spent materials or packaging? Do any consents to discharge trade effluent apply or are any required? Are there any risks to trees or other ecology – contact SHE adviser for advise where required Has consideration been given to prevention of nuisance from dust/noise to neighbours

Yes / No / NA Yes / No Yes / No Yes / No Yes / No

Signature:

Date:

Yes / No / NA Yes / No / NA Yes / No / NA Yes / No / NA

Section 3 – Task Statement

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To be completed by operative / person undertaking the work/task if the ‘proposed work method’ does not accurately describe the method of work required, complete the following to explain the safe method of working that will be adopted:

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(Explain how the work is going to be done, include things such as plant, materials, access to the work area, manual handling, sequence of work, any limitations, protection to building users, members of public etc.)

Insert names of all members of the work gang and confirm the work method has been explained. Name and position:

Signature

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Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 21

Risk Assessment/ Method Statement – Tracking and Content Sheet (SHE-FRM-1-04) Project :

Contractor :

METHOD STATEMENT TITLE :

DATE :

Review Project/Site Manager SHE Function

1st review date

Status*

Name (print)

2nd review date

Status*

Name (print)

1st review date

Status*

Name (print)

2nd review date

Status*

Name (print)

1st review date

Status*

Name (print)

2ndreview date

Status*

Name (print)

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As Required Status

Signature and date:

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Name:

Prompt List

A – Work can proceed as described B – Work can proceed when comments are incorporated C – Re-submit and review before work can proceed

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NB: Use the ‘Prompt List’ below to give a status code, as follows: *Status

Signed off by COMPANY as current working document

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Technical Advisor

Fully describes the works/individual tasks/the sequence, method and process in place to identify change requirements?

2

Names and titles of key personnel/supervisors responsible?

3

Details resources required eg equipment, plant, men and materials?

4

Programme of works and working hours identified?

5

Interfaces/security of the client/public/other contractors identified?

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Are all the hazards identified? Have all the risks been evaluated? (See item 7) Are there arrangements in place for reviewing control measures due to changing circumstances?

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Specific Risk Assessment / attached and satisfactory? 6

.

As Required

7

High risk or safety critical activities identified/controls specified?

8

Access/scaffolding requirements (including ancillary arrangements such as anchor points) fully detailed and described?

9

Certificates of competence or qualification of operatives provided?

10

Certificates for plant/equipment inspection/examination provided?

11

COSHH, noise, manual-handling issues dealt with?

12

Personal protective equipment specified?

13

Permit requirements identified?

14

Monitoring (checks and inspections) identified?

15

Any builder’s work in connection identified/adequate notice given?

16

Temporary protection/support identified (eg fire, traffic, services)?

Yes

No

In Part

N/A

Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

17

Environmental controls/waste disposal identified?

18

Cranage/lifting equipment - certificates/checklist/lifting plan in place?

19

Emergency arrangements/first aid/special welfare/?

Prompt List

Yes

Details of toolbox talks to be provided?

21

Details of temporary works schemes identified, including drawings, calculations and checks?

22

Workplace environment, design, layout and specific limitations identified, have human factors been taken into consideration, ie experience, fatigue, communication, methods, etc?

23

Conformation of briefing of method statement to operatives.

24

Any other (specify)?

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Comment/Observation (if appropriate)

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No

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Page 22

In Part

N/A

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Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 23

(SHE-FRM-1-05) Task Risk Identification and Control Statement (TRICS) Section 1 - Task Allocation To be completed by person organising task: o

Job / Contract N .:

Date:

Client:

Contact Name:

Location:

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Description of work:

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Are there any client controls e.g. Permits / clearances certificates etc required? Is there a requirement to isolate fixed plant or equipment? Will there be a requirement for Lone Working? Will there be a need to enter a confined space? Are there materials / substances used by the client which could be hazardous to the person carrying out the work Do any consents to discharge trade effluent apply or are any required?

/ / / /

No No No No

Yes / No Yes / No

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LOCATION INFORMATION

Yes Yes Yes Yes

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If the answer to any of the above is YES, consideration should be given to producing a detailed Method Statement

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The need for a Method Statement has been considered and the issue of this TRICS is acceptable for this work

Signature:

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Completed By (Name):

Yes / No

Contact Details

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Review Date

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Section 2 - Risk Assessment To be completed by the person undertaking the work/task

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Upon arrival at the work location complete this Risk Assessment before starting work. If the responses mean you cannot complete the job/task safely, discuss your concerns with the person signing above. Completed By (Name):

Signature:

Contact Details

EMERGENCY & SECURITY

SAFETY EQUIPMENT

Are barriers and signs needed to separate the work area? Do you know the location emergency procedures / fire exits / muster points / First Aid etc? Do power supplies / fire detection systems need isolating The following PPE is mandatory for COMPANY Employees. Safety Footwear Safety Helmet Gloves Eye Protection Indicate if it is available for use

Yes / No Yes / No Yes / No

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Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 24

What additional personal protective equipment is needed (tick relevant boxes)? Dust Masks Hi-Visibility Vests Hearing Protection Other (state): …………………………………………….

Check labels on materials and substances. If hazardous, has a COSHH Assessment been carried out? If yes attached to this TRICS

HEALTH HAZARDS

Yes / No / NA

List any items of plant / tools required: (Include drills, saws, compactors, breakers etc…)

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PLANT & EQUIPMENT

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Have all underground services been located and clearly marked? Is there a drawing available for the support work? Are sufficient shoring materials, as identified on the drawing, on site before starting work?

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EXCAVATIO N

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Are you experienced in their use or received the training to use them? Are all the plant / tools suitable for use, tested and inspected? Plant / tools have been visibly inspected by the user prior to use and no defects apparent

Yes / No Yes / No Yes / No

Yes / No / NA Yes / No / NA Yes / No / NA

Which is the most appropriate means of access (circle as appropriate) MEWP

Scaffolding

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Access Tower

If Mobile Elevated Work Platform are you trained and competent to operate? If scaffold / access tower has this been erected by competent person? Confirm this has been inspected by the user prior to use?

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WORK AT HEIGHT

If non of the above is practical is a ladder the proposed means of access

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Specify the type of ladder Indicate the height / no of rungs needed to provide safe access

SITE TIDINESS WORK AREA

ENVIRONME NT

Yes / No / NA Type………… … Rungs……

Are there any heavy or awkward items be moved or stacked? If lifting equipment is required is it available? Is a separate Manual Handling assessment required?

Yes / No / NA Yes / No Yes / No

Is there space in the work area to stack / store materials safely and allow access? Are all materials segregated from building users and members of the public? Are there any object / vehicles materials belonging to the client which may be a hazard? Is the area suitably lit to carry out the task safely? Are the ground / floor conditions suitable for the work to be carried out?

Yes Yes Yes Yes Yes

Are there facilities for the disposal of spent materials or packaging? Are there any risks to trees or other ecology – contact SHE adviser for advise where required Has consideration been given to prevention of nuisance from dust/noise to neighbours

Yes / No / NA

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MANUAL HANDLING

Yes / No / NA Yes / No / NA Yes / No / NA

/ / / / /

No No No No No

Yes / No / NA Yes / No / NA

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Section 11: Health and Safety Part 2.3.01: Safety Health and Environment Procedures

Page 25

Section 3 – Task Statement To be completed by the person undertaking the task. Accurately describe the safe method of working that will be adopted:

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(Explain how the work is going to be done, include things such as plant, materials, access to the work area, manual handling, sequence of work, any limitations, protection to building users, members of public etc.)

Signature:

Date:

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Completed by (Name):

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I confirm that the above statement identifies the hazards and risks associated with the works to be carried out and the control measures identified are in place.

Insert names of all members of the work gang and confirm the work method has been explained. Name and position:

Signature

QCS 2014

2

Section 11: Health and Safety Page 1 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

SAFETY AND ACCIDENT PREVENTION ADMINISTRATION SYSTEM (SAMAS)

MANAGEMENT

/ 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES

1

2.3.2

COSHH (CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH)

1

2.3.2.1 Responsibilities .................................................................................................. 4

.

2.3.2.2 Definitions of terms ............................................................................................ 5

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2.3.2.3 Appointment of COSHH Co-ordinator ................................................................ 5 2.3.2.4 Appendices .......................................................................................................11 2.3.2.5 Reference Documents ......................................................................................13

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2.3.2.6 Author ...............................................................................................................13

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2.3.2.7 Approvals ..........................................................................................................13

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Section 11: Health and Safety Page 2 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

Process Map COSHH Co-ordinator

Project Manager

Ensure procedures are in place and COSHH Co-ordinator is appointed 1.2, 3.1

Procurement

C/S Manager/ Works Package Manager

1.7, 3.8 Control exposure to hazardous substances used or created by 1.4, 3.11 Company

Request MSDS for all substances ordered by Company 1.5, 3.12

.

Ensure all appropriate information is obtained/passed over at initial SHE meetings with sub contractors

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Attend initial SHE meeting. Identify hazardous substances to be used 1.6, 3.2

3.6

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Ensure hazardous substances used or created by sub contractor has valid assessments and 3.2, 3.5 MSDS

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Agrees and monitors against method statements

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Request MSDS for all substances ordered by Company 1.5, 3.12

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When required ensure face fit tests have been carried out and records maintained 3.6

Ensure arrangements are in place for disposal of hazardous substances and containers 3.7

Key: Activity Guidance

Ensure monitoring and health surveillance is carried out where identified in COSHH assessments 3.8, 3.9

Undertake COSHH assessments for all hazardous substances and submit for approval 3.2

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1.4, 3.2

Maintain Register and file containing assessments and MSDS and advise First Aiders of location

SHE Provides support as necessary

Understand duties. Attend training if necessary 1.3, 3.5

Undertake COSHH assessments for all hazardous substances used and/or created by Company 3.3

Review arrangements at regular intervals to ensure continued effectiveness 3.2, 3.5

Sub Contractors

Control exposure in line with COSHH assessments 1.6, 3.4

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Section 11: Health and Safety Page 3 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish a system for the control of substances hazardous to health.

SCOPE This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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Governmental responsibilities regarding COSHH rest with Civil Defense & Environment Ministry.

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COMPETENT AUTHORITIES

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Section 11: Health and Safety Page 4 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

2.3.2.1 Responsibilities SHE DIRECTOR 1

Authorises this procedure. PROJECT/MANAGER

2

Ensures the procedure is established and reviewed for effectiveness. Appoints a COSHH Co-ordinator for the project.

3

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COSHH CO-ORDINATOR Carries out duties as defined in the procedure.

CONSTRUCTION/SITE MANAGER OR WORKS PACKAGE MANAGER

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Is aware of COSHH assessment controls along with other risk assessments and method statement. Monitors work to ensure it is done in line with method statement.

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Requests Material Safety Data Sheet (MSDS) for all substances ordered by COMPANY

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PROCUREMENT

Provide COSHH assessments and MSDS for all substances. Control exposure in line with COSHH assessment and method statement.

Make themselves aware of location of COSHH assessments and MSDS in case needed in an emergency.

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FIRST AIDERS

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SUB-CONTRACTORS

SHE MANAGER/ADVISER 8

Provides advice and support in the application of this procedure and monitors effectiveness of control measures.

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Section 11: Health and Safety Page 5 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

2.3.2.2 Definitions of terms HAZARDOUS SUBSTANCE ‘Substance’ means a natural or artificial substance whether in solid or liquid form or in the form of a gas or vapour (including micro-organisms).

2

A ’substance hazardous to health’ is one which, because of the way it is made, stored, transported, used or disposed of, presents a risk to health in the workplace. The definition of a hazardous substance is comprehensive. All supplied substances which are classified as hazardous must by be labelled correctly. Substances will be labelled as Very Toxic, Toxic, Harmful, Corrosive or Irritant. However, some hazardous substances can be created during processes, and these are also covered by the Qatar Regulatory Document (Construction), for example dusts of any kind in specified concentrations.

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QATAR WORKPLACE EXPOSURE LIMITS (WEL) (BASED ON UK HSE STANDARDS) This is the exposure limit approved by the UK Health and Safety Commission for a substance in relation to the specified reference period of either 15 minutes or 8 hours. A list of WEL’s is available in the HSE Publication “EH/40 Workplace Exposure Limits”, which is updated annually. The majority of WELs listed in EH40 are for single compounds or for substances containing a common element or radical, for example, 'isocyanates'. A few of the WELs relate to substances commonly encountered as complex mixtures or compounds, for example 'rubber fume'. If the Safety Data Sheet lists a substance with a WEL, the employer should ensure that the WEL is not exceeded.

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Is a dust of any kind present in the air at concentrations equal to or greater than 10 mg/m 3 over an 8 hour period if inhalable (i.e. can be breathed in) or 4 mg/m over an 8 hour period if respirable (i.e. small enough to reach to the very base of the lungs).

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HAZARDOUS DUST

The Project Manager is responsible for appointing a COSHH Co-ordinator

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2.3.2.3 Appointment of COSHH Co-ordinator

ASSESSMENT OF RISK 2

Under COSHH the risk presented by any hazardous substance used, stored, transported, created or disposed of in the workplace must be assessed.

3

If a substance is supplied or created by COMPANY, the COSHH Co-ordinator is responsible for ensuring a COSHH assessment has been undertaken. The COSHH Co-ordinator should ensure that a register of all hazardous substances is maintained, and that each has a valid COSHH assessment, and where applicable a MSDS.

4

If the substance is supplied or created by a sub-contractor, it is their responsibility to provide the COSHH assessment along with all other risk assessments submitted for acceptance. These assessments are likely to accompany a method statement, and should be read as part of the method statement acceptance process as covered by procedure SHE-PRO-001. Construction/Site Managers and Works Package

5

Managers must ensure that assessments and method statements have been agreed and must monitor work to ensure it is undertaken in line with the method statement. The COSHH

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Section 11: Health and Safety Page 6 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

Co-ordinator should ensure that all hazardous substances present on a project have a valid COSHH assessment. For a supplied substance the COSHH assessment should be accompanied by the manufacturers/suppliers MSDS. 6

NB - a MSDS alone does not constitute a COSHH assessment.

7

In all cases risks to persons other than those using a substance must also be considered (e.g. those working in adjacent areas). The COSHH Co-ordinator should ensure this is done, and that suitable measures are taken. These measures may include provision of information and training to personnel other than those who will use the substance. COSHH ASSESSMENT PROCEDURE To enable COMPANY to comply with the requirements of COSHH, an assessment is required. This is in two parts:

9

Firstly, COMPANY must not carry out any work that is liable to expose employees to any substance hazardous to health, unless a suitable and sufficient assessment of the risks created by the work has been made.

10

Secondly, if the first step indicates that substances hazardous to health will be used or created, COMPANY must identify the actions to be taken to comply with COSHH.

11

The procedure itself is fairly simple but does take time and effort. It involves:

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identifying jobs, working processes and procedures that involve the use or generation of substances that are hazardous to health

(b)

identifying all the hazardous substances in use in the workplace, very toxic, toxic, harmful, corrosive or irritant

(c)

identifying how the hazardous substances are stored and used. This means how they are used, not how they should be used

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(a)

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Very toxic or toxic: Substances that, in low quantities, cause death or acute or chronic damage to health when inhaled, swallowed or absorbed via the skin.

13

Harmful: Substances that may cause death or acute or chronic damage to health when inhaled, swallowed or absorbed via the skin.

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Section 11: Health and Safety Page 7 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

Corrosive: Substances that may, on contact with living tissues, destroy them.

15

Irritant: Non-corrosive substances that through immediate, prolonged or repeated contact with the skin or mucous membrane may cause inflammation.

16

Identifying how these hazardous substances might enter the body. Normally these methods are classed as:

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inhalation into the lungs, when the substance is in the form of a gas, vapour, fume, mist, aerosol or dust

(b)

absorption through the skin or eyes by contact with a substance that can penetrate unbroken skin, or is absorbed through unprotected cuts or grazes

(c)

injection by contact with contaminated sharp objects or high-pressure equipment, e.g. water jetting

(d)

ingestion by swallowing particles of a hazardous substance resulting from handto-mouth transfer identifying the amount of exposure. This involves knowing how much of the substance will be used, how people will be exposed to it and if there are is a workplace exposure limit investigating the possible health effects of such exposure

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(a)

identifying who is at risk, for example the persons using it or anyone who enters the area within the following 24 hours

(ii)

considering the effectiveness of the control measures already in place, for example whether the concentration of vapour is likely to be above the WEL

(iii)

identifying the risk to workers if control measures deteriorate or fail or if an emergency occurs, for example if a volatile solvent is accidentally spilt resulting in a high concentration of hazardous vapour in the workplace

(iv)

finally, from the above considerations, making a decision upon whether a substance represents a health risk or not. If the answer is 'no', the findings should be recorded. If 'yes', action will be necessary to either prevent or control exposure.

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Completed assessments must be made available to the person who is going to carry out the work so that they are aware of the health hazards present and the control measures that they must use, record COSHH Assessments on SHE-FRM-2-01.

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Section 11: Health and Safety Page 8 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

CONTROL OF EXPOSURE TO HAZARDOUS SUBSTANCES The measures which need to be taken to comply with COSHH should be detailed on the COSHH assessment. The overriding duty is to prevent exposure to hazardous substances. This may be achieved by using a different process, design or technique which does not require or create the hazardous substance, or substituting the hazardous substance for a non-hazardous one. Where it is not possible or practicable to prevent exposure completely, exposure should be reduced by using an alternative less hazardous substance or version (e.g. more dilute concentration), using a different form (e.g. pellets instead of powders) or changing the process (e.g. to use less).

19

If it is not reasonably practicable to prevent exposure, then exposure must be controlled. This must be achieved as far as possible by controlling the substance at source by engineering controls. Other measures may also be needed such as provision of information and instruction, and hygiene facilities. Personal Protective Equipment (PPE) can only be used as a last resort where adequate control cannot be achieved by other means.

20

Where a substance has been assigned a WEL, this must not be exceeded.

21

Additional requirements may be necessary if substances have been identified as carcinogens, mutagens, asthmagens or are biological agents. These substances may be identified by the risk phrases R42, R42/43, R45, R46 or R49. Consult the SHE Advisor for further information if required.

22

Control measures should be monitored to ensure that they are effective. Where they prove ineffective the assessment should be reviewed, and measures modified so far as is reasonably practicable.

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DUTIES OF THE COSHH CO-ORDINATOR The COSHH Co-ordinator should ensure that first aiders know where to access information on hazardous substances used on the project. This could be achieved by maintaining a file of all MSDS and assessments which is easily accessible by first aiders.

24

COSHH Co-ordinators should liaise with Safety Co-ordinator / SHE Adviser / Managers / Environmental Adviser / First Aiders / Emergency Co-ordinators for further advice if necessary.

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RESPIRATORY PROTECTIVE EQUIPMENT (RPE) – FIT TESTING 25

COSHH requires fit testing of RPE. Where sub-contractors provide RPE for their workers they should also provide evidence that a suitable fit test has been carried out for each worker required to wear RPE. The COSHH Co-ordinator should ensure that fit tests have been carried and records are available.

26

Where COMPANY employees are required to wear RPE, COMPANY will be responsible for ensuring fit tests have been carried out. The SHE Department can undertake fit tests, or it is possible to have a member of the project staff trained to undertake the tests. Training can be provided by the SHE Department and takes half a day. Records of training should be kept on site as well as centrally.

27

Fit testing of individuals must be carried out using the appropriate RPE for the task identified in the risk assessment, and the results recorded on the Qualitative Fit Test Proforma – SHEFRM-2-02.

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Section 11: Health and Safety Page 9 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

28

Records of fit testing must be kept on the users personnel file for 5 years. If there are any changes in the wearer, such as significant weight change or dentistry that may affect the size or shape of the face, then a new fit test should be carried out.

29

Further information on RPE can be found in SHE-PRO-010 – Personal Protective Equipment (PPE). USE AND DISPOSAL OF HAZARDOUS SUBSTANCES Hazardous must only be used by persons who have received instruction and training, and must only be issued in quantities sufficient to complete the task. Hazardous substances are often harmful to the environment, and half empty containers can pose a risk to persons in the future. Therefore, all containers must be disposed of as hazardous waste, including empty containers.

.

30

The COSHH assessment will identify when exposure monitoring is required. Typically this will be required if any of the following apply: If it is possible that the failure of any control measures could result in a serious health effect;

(e)

If a substance has a WEL

(f)

If there is doubt whether exposure monitoring should be carried out, consult the SHE Dept who will advise on appropriate protocols and details of record keeping.

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Responsibility for health surveillance lies with COMPANY. Many of the tasks carried out in the construction environment will not require health surveillance to be carried out. However, if all three of the following conditions apply, then health surveillance is required: An identifiable disease or adverse health effect may be related to exposure.

(b)

There is a reasonable likelihood that the disease or effect may occur under particular conditions of work. There are valid techniques for detecting indications of the disease or the effect.

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HEALTH SURVEILLANCE

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EXPOSURE MONITORING

ARRANGEMENTS TO DEAL WITH ACCIDENTS, INCIDENTS AND EMERGENCIES 33

Arrangements to deal with emergency situations (e.g. spillages, accidental release or over exposure) should be detailed in the appropriate method statement. Emergency arrangements which cover the project as a whole should also be detailed in the construction phase plan. INITIAL SHE MEETING

34

At the initial SHE meeting (see procedure SHE-PRO-007) COMPANY will advise subcontractors of any substances used by others which could affect their employees. In addition sub-contractors will be required to advise COMPANY of all hazardous substances they will use.

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Section 11: Health and Safety Page 10 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

PROCUREMENT

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All orders and requisitions shall clearly identify the product being ordered and shall contain a requirement to comply with COSHH and to provide the MSDS. The COSHH Co-ordinator shall ensure MSDS from the supplier are delivered with the product.

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Section 11: Health and Safety Page 11 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

2.3.2.4 Appendices APPENDIX 1 – EXAMPLE OF COSHH RISK ASSESSMENT

Auto diesel

Substance hazard classification:

Flammable, harmful/irritant

Trade name(s):

Any auto fuel production company

Substance used for:

Motive power for plant and other diesel powered vehicles

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Name of hazardous substance:

Safety precautions

Inhalation: can lead to nausea and headaches.

Avoid inhaling vapour or mist; ensure good ventilation. Remove the victim from exposure.

Skin contact: can be irritating and have a defatting effect.

Avoid prolonged/repeated contact. Wear PVC gloves. Do not use as a cleaning agent.

Eye contact: will cause irritation.

Wear eye protection if splashing can Rinse immediately with plenty of occur. water until irritation subsides. Seek medical advice.

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Remove contaminated clothing. Wash skin thoroughly with soap and warm water.

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Remove to fresh air. Seek medical attention if conditions severe.

Do not eat, drink or smoke during use.

Do not induce vomiting. Wash mouth with water. Seek immediate medical attention.

Fire: products of combustion are toxic. Vapour/air mixture is explosive.

Do not smoke during use. Avoid heat sources and open flames.

Clear the area. Do not inhale vapours, smoke etc.

Spillage: fumes/vapour likely to collect in low areas.

Do not allow to enter drains. Eliminate ignition sources. Ensure good ventilation.

Contain with sand or granules. Remove into a container. Dispose of as hazardous waste.

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Ingestion: will irritate mouth, throat etc.

Emergency procedures

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Potential hazards

Additional information: Environmentally damaging. Assessment date Approved for use by (print name and position)

Next review date

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Section 11: Health and Safety Page 12 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

Signature

APPENDIX 2 - COSHH RELATED RECORD KEEPING REQUIREMENTS

Maintenance Records Examination and where appropriate test records. Maintenance records.

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PPE (various items) Respiratory Protective Equipment (RPE) e.g. cartridge type Local Exhaust Ventilation (LEV)

Archive Period None specified, recommended minimum 3 years Minimum 5 years Minimum 5 years

.

COSHH Related Record Keeping Requirements Summary Issue Document Personal Protective Equipment COMPANY Register entries

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Examination and test records Minimum 5 years (including repairs)1 Exposure Monitoring (Personal) Monitoring results or a suitable Minimum 40 years summary2 Exposure Monitoring (Not Monitoring results or a suitable Minimum 5 years Personal) summary Health Surveillance Health record containing particulars 40 years from date approved by the HSE. of last entry Disposable RPE Project specific records Minimum 5 years Breathing Apparatus Maintenance, examination and test Minimum 5 years records. Maintenance log. Fit Test Report RPE Qualitative Fit Test Records Minimum 5 years 1 All LEV systems must be examined/tested every 12 months. 2 All personal monitoring results must be treated as confidential information and consultation must be carried out through the SHE Department.

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Section 11: Health and Safety Page 13 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

2.3.2.5 Reference Documents FORMS 1

COSHH Assessment Form – (SHE-FRM-2-01)

2

COSHH RPE Qualitative Fit Test Report (SHE-FRM-2-02)

3

COSHH Training Record (SHE-FRM-2-03)



Qatar Regulatory Document (Construction) RD1.2.3

5

UK Workplace Exposure Limits (EH40)

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REFERENCE DOCUMENTS

2.3.2.6 Author

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POSITION IN COMPANY

NAME

CONTACT DETAILS

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SECTION

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SHE Manager

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2.3.2.7 Approvals

Approved by:

NAME

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

QCS 2014

Section 11: Health and Safety Page 14 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

COSHH ASSESSMENT

Name of hazardous substance: Substance hazard classification: Trade name(s):

Safety precautions

Emergency procedures

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Potential hazards

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Substance used for:

Additional information: Assessment date NEXT REVIEW DATE Approved for use by (print name and position) Signature

QCS 2014

Section 11: Health and Safety Page 15 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

Name:

Worker No:

Report Number:

Employer: Date of Test:

Name of tester:

RPE Model Number: Size of RPE Tested: Sensitivity Test Complete? Y/N

Solution Dose? 10 - 20 - 30 (circle)

Please circle test solution used. Bitter

.

Sweet

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User Seal Test carried out successfully? Y/N Exercise (Duration is 1 minute for each). Normal Breathing.

2

Deep breathing through mouth

3 4

Turn Head side to side – breathe in as head looks at shoulder. Look up and down – breathe in looking at ceiling.

5

Talking for 1 minute.

6

Jog on the spot OR bend down and then up.

7

Breathe normally.

Note - 1

The performance of RPE with a tight fitting facepiece (filtering facepieces, half and full face masks) depends on good contact between the wearer’s skin and the face seal of the mask. A good face seal can only be achieved if the wearer is clean- in the region of the seal and the facepiece is of the correct size and shape to fit the wearers’ face. Spectacles with side arms and other items of PPE must not interfere with the correct fitting of the facepiece or the face seal Dosage for Fit test – Initially, same dosage as determined in Sensitivity Test when hood is in place. Then introduce a ½ dose every 30 seconds during exercises If at any time during the test, the subject tastes the particulate then the test is failed. Wait 15 minutes before re-testing. If the retest is failed then test using a different sized mask.

Fail

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Note - 2

Pass

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Exercise 1

QCS 2014

Section 11: Health and Safety Page 16 Part 2.3.02: Control of Substances Hazardous to Health (COSHH)

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Notes: (To be used by the employee, Manager, Occupational Hygienist and/or SHE Advisor. )

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I certify that I have carried out the Fit Testing of Respiratory Protective Equipment as required under the COSHH Regulations

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Signature of tester……………………………………… Date ………………….

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I certify that I have received Fit Testing for Respiratory Protective Equipment as required under the COSHH Regulations

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Signature of employee……………………………………… Date ………………….

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THIS DOCUMENT TO BE RETAINED ON FILE FOR 5 YEARS.

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QCS 2014

Section 11: Health and Safety Part 2.3.02: Control of Substances Hazardous to Health (COSHH) Assessment Sheet No:

Substance:

Activity No:

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Contract:

Page 17

Date

Position Held

Signature

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Name

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I declare that I am in receipt of training in the precautions required for the safe use of substances list above.

Instructor's Signature: Copy to:

Site Register

Date:

QCS 2014

Section 11: Health and Safety Page 1 Part 2.3.03: Safe Working in the Vicinity of Buried and Overhead Services

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ................................................... 1

2.3

SAFETY , HEALTH AND ENVIRONMENT PROCEDURES .......................... 1

2.3.3

SAFE WORKING IN THE VICINITY OF BURIED AND OVERHEAD SERVICES ...................................................................................................... 1

.

2

Responsibilities .......................................................................................... 4

2.3.3.2

Definitions .................................................................................................. 4

2.3.3.3

Action Required To Implement This Procedure .......................................... 5

2.3.3.4

Guidance to This Procedure....................................................................... 7

2.3.3.5

Reference Documents................................................................................ 7

2.3.3.6

Author......................................................................................................... 8

2.3.3.7

Approvals ................................................................................................... 8

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Section 11: Health and Safety Page 2 Part 2.3.03: Safe Working in the Vicinity of Buried and Overhead Services

Process Map

PLANNING LOCATION

Ensure evaluation of programme & works drawings, identify requirement for excavations & equipment is available 3.1

Locator of Service

Supervisor/Electrical Engineer

SHE Advisor

Contact all relevant stat. authorities, Engineer & obtain information on all u/g and overhead services. Produce ‘Master’ drawing where practicable 3.2, 3.5

Produce activity specific service location drawing 3.2

Carry out cable/pipe/service detection survey

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3.3

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Ensure this procedure is established. Appoint Services Co-ordinator 1.2

Services Coordinator

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Project Manager

Mark location of services on ground/identify overhead services

Update activity specific service location drawing 3.3

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Undertake service plans and maintain master copy

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Ensure timed circuits are identified or isolations 3.2

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3.2

Ensure services to be removed are made DEAD or SPIKED by authorised person 3.2

Input to Method Statement as appropriate

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Identify trial holes required to establish exact location and type of service 3.2, 3.3

Agree Method Statement

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3.1 and 4

Re-assessed by competent person

OPERATIONAL CONTROLS

Approve and monitor Permit to break ground & confirm duration 3.2

Ensure service plans are updated & maintain master copy 3.2

Ensure updated plans are forwarded to H&S file

Re-assessed by competent person Key

Activity Guidance

HOLD POINT Instruct personnel in contents of Permit and Method Statement 3.4

Proceed in accordance with Permit & Method Statement and monitor. Notify Service Cocoordinator of any 3.5 change and need to review RAMS

Monitor operations & permit. Investigate any learning events or strikes 1.6 Insp. Report

HOLD POINT

QCS 2014

Section 11: Health and Safety Page 3 Part 2.3.03: Safe Working in the Vicinity of Buried and Overhead Services

PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish a safe system of work for activities carried out where buried services may exist or overhead services are present.

SCOPE This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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Qatar General Electrical and Water Corporation (KAHRAMMA) is the responsible for the distribution network cables and wire, not the Qatar General Electricity and Water Company

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Note:

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QCS 2014

Section 11: Health and Safety Page 4 Part 2.3.03: Safe Working in the Vicinity of Buried and Overhead Services

2.3.3.1 Responsibilities SHE DIRECTOR 1

Authorises this procedure PROJECT/SITE MANAGER

2

Ensures that works are carried out in accordance with this procedure and appoints the Services Co-ordinator.

Ensures that necessary information regarding services is available and undertakes the duties specified in this procedure.

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SERVICES CO-ORDINATOR

Either supervises the work activities or the sub/work package contractor undertaking those work activities and ensures preparation of the necessary control documents required by this procedure.

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SUPERVISOR/ELECTRICAL ENGINEER

LOCATOR OF SERVICES

SHE ADVISER

Provides advice and support in the application of this procedure and monitors others’ effectiveness to manage the activities.

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Undertakes the physical check and survey, in line with their training, to determine the location of both identified/unrecorded services.

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2.3.3.2 Definitions SERVICES 1

Any cable or pipe, either buried in the ground or supported overhead, providing telecommunications, electricity, gas, water, drainage or other service. ANY CABLE RISK ASSESSMENT

2

The process of hazard identification, assessment of the risk, and identification of the controls required to manage the risk to an acceptable level to ensure the health and safety of those affected by the activity.

3

Refer to SHE-PRO-001 (

).

METHOD STATEMENT

QCS 2014

Section 11: Health and Safety Page 5 Part 2.3.03: Safe Working in the Vicinity of Buried and Overhead Services

4

A statement describing the proposed working method that addresses the output from the risk assessment process and provides instruction and guidance for those individuals carrying out the activity.

5

Refer to (SHE-PRO-001). PERMIT TO BREAK GROUND

6

Control document – (SHE-FRM-3-02 ) Permit to Break Ground, to ensure that potential hazards from services during excavation or penetration of the ground are identified and risks are controlled and maintained.

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2.3.3.3 Action Required To Implement This Procedure

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PROJECT/SITE MANAGER

Ensure the evaluation of tender information, Project Programme and the works drawings to identify the requirements for breaking ground or location of overhead services.

2

Appoint a Services Co-ordinator or retain the Services Co-ordinator’s duties in 3.2.

3

Ensure the availability of suitable service location equipment and a competent operator who is appropriately trained in the use of detection equipment.

4

Agree with Services Co-ordinator the site colour-coding scheme for surface marking of services.

5

Check that the controls in this procedure are implemented.

6

Agree method statements and associated risk assessments.

7

In case of a service strike, a specific site investigation must be undertaken in conjunction with the SHE Team (SHE-FRM-8-06).

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SERVICES CO-ORDINATOR Seek out and retain copies of all statutory authority and service drawings (including client’s where applicable) relevant to the project’s scope of work.

9

Have transposed onto a master drawing(s), the details of all relevant services.

10

Have recorded on the master drawing(s) the location and depths of services installed during site establishment.

11

Confirm with the Supervisor/Electrical Engineer in control of an activity requiring a Permit to Break Ground the full extent of the intended activity. Check the activity drawings against the master drawing(s).

12

Produce an activity specific location drawing for reference by the locator of services that includes current landmarks, (SHE-FRM-3-02).

13

Request the appointed Locator of Services to undertake a thorough survey of the area where the activity is to take place with an appropriate service locator (and ‘Genny’ where circuits on timers are likely), and none energised services, e.g. gas and water, even if it has been established from drawings that there are no recorded services present.

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QCS 2014

Section 11: Health and Safety Page 6 Part 2.3.03: Safe Working in the Vicinity of Buried and Overhead Services

In conjunction with the Locator of Services, specify where and when trial holes are dug to establish the exact location and type of service identified. Provide an activity specific, location drawing (including any updates identified in the survey) for reference by the Supervisor/Electrical Engineer in control of the activity.

15

Update master drawing(s) following receipt of survey information.

16

Ensure information on master drawing(s) is transferred to ‘as-built’ drawings for inclusion in the projects Health and Safety File.

17

Ensure secure isolation of any service or purging of any pipe-work before it is worked upon or removed and be aware of any presence and effect of timed circuits.

18

Before any activities start on a site where overhead services are present or adjacent, contact the SHE Adviser for advice. Where overhead electrical supply cables are present, Qatar General Electricity & Water Company shall also be contacted for advice on re-routing or clearance and insulation. Review Method Statement/Risk Assessment before final approval by Project Manager.

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LOCATOR OF SERVICES

Physically and clearly mark the position of services on the ground in accordance with the services marking scheme.

20

Assist in establishing the exact location and type of service identified when trial holes are being dug.

21

Update the activity specific location drawing provided for reference to you by the Services Co-ordinator.

22

Advise the Services Co-ordinator of any deviations from records

23

Seek advice from the Services Co-ordinator where doubt about a signal or lack of one exists.

24

Continue to use the service locator and genny, whilst the work proceeds, to establish the presence of any services missed/not located during the initial sweep, frequency as determined by the Service Co-ordinator.

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SUPERVISORS/ELECTRICAL ENGINEER 25

Prepare or arrange for the Sub/Work Package Contractor to prepare for agreement by the Project/Site Manager a specific method statement SHE-PRO-001 for activities involving: (

26

)

(a)

excavation or penetration of the ground;

(b)

any activity beneath or in the vicinity of overhead electrical supply cables or pipework containing a hazardous substance where there is any possibility, however remote, of plant, equipment, materials or people encroaching into a safety zone;

(c)

any activity beneath or in the vicinity of any other overhead service where there is a possibility of damage.

Ensure persons under their control fully understand they do not commence excavation or penetration of the ground in an area unless the whereabouts of services has been established and a Permit to Break Ground has been prepared and approved by the Service Co-ordinator and obtained (SHE-FRM-3-02).

QCS 2014

Section 11: Health and Safety Page 7 Part 2.3.03: Safe Working in the Vicinity of Buried and Overhead Services

Ensure all personnel involved in the activities are instructed in the method statement and Permit to Break Ground and sign to confirm their understanding, including the requirement to stop work immediately in cases where a service is damaged so that the situation can be reassessed by a competent person.

28

Ensure persons under their control fully understand they may not in any way interfere with a service or remove any service cover, warning tile or other protection unless specifically authorised by their Supervisor.

29

In the event of a service being damaged, work must be stopped immediately and cordoned off so that a re-assessment can be undertaken by a competent person before work recommences.

30

Establish in conjunction with the Services Co-ordinator the need for additional surveys as the activity progresses where the location of services may have been missed.

31

Where overhead electrical supply cables are present, that persons under their control fully understand these are not insulated, therefore if contact or near contact is made with them by a conducting object, there is a risk of death or serious injury to any person in the immediate vicinity.

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2.3.3.4 Guidance to This Procedure

The Risk Assessment/Method Statement (SHE-PRO-001) shall reference the activity specific location drawing provided by the Services Co-ordinator.

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RISK ASSESSMENT/METHOD STATEMENT

Any delay between the services survey and the activities to be performed shall be minimised and a limit specified on the Permit to Break Ground, SHE-FRM-3-02 This limit for the Permit(s) must be agreed with the Service Co-ordinator. (

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REFERENCING

The Risk Assessment/Method Statement shall be referenced on the Permit to Break Ground.

4

If a sub or work package contractor is undertaking the works, the contractor’s supervisor shall confirm that the items on the Permit have been undertaken before any ground is broken (see also 3.4 stop work requirements).

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2.3.3.5 Reference Documents PROCEDURES 1

Safety, Health and Environmental Risk Management and Written Safe Systems of Work – (SHE-PRO-001)

2

Permit to Work Systems – (SHE-PRO-011) FORMS

3

Permit to Break Ground – (SHE-FRM-3-02)

QCS 2014

4

Section 11: Health and Safety Page 8 Part 2.3.03: Safe Working in the Vicinity of Buried and Overhead Services

Site Investigations of Underground Strikes (SHE-FRM-8-06) FURTHER REFERENCE Qatar Regulatory Document (Construction) , Section 1.5

6

Statutory Authorities/Client’s Plans & Drawings

7

Works Programme & Drawings

8

Site Service Plan

9

Risk Assessment/Method Statement or Task Statement

10

Site Investigation

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POSITION IN COMPANY

NAME

CONTACT DETAILS

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2.3.3.6 Author

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2.3.3.7 Approvals

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Approved by:

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

QCS 2014

Section 11: Health and Safety Page 9 Part 2.3.03: Safe Working in the Vicinity of Buried and Overhead Services

Section 1

Permit Number

2

Prepared By

3

Start – Date/Time

Date

(To be noted on the RA+MS)

Requested By

Duration Specific Location Activity Plant To Be Used (As Part Of The Safe Systems Of Work) Yes

No

Safety Pin Required

Yes

No

The services itemised below exist at the above location & on the attached sheets Service Drawing Exist Service Drawing Exist Number Yes/N Number Yes/N o o Electricity Drainage Underground Ducts Overhead CCTV Street Lighting Temporary Services Gas Others (i.e. ordinance) Telecom Approval To Remove Fibre Optics Redundant Water Mains Services Sewers Restrictions 1 Permit valid from ...................................... to ............ 2 Excavate trial holes by hand every ....................................... metres 3 Expose services along full length in works areas Yes No 4 Confirm a risk assessment and method statement have been prepared Yes Risk assessment/s and method statement/s ID Number ................................................................ 5 Service locator/survey carried out Yes by whom ...................................... Is the equipment calibration up to date Yes Date of Calibration ............................................... 6 Has ground radar survey been carried out Yes (If Yes attach appropriate drawings) No Any other comments/ restrictions identified

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Approved By: (COMPANY Authorised Person/Service Co-ordinator) Print Name .................................................... Signature ................................. Position ......................................................... Date ....................................... Acknowledgement of COMPANY/*Contractors Supervisor I understand the hazards involved in this work and that in the event of a service strike the area will be cordoned off and only re-entered following advice from the utility provider. All personnel involved will have this fully explained to them by me and sign section 9 of this permit to confirm this is the case. Print Name ................................................... Signature ...................................................Position .................................... Print Name ................................................... Signature ...................................................Position ...................................

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Quick Hitch Fitted

8

Date ............................... Confirmation of Completion of Works Print Name ............................................................... Signature ...................................... Position ................................................................... Date .............................................

9

Confirmation that personnel have been advised of Section 7 (Sign and Print Name) Date ................................

*If relevant Distribution:

White copy – Workplace recipient Pink copy – Distribute as required Blue copy – Retain in book (file copy)

QCS 2014

Section 11: Health and Safety Part 2.3.04: Electricity at Work

Page 1

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ------------------------------------------- 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ---------------------- 1

2.3.4

ELECTRICITY AT WORK ------------------------------------------------------------------ 1

2.3.4.1 2.3.4.2 2.3.4.3 2.3.4.4 2.3.4.5 2.3.4.6 2.3.4.7

Responsibilities ........................................................................................................... 4 Definitions ................................................................................................................... 4 Actions Required to implement This Procedure .......................................................... 5 Appendices ................................................................................................................. 7 Reference documents............................................................................................... 10 Author ....................................................................................................................... 10 Approvals ................................................................................................................. 10

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QCS 2014

Section 11: Health and Safety Part 2.3.04: Electricity at Work

Page 2

Process Map - Control of Electrical Operations Services Coordinator

Locator of Service

Appoint an Electrical Duty Holder for the Company/Region

Issue current version of RES to Project Managements/Electric al Contractors

3.1

3.2

Supervisor/Engineer

Appoint an Authorised Person for electrical works for the location 3.3

Appoint an Authorised person for the Permanent and Temporary Works

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Obtain and update a drawing showing the locations Temporary Electrical System 3.3

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Appoint a Permanent Works Electrical Duty Holder 3.5

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Audit the electrical installation/equipme nt 3.2

Key:

Activity Guidance

Control the Permit of Work System and issue the appropriate permits 3.2

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3.2

Display the appointment on the location notice Board 3.3

SHE Advisor

.

Project Manager

Ensure the Schedule tests are carried out 3.3

QCS 2014

Section 11: Health and Safety Part 2.3.04: Electricity at Work

Page 3

PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish a safe system of work in relation to the design, installation, maintenance, and examination and testing of electrical systems/equipment.

SCOPE

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This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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QCS 2014

Section 11: Health and Safety Part 2.3.04: Electricity at Work

Page 4

2.3.4.1 Responsibilities SHE DIRECTOR 1

The SHE Director shall approve this procedure MANAGING DIRECTOR

2

The Managing Director shall appoint in writing an Electrical Duty Holder (EDH) for the Company/Region who shall be a qualified Electrical Engineer or appoint an Electrical Consultant to manage the EDH duties

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PROJECT/SITE MANAGER

Ensure any applicable sections of this procedure are established, and complied with.

4

The responsibility for electrical safety of the permanent works under construction shall remain with the operational line management.

5

The appointment of a Permanent Works Electrical Duty Holder shall be the responsibility of Site Manager with reference to the EDH.

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ELECTRICAL DUTY HOLDER (EDH)

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3

It is the responsibility of the EDH to implement this procedure and monitor that all portable electrical appliances provided by COMPANY for use by COMPANY personnel or others comply with it.

7

The EDH shall be responsible for electrical safety with respect to the whole or defined parts of the Company’s electrical systems and/or equipment, ensuring compliance with the Rules for Electrical Safety and, with regard to installations, planned preventative maintenance.

8

The vetting/approval of temporary electrical sub-contractors shall be the responsibility of the EDH or the Operational/Area Director following consultation with his/her SHE Adviser in circumstances where the EDH duties are delegated to an approved electrical contractor.

9

It is acknowledged that different arrangements exist in respect of site set ups, some being under the control of the client/external partners. In circumstances where deemed necessary the EDH shall endeavour to influence the client/external partners to adopt COMPANY standards.

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2.3.4.2 Definitions 1

A full set of definitions are contained in the COMPANY Rules for Electrical Safety. DESIGNATED PERSONS ELECTRICAL DUTY HOLDER

2

An Electrical Engineer appointed by the Managing Director in writing to be responsible for ensuring electrical safety with respect to the whole or defined parts of the Company's electrical system and/or equipment.

QCS 2014

Section 11: Health and Safety Part 2.3.04: Electricity at Work

Page 5

AUTHORISED PERSON 3

An electrical contractor or electrically qualified Engineer or Technician appointed by the Electrical Duty Holder in writing, to carry out specified duties on the electrical system or equipment and to take control of any danger that is to be avoided and who is competent to accept such responsibility. SUB CONTRACTOR'S AUTHORISED PERSON

4

An electrically qualified Engineer or Technician appointed by the by the Sub-Contractor in writing, to carry out specified duties on the electrical system or equipment and to take control of any danger that is to be avoided and who is competent to accept such responsibility.

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The Site/Location Manager will be the Site Electrical Co-ordinator for the site/location under that person's control, unless the position is otherwise delegated in, writing and that person is approved by the Electrical Duty Holder in writing.

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2.3.4.3 Actions Required to implement This Procedure

The MD for the Company/Region shall appoint in writing an Electrical Duty Holder for their area of responsibility.

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MANAGING DIRECTOR

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The Electrical Duty Holder shall :

Ensure ALL work is carried out in accordance with the COMPANY Rules for Electrical Safety.

(b)

Assess and approve all temporary electrical contractors prior to their appointment.

(c)

In conjunction with the Site/Project Manager appoint in writing an Authorised Person for each location.

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ELECTRICAL DUTY HOLDER

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(d)

Take reasonable steps to ensure that the Site Electrical Co-ordinator has the competency to undertake the role.

(e)

Ensure that all projects and appropriate contractors have a copy of the latest Rules for Electrical Safety.

(f)

Undertake independent inspection/audit of site electrical installation/equipment under COMPANY UK control.

(g)

During inspection/audit of the temporary electrical installation shall also consider the electrical safety controls in place for the permanent works.

The minimum frequency of inspection/audits shall be carried out at a frequency as deemed necessary by the EDH in agreement with the Area Director responsible for the site. SITE ELECTRICAL CO-ORDINATOR

4

The Site Electrical Co-ordinator shall :

QCS 2014

Section 11: Health and Safety Part 2.3.04: Electricity at Work

Page 6

(a)

Ensure ALL work is carried out in accordance with the COMPANY Rules for Electrical Safety.

(b)

After consultation with the EDH, appoint in writing an Authorised person for the location he is responsible for.

(c)

Display the appointment of the Site Electrical Co-ordinator and Authorised Person on the location notice board and electrical switch gear.

(d)

Keep an up-to-date drawing showing the electrical circuits for the location’s temporary electrical system.

(e)

Ensure schedule tests are carried out on installations and equipment.

AUTHORISED PERSON

Control the permit to work system and issue permits as required.

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The Authorised Person shall :

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SITE/PROJECT MANAGER

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The Site/Project Manager shall :

Ensure ALL work is carried out in accordance with the COMPANY Rules for Electrical Safety.

(b)

After consultation with the EDH appoint in writing a permanent works Electrical Duty Holder.

(c)

Ensure that the specification for the temporary site electrics is communicated to the temporary electrical contractor.

(d)

Undertake the duties of the Site Electrical Co-ordinator or appoint appropriate person to undertake those duties.

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Section 11: Health and Safety Part 2.3.04: Electricity at Work

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QCS 2014

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2.3.4.4 Appendices

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APPENDIX 1 – SUGGESTED INSPECTION AND TEST FREQUENCIES FOR ELECTRICAL EQUIPMENT Formal Visual Inspection No

No

No

No

Information technology: e.g. desktop computers, VDU screens

Yes, 2-4 years

No if double insulated – otherwise up to 5 years

Photocopiers, fax machines: NOT hand-held Rarely moved

Yes, 2-4 years

No if double insulated – otherwise up to 5 years

Double insulated equipment: NOT hand-held. Moved occasionally, e.g. fans, table lamps, slide projectors

Yes, 2-4 years

No

Double insulated equipment: HAND-HELD e.g. some floor cleaners

Yes, 6 months – 1 year

No

Earthed equipment (Class 1): e.g. electric kettles, some floor cleaners

Yes, 6 months – 1 year

Yes, 1-2 years

Cables (leads) and plugs connected to the above. Extension leads (mains voltage)

Yes, 6 months – 4 years depending on the type of equipment it is connected to

Yes, 1-5 years depending on the type of equipment it is connected to

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Battery operated: (less than 20 volts)

Combined Inspection and Testing

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Extra low voltage: (less than 50 volts AC) e.g. telephone equipment, low voltage desk lights

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Section 11: Health and Safety Part 2.3.04: Electricity at Work

Page 8

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QCS 2014

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OFFICES AND OTHER LOW RISK ENVIRONMENTS ONLY CONSTRUCTION SITES

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Battery operated power tools and torches

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25V portable hand lamps (confined or damp situations) 50V portable hand lamps

Formal Visual Inspection

Combined Inspection and Test

Less than 25 volts

No

No

25 volt secondary winding from transformer

No

No

Secondary winding centre tapped to earth (25 volt)

No

Yearly

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Equipment/Application

Voltage

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110V portable and hand-held tools, extension leads, Secondary winding centre tapped to earth site lighting, moveable wiring systems and associated (55 volt) switchgear

Monthly

Before first use on site and then 3 monthly

230 volt mains supply through 30mA RCD

Weekly

Before first use on site and then monthly

230V equipment such as lifts, hoists and fixed floodlighting

230V supply fuses or MCBs

Monthly

Before first use on site and then 3 monthly

Weekly

*Before first use on site and then 3 monthly

6 monthly

Before first use on site and then yearly

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230V portable and hand-held tools extension leads and portable floodlighting

RCDs

Fixed**

Equipment in site offices

230 volt office equipment

*Note: RCDs need a different range of tests to other portable equipment, and equipment designed to carry out appropriate tests on RCDs will need to be used. ** It is recommended that portable RCDs are tested monthly.

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Section 11: Health and Safety Part 2.3.04: Electricity at Work

Page 9

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QCS 2014

qa

ta

APPENDIX 2 - VISUAL INSPECTION OF ELECTRICAL EQUIPMENT CHECKLIST THIS IS A SIMPLE INSPECTION REQUIRING THE MINIMUM OF TRAINING. THE FOLLOWING CHECKLIST COVERS THE REQUIREMENTS.

se

as

Plug

m

et

General

N.B.

ov

ito

Appliance Casing

er

Cable

No damage, cracks or bent pins, cable sheath secured. Inspection of the inside of the plug to check correct fusing/wiring in place can also be part of the visual inspection.

No damage, significant abrasions, cuts, taped joints

No damage, loose parts or screws missing No evidence of overheating (discoloured/hot areas), air intakes not choked, appliance is dry (where appropriate) appliance is dry (where appropriate) appliance is within its test period (check tag) Use the right tool for the job in the right place – don’t improvise. UNPLUG APPLIANCES WHILST INSPECTING. IF APPLIANCE IS DEFECTIVE DON’T USE IT – REPORT IT!

QCS 2014

Section 11: Health and Safety Part 2.3.04: Electricity at Work

Page 10

2.3.4.5 Reference documents 1

Qatar Regulatory Document (Construction) RD1.5

2

COMPANY Rules for Electrical Safety (RES) (Qatar General Electricity & Water Company to Supply)

POSITION IN COMPANY

NAME

CONTACT DETAILS

rw

SECTION

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.

2.3.4.6 Author

qa

ta

SHE Manager

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POSITION IN COMPANY

er

NAME

as

2.3.4.7 Approvals

SHEQ Director

m

et

ito

ov

Approved by:

END OF DOCUMENT

SIGNATURE & DATE

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ..................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONEMNT PROCEDURES..............................1

2.3.5

POWERED WORK EQUIPMENT PROCEDURE ..............................................1

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.

2.3.5.1  Responsibilities ..................................................................................................4  2.3.5.2  Definitions ..........................................................................................................5 

rw

2.3.5.3  Action Required to Implement this Procedure ...................................................6  2.3.5.4  Guidance To This Procedure .............................................................................8 

ta

2.3.5.5  Appendices ......................................................................................................11 

qa

2.3.5.6  Reference Documents .....................................................................................13  2.3.5.7  Author ..............................................................................................................13 

m

et

ito

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as

2.3.5.8  Approvals .........................................................................................................13 

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 2

PROCESS MAP Plant Coordinator

Supervisors

Procurement Quantity Surveyor

Identify PWE requirements and produce PWE schedule

Provide proof of competence Review PWE schedule and maintain during the project

3.7

3.2

Regional Training Coordinator

qa

Operate, inspect and maintain plant

3.2

ov

er

3.3

m

et

ito

Ensure relevant Certification is available for PWE on site 3.3

Key: Activity Guidance

Monitor use, inspection and maintenance f PWE 3.3

Advise Subcontracto r Management of PWE requirement at pre-start

Report defects as identified

3.5, 3.6

3.7

se

Report defects as identified 34

as

3.7

Develop and revise PW Schedule

SHE Team

Assist and advise on plant requirements use and maintain as 3.8

ta

Monitor use of PWE including inspection and 3.4

Appoint a plant Co-ordinator

Contractor

rw

3.1

Operator

.

Project Site Manager

.l. l

Estimator/ Bid Manager

Identify PWE equipment and provide a copy to COMPANY Plant Co3.8

Arrange training as requested by Project Team 3.9

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 3

PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish a system for the control and safe use of powered work equipment.

SCOPE

et

ito

ov

er

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as

qa

ta

rw

.l. l

.

This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

m

1

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 4

2.3.5.1 Responsibilities SHE DIRECTOR 1

Authorises this procedure ESTIMATOR/TENDER TEAM

2

Ensures that information provided by designers is utilised at tender stage for inclusion of resource to allow compliance by others with this procedure.

Ensures this procedure is established on Projects under his control. For the purposes of this procedure, Project/Site Manager may also mean Office Manager.

rw

3

.l. l

.

PROJECT/SITE MANAGER

ta

PLANT CO-ORDINATOR Applies the requirements of this procedure.

5

Note: The person appointed must be site based and competent to carry out their duties. PROCUREMENT/BUYER/QS

Supports the Plant Co-ordinator in the application of this procedure.

se

6

ito

ov

Supports the plant co-ordinator in the application of this procedure. OPERATOR

Operates Plant in accordance with the requirements of this procedure.

et

8

er

SUPERVISOR 7

as

qa

4

9

m

SHE ADVISER Provides advice and guidance in support of this procedure and monitors the effectiveness of its application. CONTRACTOR 10

Ensures only competent personnel are dedicated/owned/hired plant and equipment.

authorised

11

Ensures maintenance is completed and recorded as appropriate.

to

REGIONAL TRAINING CO-ORDINATOR 12

Processes formal training requests from the Project/Site Manager.

operate

specifically

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 5

2.3.5.2 Definitions POWER 1

The Provision and Use of Work Equipment. POWERED WORK EQUIPMENT (PWE)

2

Powered Work Equipment as referred to in PUWER.

3

NB. The Requirements for the use of Lifting Equipment are contained in SHEPRO-010

Defines the equipment as fit for its intended use within its design and operational parameters.

rw

4

.l. l

.

SUITABILITY OF PWE

For the purposes of this procedure, ‘use’ includes all activities involving PWE such as starting, operating and stopping the equipment, plus any setting, repair, modification, maintenance, servicing, transportation and cleaning.

qa

5

ta

USE

se

‘Contractor’ means any work package contractor or their sub-contractor and include any PWE supplier.

er

6

as

CONTRACTOR

The individual’s demonstrated capacity to perform, i.e., the possession of knowledge, experience, training, skills and personal characteristics needed to satisfy the special demands or requirements of a particular situation.

ito

7

ov

COMPETENCE

A control/management document displayed within the project office to be updated regularly by the Plant Co-ordinator. SHE-FRM-5-001.

m

8

et

PWE SCHEDULE

PWE CHECKLIST 9

An aide memoir and control document to be completed by the Plant Coordinator (COMPANY and Contractor) or nominated person for any equipment received onto site and filed within the SHE Register. SHE-FRM-5-02. PLANNED PREVENTIVE MAINTENANCE (PPM)

10

Involves replacing parts and consumables or making necessary adjustments at preset intervals so that risks do not occur as a result of the deterioration or failure of the equipment.

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 6

CONDITION-BASED MAINTENANCE 11

Involves monitoring the condition of safety-critical parts and carrying out maintenance whenever necessary to avoid hazards which could otherwise occur. BREAKDOWN MAINTENANCE

12

Involves carrying out maintenance only after faults or failures have occurred. It is appropriate only if the failure does not present an immediate risk and can be corrected before risk occurs, It is unlikely that this system of maintenance would be acceptable for the PWE covered by this procedure.

.l. l

Identify the PWE requirements for the project and complete the initial PWE schedule (Appendix 1) Allow resource for any equipment in the bid and include details and information relative to the same in the handover process between the pre-construction and construction teams.

qa

ta

1

rw

ESTIMATOR/TENDER TEAM

.

2.3.5.3 Action Required to Implement this Procedure

as

PROJECT/SITE MANAGER

Review the initial PWE schedule (Appendix 1) and amend / maintain as required throughout the Project duration.

3

Where appropriate, appoint a Plant Co-ordinator or retain the duties of that appointment.

4

Arrange training for Directly employed persons through the Regional Training Co-ordinator as necessary to ensure the competence of appointees.

5

Monitor PWE use on site to ensure the effectiveness of controls.

ito

ov

er

se

2

7

Take control of, review and develop the PWE Schedule as the project progresses.

m

6

et

PLANT CO-ORDINATOR

Enter all details of PWE received on site into the PWE Schedule (SHE-FRM-5-01).

8

Act as the focal point for all PWE used on site and assist other management/supervision in the selection and control of the PWE used.

9

Must ensure either a certificate of thorough inspection not more than 12 months old (6 Months where lifting persons) for any lifting equipment received on site is attached to the site register and the next inspection date is logged on the PWE Schedule (SHE-FRM-5-001).

10

Arrange/Complete all pre-use checks as detailed on SHE-FRM-5-002.

11

Record operators/users of each PWE on the PWE Schedule.

12

Complete or ensure the completion of all regular inspections and maintenance of PWE in the appropriate Project SHE Register or the equivalent subcontractor control document.

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 7

13

Ensure arrangements are made for the safe-keeping and issue of all ignition and security keys and for smaller PWE for its safe storage and controlled issue.

14

Confirm a system of PPM or Condition Based Maintenance is applied by all sub-contractors on any PWE used on site.

15

Implement a system of PPM or Condition Based Maintenance on any PWE purchased for use on site based on manufacturers guidelines and completed by competent people (externally contracted as necessary). SUPERVISORS Complete all duties as appointed and authorised by the Plant Co-ordinator.

17

Monitor PWE use on site to ensure the effectiveness of controls, maintenance and servicing.

rw

.l. l

.

16

PROCUREMENT/BUYERS

Advise sub-contractor management at pre-start of requirements regarding PWE (see ‘Contractor’ actions below).

qa

ta

18

QS

as

Advise sub-contractor management at pre-start of requirements regarding PWE (see ‘Contractor’ actions below) and issue copy of Appendices 1 & 2 where no sub-contractor internal control documents/system exists.

se

19

er

OPERATOR

Provides proof of competence.

21

Operates plant and equipment when authorised to do so, in approved areas, subject to site or ordered limitations and in compliance with training and manufacturer’s guidelines.

22

Ensures maintenance is completed in accordance with training, employers Risk Assessment and manufacturer’s guidance.

23

Ensures defects are promptly reported to the plant co-ordinator and where necessary secures unsafe equipment in a safe location/state.

m

et

ito

ov

20

CONTRACTOR 24

Identify the PWE requirements for the project and complete an initial PWE schedule (Appendix 1) or similar ‘in-house’ control document. Provide copy to COMPANY Project Manager/Plant Co-ordinator.

25

Monitor PWE use on site to ensure the effectiveness of controls, maintenance and servicing. REGIONAL TRAINING CO-ORDINATOR

26

Deliver or arrange to be delivered any training formally requested by the Project Team to ensure the competence of Directly employed appointees.

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 8

SHE ADVISER 27

2.3.5.4

Assist pre-construction and construction teams as requested in application of this procedure.

Guidance To This Procedure

1

This procedure and guidance is intended to ensure compliance with statutory requirements for all COMPANY projects regarding PWE.

2

Although POWER covers all ‘work equipment’, this procedure and guidance is only intended to provide direction on the control of Powered Work Equipment (PWE) which would include but is not limited to the following: Drills - cable fed, hydraulic and petrol driven (it is not intended that sites include low risk battery drills etc within the scheduled part of this procedure however this does not remove the needs to monitor the use of such equipment to ensure it is fit for purpose and used correctly).

(b)

Saws – circular, reciprocating, bench and rip

(c)

Breakers/Hammers/Chisels/Tampers – All

(d)

Electric/petrol/diesel/gas Powered Plant – All

(e)

Self Propelled Work Equipment – Dumpers, Dozers, Rollers, Excavators etc

(f)

Cartridge Operated Fixing Tools - All

(g)

Lifting Equipment - FLTs, Hoists, HIABs, MEWPs

(h)

n.b. Other than inclusion on the PWE Schedule, all Crane Lifting Operations controls and requirements are covered in SHE-PRO-010.

ta

qa

as

se

er

ov

RISK ASSESSMENT

Where the specific controls required for the use of PWE have not been considered under the general Risk Assessment for work, a specific Risk Assessment is required prior to its use. The Plant Co-ordinator or Contractor (in the case of sub-contractor equipment) is responsible for its completion. See SHE-PRO-001.

et

ito

3

rw

.l. l

.

(a)

4

5

m

SELECTION AND SUITABILITY The equipment ordered must be suitable to the work intended and the operating environment, e.g. (a)

Telehandler – consider: loads, reach, site height/width/ground restrictions, operator competence/ability and delivery restrictions etc.

(b)

Breaker – consider: Individual capability, material to be broken, access, technological developments (noise/vibration suppression), tool outputs etc.

Experience coupled with Risk Assessment should allow the selection of the correct equipment, however, if doubt exists consult your local SHE Adviser. PRE-USE/RECEIPT INSPECTION

6

To ensure serviceability, all equipment received on site (COMPANY and Sub-contractor) must be subject to a pre-use inspection using either the COMPANY PWE Checklist (SHEFRM-5-002) or manufacturers guidance as appropriate.

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 9

REGISTRATION AND AUTHORISATION 7

To assist in ensuring only competent and authorised personnel use PWE on site, all operators shall be recorded on the PWE Schedule (SHE-FRM-5-001). COMPETENCE Where a recognised industry standard exists i.e. certificate of training achievement, to show competence for the operation of particular equipment, the operator shall possess that appropriate certification, the details of which shall be entered on the PWE Schedule.

9

Where there is no recognised industry standard/certificate of training achievement, the operator shall possess evidence of training on that particular equipment or his employer shall provide written confirmation of training on that particular equipment.

rw

.l. l

.

8

REGULAR INSPECTION

The purpose of an inspection is to identify whether the equipment can be operated, adjusted and maintained safely and that any deterioration (for example defect, damage, wear) can be detected and remedied before it results in unacceptable risks. Inspection should include, where appropriate, visual checks, functional checks and testing. Regular inspections in this context should be completed by the nominated competent person (usually the operator) and conform to the requirements of the Risk Assessment taking into account, training requirements, manufacturers guidelines and equipment specifications.

11

All PWE in use on COMPANY sites will subject to a regime of regular recorded inspection. The maximum period between inspections shall be 7 days and these inspections shall be recorded in the site SHE Register.

12

The above does not include any pre-use checks required of the operator, the occurrence of which should be included in the monitoring checks.

ov

er

se

as

qa

ta

10

In line with current statutory requirements, all lifting equipment must be subject to thorough inspection: Before being put into service for the first time unless either ;

m

(a)

et

13

ito

THOROUGH INSPECTION (LIFTING EQUIPMENT)

(i)

the lifting equipment has not been used before; and

(ii)

in the case of lifting equipment, the employer has received such a declaration made not more than 12 months before the lifting equipment is put into service or if it is obtained from the undertaking of another person, it is accompanied by physical evidence of thorough inspection

(iii)

Where the safety of the lifting equipment is dependent on the installation conditions

14

Where it is exposed to conditions causing deterioration which is liable to result in dangerous situations

15

As a maximum the thorough inspection should be completed at 12 monthly intervals, where the equipment is used for the lifting of persons, the period is reduced to 6 months.

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 10

MAINTENANCE 16

It should be remembered that different maintenance management techniques have different benefits:

17

Where safety-critical parts could fail and cause the equipment, guards or other protection devices to fail and lead to immediate or hidden potential risks, a formal system of PPM or Conditioned Based Maintenance is likely to be required. RECORDS The following records shall be maintained throughout the use of any PWE on site: PWE Schedule - Completed on receipt of any PWE and maintained with all relevant detail until the PWE is removed from site. Any PWE merely ‘Off-Hired’ shall be subject to the same controls as other ‘in-use’ equipment.

(b)

Maintenance – A record of all maintenance completed shall be kept in the site SHE Register.

(c)

Regular Inspection – All regular inspections shall be recorded in the site SHE Register.

(d)

Thorough Inspection – A record of all thorough inspections completed prior to or during the PWE time on site shall be maintained in the site SHE Register.

et

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as

qa

ta

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(a)

m

18

qa

APPENDIX 1 – PWE SCHEDULE

as

Registration/ Date Checklist Equipment Fleet/ Received Completed Type Serial on By Number Site

m

et

ito

ov

er

se

COMPANY

Works Package/ Subcontractor

.

ta

2.3.5.5 Appendices

Owner

Page 11

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Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

rw

QCS 2014

Date of Last Thorough Inspection

Date of Next Thorough Inspection

Authorised User(s) By Name

Competence Details

Risk Assessment Completed and Communicated By

Competent Inspector

Date Removed From Site

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 12

Appendix 2 – PWE Checklist PLANT/WORK EQUIPMENT DETAILS Contract:

Location:

Type of plant/Equipment: Equipment Fleet or Serial No: Order No:

Received by:

Date:

.l. l

.

Supplier:

User (COMPANY or Sub-Contractor):

rw

CHECKLIST

Yes

ta

WORK EQUIPMENT

qa

1. Is the item of plant/work equipment as ordered or a suitable alternative?

m

et

ito

ov

er

se

as

2. Is the item of plant/work equipment in good condition? Are there any noticeable defects i.e. oil leaks, damaged panels, tyres, guards missing, etc? 3. Has plant/equipment been supplied with the necessary; • Operating instructions • Manufacturer’s Handbook • Completed maintenance Checklist (PPM/Service Record) • Warning Notices/Signs/Safety Equipment (locking bars/pins etc.) attached • Appropriate Drip Trays/Spill Response Kit • Is all information in English 4. Has a current certificate of thorough examination (or EU Declaration of Conformity) been supplied/provided with the equipment (Lifting Equipment only) 5. Where equipment has been assembled on site, has a written confirmation been provided as to its fitness for use? Defects/Comments/Actions:

Signature:

Date:

Notes: 1: Where a suitable alternative has been provided, the person completing the checklist must revisit the Risk Assessment and amend controls as necessary. 2: Where lifting equipment is supplied for the lifting of persons, the thorough inspection/EU Declaration must be within 6 months of issue date.

COMPLETED FORM TO BE FILED IN PROJECT SHE REGISTER

No

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 13

2.3.5.6 Reference Documents PROCEDURES 1

SHE PRO 001 – SHE Risk Management and Written Safe Systems of Work

2

SHE PRO 010 – The Safe Use of Cranes and other Lifting Appliances REFERENCE DOCUMENTS Qatar Regulatory Document (Construction) RD1.4

rw

.l. l

.

3

NAME

POSITION IN COMPANY

CONTACT DETAILS

qa

SECTION

ta

2.3.5.7 Author

se

as

SHE Manager

er

2.3.5.8 Approvals

m

et

Approved by:

ito

ov

NAME

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

Page 14

PLANT/WORK EQUIPMENT DETAILS Contract:

Location:

Type of plant/Equipment: Equipment Fleet or Serial No: Supplier:

Order No:

Received by:

Date:

.l. l

.

User (COMPANY or Sub-Contractor): CHECKLIST

rw

WORK EQUIPMENT

Yes

No

ta

1. Is the item of plant/work equipment as ordered or a suitable alternative?

m

et

ito

ov

er

se

as

qa

2. Is the item of plant/work equipment in good condition? Are there any noticeable defects i.e. oil leaks, damaged panels, tyres, guards missing, etc? 3. Has plant/equipment been supplied with the necessary; • Operating instructions • Manufacturer’s Handbook • Completed maintenance Checklist (PPM/Service Record) • Warning Notices/Signs/Safety Equipment (locking bars/pins etc.) attached • Appropriate Drip Trays/Spill Response Kit • Is all information in English 4. Has a current certificate of thorough examination (or EU Declaration of Conformity) been supplied/provided with the equipment (Lifting Equipment only) 5. Where equipment has been assembled on site, has a written confirmation been provided as to its fitness for use? Defects/Comments/Actions:

Signature:

Date:

Notes: 1: Where a suitable alternative has been provided, the person completing the checklist must revisit the Risk Assessment and amend controls as necessary. 2: Where lifting equipment is supplied for the lifting of persons, the thorough inspection/EU Declaration must be within 6 months of issue date.

COMPLETED FORM TO BE FILED IN PROJECT SHE REGISTER

QCS 2014

Section 11: Health and Safety Part 2.3.05: Powered Work Equipment Procedures

GENERAL REQUIREMENTS

Y

N

Page 15

Y

SPECIFIC REQUIREMENTS 1 Satisfactory guards provided for dangerous parts of machinery?

1 Suitable for its purpose 2 Suitable for its location

2 Other hazards minimised? 3 In a good order a) Ejection/falling of anything 4 Restricted to use by authorised personnel (if necessary)

b) Disintegration/collapse of equipment

5 Provided with instruction for use and maintenance (in Arabic & English)

c) Fire or overheating

6 Have operators been trained?

e) Hot/cold surfaces

7 Have supervisors been trained?

3 Controls satisfactory?

8 Is a maintenance log kept (plant and machinery only)

a) Stop/start

ta

rw

.l. l

.

d) Explosion of equipment or contents

qa

b) Emergency (over-rides others) 9 Is log kept up to date (plant and machinery only

as

c) Run controls

d) Audible/visual warnings

10 Are maintenance arrangement satisfactory

m

et

ito

ov

er

se

e) Clearly indicated, visible, safely positioned f) “Fail safe” g) Isolation arrangements 4 Is equipment stable? 5 Is lighting adequate? 6 Have the safety of maintenance personnel been considered? 7 Is safety information marked on the equipment 8 Are necessary warnings/warning devices on equipment? 9 If warnings not marked and necessary is there a written system of work/permit?

N

QCS 2014

Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

Page 1

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ..................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES..............................1

2.3.6

SAFETY, HEALTH AND ENVIRONMENTAL TRAINING FOR ALL EMPLOYEES, NEWLY ASSIGNED EMPLOYEES, PROMOTEES AND SUBCONTRACTOR PERSONNEL ...........................................................................1

.l. l

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2

2.3.6.1  Responsibilities ...................................................................................................5 

rw

2.3.6.2  Definitions ...........................................................................................................6 

ta

2.3.6.3  Action Required To Implement This Procedure .................................................7  2.3.6.4  Guidance To This Procedure ..............................................................................9 

qa

2.3.6.5  Reference Documents ......................................................................................10 

as

2.3.6.6  Author ...............................................................................................................11 

m

et

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2.3.6.7  Approvals ..........................................................................................................11 

QCS 2014

Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

Page 2

PROCESS MAP - INDUCTION FLOWCHART

Ensure project specific inductions are developed and delivered (including supervisors) 1.3, 3.2, 3.3 Attend all inductions and complete any questionnaires for project specific inductions

Ensure all their employees receive SHE Inductions, provide support to employees if i d 1.2, 3.1, 3.4

Contracts Managers and Supervisors

Contractors Employees & Site Visitors

SHE Team

Advise on content of inductions. Use Company standards as the baseline 1.4

Attend project inductions and additional; supervisors induction. Ensure evaluation of understanding 1.7, 3.2, 3.3

.

Employees

3.6, 5.2, 5.4

Attend project induction and complete questionnaire (if required) 1.7, 3.2, 3.6

ta

rw

Ensure all their employees and subcontract employees attend project induction 1.4, 3.2

.l. l

Project and Site Manager

Line Manager

m

et

ito

3.8, 3.10

ov

Check training and competency certification where required

er

se

as

qa

Check understanding of content with individual(s). Take suitable action if i d 3.2,

Maintain induction, training and competence records

Monitor inductions are taking place and that required standards are being achieved 1.4

1.3, 3.8, 3.10

Provide assistance to project teams 1.4

Key:

Activity Guidance

QCS 2014

Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

PROCESS MAP - TRAINING FLOWCHART Line Manager

Project and Site Manager

Training Co-ordinators

Employees

SHE Team

Develop and review SHE training strategy and matrix

Arrange training to meet line managers 1.5, 3.8

rw

Ensure all Employees have had training as defined by SHE training Strategy Matrix. Make arrangements for additional training to fill short falls (ie sickness absence)

.l. l

.

1.4, 3.1

ta

Attend all training within required timescales

1.2, 1.3, 3.1, 3.7, 3.9

1.6, 3.7, 3.9

m

et

ito

ov

er

se

as

3.8, 3.9, 3.10

qa

Maintain training records

Key:

Activity Guidance

Monitor training is being provided in line with strategy and matrix 1.

Page 3

QCS 2014

Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

Page 4

PURPOSE 1

The purpose of this procedure is to outline measures to be taken to ensure the provision of consistent levels of Safety, Health and Environmental inductions and training throughout all managerial levels and operations across the business, thereby ensuring that each employee receives appropriate training in safety, health and environmental matters which reflect their operational needs. None of the processes described in this procedure are intended to replace external schemes. SCOPE

et

ito

ov

er

se

as

qa

ta

rw

.l. l

.

This procedure covers all COMPANY projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

m

1

QCS 2014

Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

Page 5

2.3.6.1 Responsibilities SHE DIRECTOR 1

Authorises this procedure LINE MANAGERS Line managers are responsible for ensuring that all staff for whom they are responsible have received the training and inductions, and that necessary standards have been attained. Should any staff for whom they are responsible fail to achieve required standards, line managers must provide appropriate support to assist employees.

.l. l

.

2

In addition to the above, Project and Site Managers must ensure that a suitable site specific induction programme is in place, and that necessary records are kept on site.

ta

3

rw

PROJECT/SITE MANAGERS

Safety, Health and Environmental Advisors will provide advice on the content of Safety, Health and Environmental inductions, and they will also monitor that inductions are being provided as necessary, and that standards are being achieved.

Training Co-ordinators are responsible for the co-ordination and standards of training required by this procedure. EMPLOYEES

ito

Will attend all training (including inductions) they are required to do to ensure compliance with the safety, health and environmental training strategy. Where there is a problem attending courses, this will need to be raised at the earliest opportunity, with appropriate authorisations obtained from their Line Manager and or Director.

m

et

6

ov

er

5

se

TRAINING CO-ORDINATORS

as

4

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SAFETY, HEALTH AND ENVIRONMENTAL TEAM

CONTRACTORS

7

Attend all site inductions, and ensure all sub-contract staff also attend. Only where authorised to do so, deliver COMPANY site inductions and ensure records are kept.

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Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

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2.3.6.2 Definitions EMPLOYEES 1

For the purposes of this procedure, any person carrying out work activities for or on behalf of COMPANY, this will include agency personnel and labour, but not contractors. NEWLY ASSIGNED EMPLOYEES

2

Any employee who is new to a site/location, or new to their role.

The person within a business unit given the responsibility of co-ordinating delivery and recording of training provided to employees and, where Contractors appropriate, within the business unit.

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TRAINING CO-ORDINATORS

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Any person who is not carrying out work activities for or on behalf of COMPANY but is visiting the project for other reasons, i.e. Client staff, Trade representatives.

Workers with the adequate:

Knowledge – Mentor or classroom gained.

(b)

Ability – Competence based assessment.

(c)

Technical Training – International Certification i.e. NEBOSH, CITB, OSHA.

(d)

Experience – Site hazard and operations awareness.

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COMPETENT OPERATIVES

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VISITOR

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Page 7

2.3.6.3 Action Required To Implement This Procedure 1

Refer to the Induction flowchart to ascertain who is assigned the actions required to implement this procedure. SAFETY HEALTH AND ENVIRONMENTAL TRAINING STRATEGY The Safety, Health and Environmental Team will be responsible for producing and reviewing a safety, health and environmental training strategy for the whole business. The training strategy and associated training matrix will be available on the COMPANY intranet*. This will ensure that the latest version is always available. The Safety, Health and Environmental training strategy will identify which training is to be provided to whom, and at which stage of their employment.

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THE INDUCTIONS

All newly assigned employees will receive a Safety, Health and Environmental induction. The induction format can be found on the COMPANY intranet*. In addition a location specific induction will be required to ensure all necessary safety, health and environmental information is provided.

4

Project inductions will not be given to any person who cannot provide evidence of competency relevant to their role.

5

Projects will provide a full Safety, Health and Environmental induction for everyone who will be on site, except accompanied visitors – see below. This induction must be provided before an individual is allowed to go onto the site. A standard format will be used for site inductions. This format is available on the COMPANY Intranet. Project Managers are responsible for ensuring that a site specific induction is in place and provided as required.

6

Visitors to sites, and other locations such as offices, must receive a tailored Safety, Health and Environmental induction if the full induction is not provided. This will cover important arrangements such as access and egress (including emergencies), muster point, location of first aid, etc. Visitors must be accompanied by a suitable person who has attended a full site induction. This will usually be a member of the site or contractor’s management team, but could be other designated persons by agreement with the Project or Site Manager. The induction formats are available on the COMPANY Intranet*.

7

All inductions should be interactive, and seen as an opportunity for two way communication. Where aids such as video/DVD are used these must not be used as the sole means of delivering the induction.

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Site inductions will include a short evaluation. There are two example formats one on the reverse of the Induction Record sheet (SHE-FRM-6-02 and a separate question set and * guidance which may be used is available on the COMPANY Intranet . Local project management will need to determine what action to take should any individual fail to demonstrate a good level of understanding of the project requirements, including safety critical items. This should begin with taking reasonable steps to provide some assistance which may include further explanation, assistance with language difficulties, or assistance with reading and/or writing. )

SUPERVISORS’ INDUCTIONS 9

Any person on a site who will act in a supervisory capacity must undergo a top up induction. This will identify what COMPANY will expect of them as a supervisor or manager. In particular it will cover expected standards of behaviour on site, and dealing with

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Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

Page 8

instances of unsafe behaviour. A format for the supervisors’ induction is available on the COMPANY Intranet*. NEWLY ASSIGNED COMPANY EMPLOYEES Newly assigned COMPANY staff shall not commence their duties until they have: (a)

Received a copy of the Safety Health and Environmental Policy Statement and their Safety, Health and Environmental Responsibilities. If the role involves managing or supervising others they must also receive a copy of the responsibilities of those grades they will be managing or supervising. Responsibilities should be explained to them by their Line Manager.

(b)

Been informed where they can access a copy of the Safety Health and Environmental procedures, and the name of the person they should contact to explain those procedures (usually their local Safety Health and Environmental Advisor).

(c)

Received general advice

(d)

Been informed of any significant findings of risk assessments for the work they will undertake.

(e)

Received inductions as required by this procedure.

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If site based, they will also need to be informed of the Safety Health and Environmental Standards and Guidance, requirements for daily briefings and communication of safety, health and environmental matters.

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AGENCY STAFF & DIRECT LABOUR

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Any special occupational qualifications or skills required to do the job, including any specific accredited training or evidence of competence.

(b)

Specific features of the job that may effect health and safety (e.g. work at heights, heavy manual handling operations, etc).

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(a)

Before starting work the line manager of agency staff or labour is required to check that they hold the necessary qualifications, and that they have been informed of any features identified to the agency as above.

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When requesting staff or labour COMPANY is required to specify to an employment agency:

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PROVISION OF INDUCTIONS BY CONTRACTORS’ PERSONNEL

(To be read in conjunction with guidance in Section 4)

15

Only in exceptional circumstances will contractors be allowed to undertake COMPANY site induction training. Agreement of the appropriate Project Manager and Safety, Health and Environmental Team will be required.

16

Where a contractor delivers this training COMPANY will provide contractors with sufficient site specific details to enable the training to be properly conducted. The same records will be maintained as would be if COMPANY were undertaking the training, including any test results.

17

In addition to the COMPANY Induction contractors may undertake their own induction training to their own staff or sub-contractors.

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TEMPORARY COVER 18

Whenever temporary cover is provided for a post, particularly posts with key safety, health and environmental responsibilities, the immediate Line Manager shall ensure that the person undertaking the temporary cover is fully conversant with, and inducted in, the safety, health and environmental responsibilities of their temporary position. The responsibility to ensure this training has been delivered to the temporary post holder remains with the Line Manager, even if the delivery is delegated to the outgoing post holder or another. SAFETY, HEALTH AND ENVIRONMENTAL TRAINING ARRANGEMENT Safety, health and environmental training will be arranged by the relevant Training Coordinator, who will also maintain safety, health and environmental training records. The only exception to this will be project specific site inductions which will be arranged and delivered by site personnel, with records maintained on site.

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See SHE-PRO-005

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PLANT AND MACHINERY

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RECORDS

Records of training, including all inductions, will be maintained to provide proof of inductions and training, also these records will allow accurate planning for future training needs. Records will include evidence such as copies of certificates or tests (where they have been used) and will be maintained on site and where appropriate forwarded to the Training Co-ordinator.

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Project Introduction to Health & Safety at Work SHE-FRM-6-02. (

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2.3.6.4 Guidance To This Procedure This procedure and the roles and responsibilities highlighted within it aim to ensure that a consistent and relevant level of safety, health and environmental inductions and training is provided across the business.

2

One vital element required to achieve this aim is in the delivery of the inductions, this is often one of the first contacts with personnel working on COMPANY projects/sites and as such is the opportunity to engage with people and to set out the culture required to achieve a safe environment.

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Delivery of inductions may not be an easy task for individuals to perform and to aid with this process the Safety Health and Environmental Team has produced a short training session for personnel who may be required to undertake this operation, it is then envisaged that only these personnel should carry out the inductions as far as possible. This process will then produce a standardised, consistent and comprehensive approach to inductions throughout COMPANY

4

Evaluation of understanding of the induction is useful in gauging retention of information and to highlight any areas of confusion or further clarification, an example of a format that may be utilised is form SHE-FRM-6-02 (

5

).

Clarification of understanding may also be obtained via the use of questions and answers amongst the participants both during and at the completion of an induction. For further

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Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

Page 10

advice and clarification on the type and circumstances of use of evaluation contact the Safety, Health and Environmental Team. Following a number of incidents it has become necessary to ascertain if inductees working under the control of COMPANY have any health issues that may affect their work, such issues can include for example :

(b)

Taking medication that makes you feel drowsy

(c)

Diabetes

(d)

Epilepsy

(e)

Lone working restrictions

(f)

Issues First Aiders need to know about, etc

On the induction record sheet SHE-FRM-6-02 there is a space for this information. The completed sheet must be kept in a secure, locked location on the project and regularly reviewed so that data that is no longer relevant can be appropriately destroyed. (

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(a)

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2.3.6.5 Reference Documents FORMS

Project Introduction to Health & Safety at Work and Induction Evaluation SHE-FRM-6-02

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DOCUMENTS

Qatar Regulatory Document (Construction) All Sections

3

Safety Health and Environmental Policy Statement & SHE Responsibilities

4

Safety Health and Environmental Standards & Guidance

5

Safety Health and Environmental Training Strategy and Matrix

6

Visitors Induction Format & Guidance

7

Site Specific Induction Format & Guidance

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Active Behavioural Change Induction & Guidance

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Supervisors Induction & Guidance

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Office Induction Format

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Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

2.3.6.6 Author SECTION

POSITION IN COMPANY

NAME

CONTACT DETAILS

POSITION IN COMPANY

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SHEQ Director

SIGNATURE & DATE

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NAME

Approved by:

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2.3.6.7 Approvals

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Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

Page 12

Accurate completion of this form will enable us to make the necessary provisions without delay (PLEASE GIVE SITE/MOBILE CONTACT NUMBER)

Name:

Site/Dept:

Job Title:

Staff/Hourly Paid:

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Please state why the person requires training.

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If a specific course is required give full details below.

Fee:

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Course Title

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Course organiser

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Location of course

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Preferred dates

Signed by Trainee

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Signed by Nominating Manager

Send copies of arrangements to: Authorisation for Booking and Cheque for £

made payable to:

Approved/not approved

Date Director

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QCS 2014

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RECORD OF INDUCTION ATTENDANCE  

CARRIED OUT BY(print:name)………………………………………

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DATE OF INDUCTION: …………………………………………

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NAME of attendee: (capitals) Mr. Mrs. Ms ……………………………………… HOME POSTCODE (First 3 digits) …………………… EMPLOYED BY (company name); : …………………………………………………………………………………………………………………………….

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OCCUPATION; ……………………………………………………………………… NUMBER OF YEARS IN OCCUPATION:………….

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EVIDENCE OF COMPETENCY HELD:…………………………………………………………………………………………………………………….

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NUMBER AND EXPIRY DATE : ……………………………………………………………………………………………………………………………..

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Is attendee a SUPERVISOR OR OPERATIVE (state which)……………………………………………………………………………………………………

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Please detail below any medical condition(s) that may affect your normal day to day activity or require specialist attention or medication during your working day.

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For example:, Taking prescribed medication may make you feel drowsy; and expose you to potential danger. If you have Diabetes or Epilepsy this may require us to implement, for example Lone Working Restrictions in case of a potential seizure. …………………………………………………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………………………………………………… SIGNATURE of attendee

……………………………………………………………………Date……………………………………………. Please be assured that any medical information you provide will be treated as confidential, securely stored and disposed of when no longer required, in accordance Company procedures. It is requested solely for the purpose of assisting COMPANY to maintain its duty of care obligations to all individuals working on our sites and will enable us to provide appropriate support as required. Induction Evaluation (please tick appropriate answer)* 

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Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

Who can operate mobile plant on COMPANY sites?

1.

The nearest person to it when it needs to be moved

2.

Anyone with a car driving licence

3.

Page 14

Q5

What is needed to achieve Perfect Delivery?

1.

Four cornerstones completed

2.

Three out of the four cornerstones completed

Only suitably trained, certificated and appointed drivers

3.

Two out of Four as long as plan is in place to complete

4.

Anyone with 30 years experience on a building site

4.

What event the client allows

Q2

If you have any doubt about your task you should?

Q6

Who could potentially be affected if you had an accident

1

Use your best guess and carry on.

1.

Yourself

2

Don’t start work, stop and ask.

2.

Yourself and your colleagues

3

Follow what everyone else is doing.

3.

Yourself, colleagues, family, friends & anyone else connected

Q3

What mandatory P.P.E must be worn on this site?

Q7

Where should re-fuelling of plant take place

1.

Hard hat and Safety footwear

1.

Anywhere

2.

Hard hat, safety boots, hi – viz jacket, eye protection and gloves

2.

Where directed and in designated area

3.

Hard hat, ear protection and safety boots

3.

In parking area for plant

4.

Hard hat, eye protection and gloves

Q8

The COMPANY LIFE programme asks for your help by

Q4

Which of the following should be reported immediately?

1.

Being responsible for you and your workmates

1.

Accidents

2.

Challenging unsafe behaviours

2.

Environmental incidents (spills etc)

3.

Believing we can achieve an incident free environment

3.

Learning events (near misses)

4.

Going home from work in the same condition you arrived in

4.

All the above

5.

Everything mentioned above

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Answer

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QCS 2014

Answer

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Section 11: Health and Safety Part 2.3.06: Safety, Health and Environmental Training

Page 15

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QCS 2014

Q9.

As a supervisor you must

Answer

Communication is vital in helping build a good safety culture and incident free environment, should you?

1.

Ensure that job is completed at all costs

1.

Select pieces of information that apply only to your work

2.

Ensure that there are site specific risk assessments and method statements in place before job commences

2.

Communicate with all parties anything that will impact on the operation of the site

3.

Ensure that only your own personnel are working safely

3.

Not give feedback to people raising issues

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Q10.

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Additional questions to be completed by supervisors only

Answer

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*It is appreciated this type of evaluation by testing will not fit all circumstances and arrangements, ie special works or property services but some form of evaluation must take place via discussions or interactive sessions.

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Section 11: Health and Safety Page 1 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ....................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES............................... 1

2.3.7

CONTRACTORS INITIAL SAFETY, HEALTH AND ENVIRONMENTAL MEETING 1

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2.3.7.1  Responsibilities.............................................................................................. 4  2.3.7.2  Definitions ...................................................................................................... 4 

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2.3.7.3  Actions Required to Implement This Procedure ........................................... 5 

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2.3.7.4  Reference Documents ................................................................................... 6 

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2.3.7.5  Author ............................................................................................................ 6 

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2.3.7.6  Approvals ....................................................................................................... 6 

QCS 2014

Section 11: Health and Safety Page 2 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting

Process Map Project/Site  Manager 

Contractor 

 

Supervisors 

SHE advisor 

 

.

Evaluate each Contractor Scope of Works to assess Risk Rating SHE FRM 7 02 3.1

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Where the Activity Risk Rating is high, notify the SHE Advisor

Attend Contractor SHE Meeting when required

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3.1

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Arrange for Contractors and others to attend the pre-start SHE meeting

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Review the Contractors Pre-start Agenda in line with the “Creating a Safe Environment” document and record the outcome of discussions

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3.1

Monitor the site performance against the agreed record

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3.1

Address any non-compliance noted during monitoring 3.1

Key 

Activity Guidance

3.1

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Section 11: Health and Safety Page 3 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting

PURPOSE 1

The purpose of this procedure is to provide appropriate SHE information to sub-contractors and ensure a clear and common understanding in respect of contractor’s activities, obligations, responsibilities and expectations in relation to SHE matters.

SCOPE

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This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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Section 11: Health and Safety Page 4 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting

2.3.7.1 Responsibilities SHE DIRECTOR 1

Authorises this procedure

PROJECT/SITE MANAGER Ensures that any initial safety meeting, as defined in the procedure, is carried out in accordance with this procedure and relevant information is communicated to interested parties.

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2

Provides advice and support in the application of this procedure.

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SHE MANAGER/ADVISER

SUPERVISOR/CONTRACTORS CO-ORDINATOR#

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To monitor any identified arrangements are adhered to and report any non-compliance to Contractor/Project Manager.

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Where they are responsible for the procurement of the contractor, they are to ensure that a copy of the Safe Delivery Document is included in the enquiry/tender documentation and that the contractor acknowledges receipt.

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QUANTITY SURVEYOR/ESTIMATOR/BUYER

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2.3.7.2 Definitions

CONTRACTOR

1

The organisation undertaking the activity or arranging for the activity to be undertaken.

HIGH RISK ACTIVITIES 2

Any work evaluated as High Risk on form SHE-FRM-7-02

ANY WORK INTERESTED PARTY 3

Any person/s who will benefit and/or need to know the information or arrangements that are defined in the outputs/actions from the initial safety meeting, detailed in this procedure.

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Section 11: Health and Safety Page 5 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting

2.3.7.3 Actions Required to Implement This Procedure SCOPE OF WORK 1

TheProject/Site Manager will evaluate each contractor’s scope of work to assess the Risk rating, using form SHE-FRM-7-02.

HIGH RISK ACTIVITY The Project/Site Manager will notify SHE Adviser of any meeting taking place, for High Risk activities.

3

The SHE Advisor will attend any meeting for High Risk activities when requested to by the Project Manager.

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The Project/Site Manager shall ensure the Contractor is aware of site arrangements for Safety, Health and Environmental issues by holding an initial SHE meeting prior to the Contractor commencing work on site.

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SITE ARRANGEMENTS

In conjunction with the COMPANY Safe Delivery Document each item in the checklist at SHE-FRM-7-01 – Checklist for Contractor’s Initial SHE Meeting shall be covered or deleted/struck through where not applicable, and where appropriate a record of the discussion taken.

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RECORDS

On completion of the checklist it shall be stored for record purposes and distributed to all interested parties who have duties identified within the checklist detail. This, for example, could include the Contractors Site Manager, Supervisor and Safety Manager, who needs to be informed in relation to any of the arrangements/agreements.

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RECORD STORAGE

PERFORMANCE MONITORING 7

The Project Manager / Supervisor(s) / Co-ordinator(s), shall monitor the performance of the contractor against the agreements made to ensure compliance, and report on any nonconformance.

NON COMPLIANCE 8

The Project Manager will act on any Reports to ensure the non- compliance is addressed.

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Section 11: Health and Safety Page 6 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting

2.3.7.4 Reference Documents FORMS 1

Checklist for Contractor’s Initial SHE Meeting – (SHE-FRM-7-01)

2

Risk Evaluation form – (SHE-FRM-7-02)

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DOCUMENTS Qatar Regulatory Document (Construction) RD1.1.4 and RD1.1.8

4

Standard SHE Rules for Subcontractors

5

Contract Documents

6

CDM Evaluation Information

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2.3.7.5 Author NAME

POSITION IN COMPANY

CONTACT DETAILS

SHE Manager

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SECTION

2.3.7.6 Approvals

NAME

Approved by:

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

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Section 11: Health and Safety Page 7 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting Section A

Contract:

Contract Nr.:

Venue:

Meeting Date:

Tel. Nr.

Tel. Nr.

Mobile Nr.:

Mob. Nr.:

Fax Nr.:

Fax Nr.:

e-mail:

.

Contract Address:

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Trading Address:

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Trade:

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Subcontractor Name:

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Subject to Contract The matters agreed at the pre-contract meeting, as recorded in these minutes, are not binding on the parties unless and until the issue by . …………of a Letter of Intent or Sub-Contract order. Once a Letter of Intent or Sub-Contract order is issued by …………….. the matters set out in these minutes shall be incorporated as terms and conditions of the Letter of Intent and / or Sub-Contract, as appropriate.

e-mail:

Company Representatives Present

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Subcontractor's Representatives Present Job Title

Name

Job Title

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By signing below, the Sub-Contractor’s representative is deemed to have the authority to agree to the following and hereby confirms that these minutes are a true and accurate record

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Name:

Signature:

Date

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Signature:

Name:

Is the Sub-Contractor approved within the COMPANY Pre Qualification System?:

YES

NO

Date

If NO refer to COMPANY Regional Commercial Director before proceeding with this meeting or any works

Subcontractor Staff Responsible

COMPANY Staff Responsible

Director / Principal:

Project Manager:

Manager / Supervisor:

Contract Manager

Foreman:

Foreman:

Safety Advisor

SHE Advisor:

First Aider:

First Aider:

The Sub-Contractor proposes to Sub Let the following works The prior written consent of COMPANY is a condition precedent to any sub letting or assignment of the Sub-Contract works or any part thereof. Item to be Sub Let

Company Details

QCS 2014

Section 11: Health and Safety Page 8 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting Section B SCHEDULE OF ATTENDANCE

CONTRACT…………………………………………..CONTRACTOR………………………………………….. Item

N/A

Provided by ………..

Contractor

Maintained By …………

Contractor

Records & Inspections By ………….. Contractor

Mechanical Plant Small tools and tackle Access Scaffold Cradles/Suspended Access Equipment Mobile Elevated Work Platforms

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Public Protection / Fans etc

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Bandstands, hop-ups etc Safety Scaffold

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Roof edge protection

N/A

N/A

N/A

N/A

Distribution of materials

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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Unloading

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Hoist Piling mat Crane facility

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Lifting gear Offices, stores etc

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Space for offices, stores etc 1st Aid equipment

N/A

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First aid room

N/A

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Water Supply Electrical Power 110v

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Leads, spiders etc Safety Lighting

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Task Lighting Set out grid lines and levels

N/A

N/A

Clear rubbish to centre point

N/A

N/A

N/A

N/A

Clear away rubbish on a daily basis

N/A

N/A

N/A

N/A

Skips

N/A

N/A

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Set out from grid lines and levels

N/A

N/A

Protection of work in progress

N/A

N/A

Protection of work on completion Remove temporary protection (from other trades) and make good

N/A

N/A

Holes and chases (mark/cut) Signed for COMPANY

Signed for Contractor

Date:

Date:

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

QCS 2014

Section 11: Health and Safety Page 9 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting Section C

Scope & Definitions The purpose of the meeting is to ensure that there is a clear and common understanding as to the package contents, respective obligations, responsibilities and expectations. The term “Contractor” throughout these minutes shall mean the prospective Sub-Contractor named above, and subject to the requirements of section A the agreements reached shall apply to ALL sub-sub-contractors appointed by the sub-contractor to carry out works on his behalf. All Reference to numbered rules in this document are the rules contained ………………. Creating a Safe Environment Document, which has been issued to the subcontractor and forms part of the Sub-contract and Suppliers conditions. Matters for Discussion (Delete Where Not Applicable)

Manager / Supervisor

(b)

Forman / Foremen

(c)

Site Safety Supervisor

(d)

Temporary Works Co-ordinator

First Aiders

(g)

Emergency/Fire Marshall

(h)

Waste Controller

(i)

Scaffold Inspector

(j)

Electrical Duty Holder

(k)

Safety Advisor / Supervisor

(l)

Services Co-ordinator

(m)

Plant Co-ordinator

(n)

Appointed Person for Cranes

(o)

Crane Supervisor/s

(p)

Induction Presenter

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(f)

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COSHH Co-ordinator

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Temporary Works Supervisor (e)

Contractor

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(a)

COMPANY

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Appointed Persons & Duty Holders The following persons were identified as carrying out the specified roles for the Contractor on this project.

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Notes / Actions (Agreement Reached or N/A)

Where these names are not known at this time they are to be advised to ……………….. in writing not less the 2 weeks prior to commencement of the Contractors Works. Failure by the Contractor to notify by this time may delay the start of the contractors works.

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Section 11: Health and Safety Page 10 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting Section D

1

General

…………… to provide the Contractor with a copy of the Project’s Construction Phase Plan and/or specify where available on site.

Copy provided / Available in …………. site office

Health & Safety File / Operational & Maintenance Manuals / As installed Drawings The Contractor is to supply the following to be included in the CDM Safety File

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Details to be added as appropriate to the project

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All information is to be Delivered to ……………….. as specified by the Project manager and in any case within 14 days of the completion of the contractor's works, or 7 days before the practical completion date of the project which ever is the sooner. OR*

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………………… confirmed that these are not required.

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The contractor will be issued with a copy of the COMPANY Document “Creating a Safe Environment” which contains reference in the form of Rules to the topics listed below.

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The COMPANY Manager and the representative of the Contractor at this meeting will review the Creating a Safe Environment Rules and indicate:-

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1. Whether the rule applies to the contractors works , and

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2. The contractors understanding and agreement to those applicable rules.

In addition to these rules some of the topics require further site specific details to be agreed, these specifics are contained in Section E of this document and where applicable the attendees must discuss these items and reach agreement or detail the actions to be taken in the relevant sections, in order for the works to be carried out in a controlled and safe manner. Where agreement cannot be reached then the work must not proceed until persons of appropriate seniority have discussed and assigned actions to enable the works to be carried out safely and without risk.

QCS 2014

Section 11: Health and Safety Page 11 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting Applicable Yes / No

Item / Rule Entry to site

Yes / No

3.0

Site Safety, Health and Environmental supervision and visits (see additional information in section E)

Yes / No

4.0

Safety, Health and Environmental training, instruction and competence (see additional information in section E)

Yes / No

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Housekeeping (see additional information in section E) Fire precautions (see additional information in section E) Personal Protective Equipment (see additional information in section E) Hazardous substances (see additional information in section E) Environmental impact Waste management (see additional information in section E) Work at height (see additional information in section E) Scaffolding and safe means of access Mobile Plant Other plant and equipment (see additional information in section E)

Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

.

First aid and welfare facilities Pre-agreement as to safe work procedures (see additional information in sectio E) Permits to work (see additional information in section E)

Lifting operations and lifting equipment (including Piling)(see additional information in section E)

Yes / No

19.0

Excavations and confined spaces

Yes / No

20.0

Electrical work (see additional information in section E)

Yes / No

21.0

Noise at work

Yes / No

22.0

Asbestos

23.0

Explosives and sources of ionising radiation

Yes / No

24.0

Services and operating processes

Yes / No

25.0

Substance abuse

Yes / No

26.0

Reporting of accidents and dangerous occurrences

Yes / No

27.0

Statutory improvement, prohibition and other notices

Yes / No

28.0

Safety representatives, safety committees and worker engagement

Yes / No

29.0

Non-English speaking personnel

Yes / No

30.0

Temporary works/false work/formwork (see additional information in section E)

Yes / No

31.0

Manual Handling

Yes / No

32.0

Demolition (see additional information in section E)

Yes / No

33.0

Vehicle drivers including delivery drivers

Yes / No

34.0

Installation and commissioning of lifts

Yes / No

35.0

Working in occupied premises

Yes / No

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18.0

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5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0

Yes / No

Agreement & Understanding Confirmed (9)

QCS 2014

Section 11: Health and Safety Page 12 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting

Section E Additional Topics to be discussed in Detail and agreement reached

INSPECTIONS & AUDITS

Yes /No

THE CONTRACTOR AGREED TO UNDERTAKE REGULAR SITE SHE INSPECTIONS AT A FREQUENCY AGREED BY COMPANY.

The Contractor indicated that he would be undertaking Senior Manager SHE inspections / audits.

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The following requirements were confirmed to the Contractor

Yes / No

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The contractor will be encouraged to participate in the COMPANY VOICE consultation process and COMPANY Behavioural Change Programme which will be / is running on this project.

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The contractor and COMPANY agreed a schedule for the submission of SHE Method Statements prior to commencement of the work activity (attach schedule to these minutes)

Yes / No

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PRE-AGREEMENT AS TO SAFE WORK PROCEDURES RISK ASSESSMENT/SAFETY METHOD STATEMENT

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The following requirements were confirmed to the Contractor

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The attached Method statement review form will be used to assess the completeness of the Contractors Method statements, the contractor should ensure that all the relevant points noted on the review sheet are addressed.

7

Permit to Work

7a

The following permits will operate on this project:-

QCS 2014

Section 11: Health and Safety Page 13 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting

8

Housekeeping & Clearance of Rubbish

8a

The storage area for the Contractors materials was agreed as.

9

Liquefied Petroleum Gases / Welding and Cutting

Yes / No

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The contractor will be bringing LPG to site

Yes / No

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The contractor indicated he would be carrying out welding / cutting operations

Flammable Liquids and Compounds

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9b

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The location of the storage for gas bottles was agreed with COMPANY site management as

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If Yes the contractor is to provide detail

Yes / No

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Are any types of flammable liquids or compounds e.g. petrol, diesel, Solvents, mastics etc. to be brought to site by the contractor

Personal Protective Equipment

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The location of the storage for flammable liquids etc was agreed with COMPANY site management as

COMPANY will provide PPE to the contractor as a last resort but will charge the contractor at the following rates; Safety Helmets Hi Viz Vest Standard Gloves Standard Light Eye Protection Ear Protection (Muffs) Safety Boots Other (Specify)

Hazardous Substances 11

Does work involve the use of any substances that can give rise to hazards in use?

Yes / No

QCS 2014

Section 11: Health and Safety Page 14 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting

If Yes the contractor is to provide detail 11a

11b

COMPANY provided a list of substances to Contractor that may affect his employees on site, including land contamination or biological hazards. List to be attached to this document

12

Environmental Impact

12a

Yes / No

Yes / No

Are any substances being used that may harm the environment

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If Yes Details are to attached to this document

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Are there any contaminants which may affect the Contractor’s working area? 12b

Yes / No

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If yes COMPANY are to supply details and a list is to be attached to this document

Waste Management

13a

The Contractor was informed of the locations of disposal skips & the recycling arrangements which will be adopted & the arrangements for temporary storage.

Yes / No

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Work At Height

14a

Specify any access equipment e.g. elevating platforms, MEWPS or facilities for safe working places e.g. scaffolding, edge protection to be used by the Contractor’s.

18

Piling Operation

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The Contractor supplied details and specification of the Piling Mat

Yes / No

If yes a copy is to be attached to this document

20

Electrical Work A Copy of The COMPANY Rules for Electrical Safety (RES) has been issued to the contractors as the works they are undertaking involve the provision of or connection to electrical systems or equipment

Yes / No

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22

Section 11: Health and Safety Page 15 Part 2.3.07: Contractors Initial Safety, Health and Environmental Meeting

Asbestos It has been identified that this project / building contains Asbestos Containing Materials (ACMs). If yes the contractor was made aware of the requirement for ALL persons who work on this Project to have suitable asbestos awarness training. NB any person not able to provide evidence will not be admitted to site.

Temporary Works / Falsework / formwork Yes / No

The contractor confirmed that he will be designing the Temporary Works and therefore will have additional duties under CDM.

Yes / No

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The Contractor confirmed that his work will require elements of temporary works.

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The contractor confirmed his appointed Temporary Works Supervisor for his works is:

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TEMPORARY WORKS DESIGN

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If the contractor has indicated that temporary works design will be included in their scope of works the following information should be provided for the design staff to be employed on this project (direct and agency) and the breakdown of relevant qualifications and experience. Employer

Discipline

Qualifications / Experience

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Name

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Yes / No

The following requirements were confirmed to the Contractor A Temporary Works Co-ordinator has been / will be appointed. The Contractor’s full co-operation is required in helping to ensure that his duties can adequately be fulfilled.

QCS 2014

Section 11: Health and Safety Page 1 Part 2.3.08: The Report and Investigation of Accidents and Incidents

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ....................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES............................... 1

2.3.8

THE REPORT AND INVESTIGATION OF ACCIDENTS AND INCIDENTS ...... 1

.

2

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2.3.8.1  Responsibilities.............................................................................................. 4 

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2.3.8.2  Definitions ...................................................................................................... 4 

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2.3.8.3  Action to Be Taken To Implement This Procedure ....................................... 5 

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2.3.8.4  Appendices .................................................................................................. 12  2.3.8.5  Reference Documents ................................................................................. 20 

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2.3.8.6  Author .......................................................................................................... 20 

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2.3.8.7  Approvals ..................................................................................................... 20 

QCS 2014

Section 11: Health and Safety Page 2 Part 2.3.08: The Report and Investigation of Accidents and Incidents

PROCESS MAP Project/Site  Manager   

Contract  Manager/Director 

SHE  Manager/Adviser/Dept 

 

Client/Regulatory  Bodies 

Human  Resources 

MIT 

Insurers 

  Incident Control

Determine type and nature of incident/occurrence

1.3, 3.12

. Receive First Alert

Contact Regulators as required

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Contact Regulators as required

Tie in with any contractual reporting requirements

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Receive First Alert

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Inform all relevant parties by first alert (within 24 hours)

Provide support, as circumstances dictate

Investigation of Anon emergency procedures including consider use of company emergency telephone number and informing Company Media Representative

If appropriate obtain a copy of the F100 and distribute to relevant parties

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3.1, 3.2, 3.3

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Receive copy of F100/A

3.1, 3.2, 3.3

 

Receive copy of Accident Register/Book

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3.7

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If appropriate, complete and forward accident book form to Regional Office

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Involvement of Comapny SHE Director, as circumstances dictates

Agree requirement for investigation and report based on outcome and/or potential 3.1, 3.2, 3.3, 3.4, 3.5

Carry out investigation, prepare report action plan and distribute as required. (Interim report to be issued within 7 days of incident)

Provide detail, if required

Provide detail, if required

3.1, 3.2, 3.3, 3.4, 3.5 Produce Monthly Returns form and send to SHE Department 3.8

Key 

Activity Guidance

Log into data base

Receive information for processing

Receive copy of F100/A and Investigation Report

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Section 11: Health and Safety Page 3 Part 2.3.08: The Report and Investigation of Accidents and Incidents

PURPOSE 1

The purpose of this procedure is to focus on the potential of incidents, NOT just the outcome, and to assign responsibilities and establish a system for the reporting and investigation of Safety, Health or Environmental accidents/incidents, diseases, dangerous occurrences and learning events as required by both Qatar Legislation (RIDDOR) and COMPANY and client requirements.

SCOPE

.

This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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Note: Qatar Civil Defence and the Environment Ministry have responsibilities and authority in relation to the reporting of fires and environmental impacts, respectively.

QCS 2014

Section 11: Health and Safety Page 4 Part 2.3.08: The Report and Investigation of Accidents and Incidents

2.3.8.1 Responsibilities SHE DIRECTOR 1

Authorises this procedure and decides whether an incident review is necessary. He may also delegate responsibility for chairing this review.

CONTRACTS DIRECTOR / MANAGER Provides support in the application of this procedure, assists the Major Incidents Team (MIT) in the investigation process and the production of reports.

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2

Ensures that any reporting and investigation of an incident is carried out in accordance with this procedure (and any associated client procedures), and that appropriate contact is made with the SHE Department and other interested parties

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3

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PROJECT/SITE MANAGER

Provides advice and support in the application of this procedure, assists the Project/Site Manager and the Major Incidents Team (MIT) in the investigation process and the production of reports.

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4

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SHE ADVISER / MANAGER

To report all accidents, incidents, diseases, dangerous occurrences and learning events to the appropriate person.

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5

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EMPLOYEE / CONTRACTOR EMPLOYEE

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2.3.8.2 Definitions

CONTRACTS MANAGER

1

Project or Office based Manager overseeing a number of projects.

PROJECT / SITE MANAGER 2

For the purposes of this procedure, Project / Site Manager may also mean Depot Manager or Office Manager.

MAJOR INCIDENT TEAM (MIT) 3

A team appointed by the Regional Managing Director to investigate all major incidents in line with the matrix in Appendix 5.

QCS 2014

Section 11: Health and Safety Page 5 Part 2.3.08: The Report and Investigation of Accidents and Incidents

RIDDOR 4

Qatar Regulatory Document (Construction) Report of Injuries, Diseases and Dangerous Occurrences

LEGAL REPRESENTATION 5

A firm of Solicitors, approved by the Company.

LEGAL PRIVILEGES

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ACCIDENT / INJURY CLASSIFICATION

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Classification of accidents and injuries are detailed in Appendix 2.

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7

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Any report formed under request from legal representation.

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2.3.8.3 Action to Be Taken To Implement This Procedure

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REPORTING AND INVESTIGATING A MAJOR ACCIDENT/INCIDENT (FATAL ACCIDENT OR MAJOR INJURY) – PROJECT / SITE MANAGER Ensure first aid is provided and an ambulance is called and/or medical attention administered.

2

Where advised by the appointed 1st Aider, do not move the person unless this is absolutely essential.

3

Ensure that the scene of the accident is not interfered with. Cordon off area wherever possible (instruct line supervision accordingly).

4

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1

Contact your SHE Adviser / Manager. The SHE Adviser / Manager will inform the MIT and prior to commencing the investigation and following consultation with the SHE Manager / Director, will advise our legal representatives.

5

If an COMPANY employee is involved, notify HR Department who will arrange for notification of relatives of the person concerned as soon as possible and preferably by personal visit by someone who knows the family etc.

6

Obtain photographs of the area. (Any digital prints may be verified by date and signature.)

7

In conjunction with SHE Adviser / Manager, complete/send First Alert form SHE-FRM-8-01 to ensure that relevant persons are informed (see distribution list on First Alert form).

8

Complete the accident book entry report. (Accident Investigation Report Part 1, AIR SHEFRM-8-03)

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9

Section 11: Health and Safety Page 6 Part 2.3.08: The Report and Investigation of Accidents and Incidents

If appropriate : (a)

Consider also any specific client requirements.

(b)

Contact the COMPANY Emergency Media Telephone Number.

REPORTING AND INVESTIGATING A FATAL ACCIDENT OR MAJOR INJURY – SHE MANAGER /ADVISER Ensure that the Qatar Labor Ministry, Workplace Inspector has been informed. applicable ensure that the Police have been informed.

Where

11

Inform SHE Director / SHE Manager.

12

Carry out an immediate investigation of the accident in conjunction with MIT.

13

Ensure that a copy of the form F100 is completed and sent to the Labor Ministry within 10 days of the accident, or in the case of a non COMPANY employee, obtain a copy from their employee and ensure that a copy is forwarded to the COMPANY Insurer.

14

Ensure copies of any relevant reports and forms are forwarded to the SHE Department.

15

Complete an AIR Part 1 SHE-FRM-8-02 and 2 SHE-FRM-8-03 and agree distribution with the Business SHE Manager.

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REPORTING AND INVESTIGATING AN OVER 3 DAY INJURY – PROJECT / SITE MANAGER Ensure first aid is provided and an ambulance is called and/or medical attention administered.

17

Where advised by the appointed 1st Aider, do not move the person unless this is absolutely essential.

18

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16

Investigate cause of accident, record physical evidence, and take steps to prevent recurrences.

19

Inform the SHE Department and Contracts Manager as soon as the accident becomes a possible “over 3 day reportable”.

20

In conjunction with the SHE Manager / Advisor complete Accident/Incident First Alert report form and distribute.

21

Obtain from any sub-contractor a copy of the F100.

22

Report the accident in the accident book and send a copy to the SHE Department and Insurance Broker.

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23

Section 11: Health and Safety Page 7 Part 2.3.08: The Report and Investigation of Accidents and Incidents

Agree with the SHE Manager / Adviser who will produce the investigation report and the timing of this, including any interim report if necessary.

REPORTING AND INVESTIGATING A NON RIDDOR REPORTABLE ACCIDENT (‘LOST TIME INJURY’ AND ANY OTHER PERSONAL ACCIDENT) – PROJECT / SITE MANAGER Ensure first aid is provided and an ambulance is called and/or medical attention administered.

25

Where advised by the appointed 1st Aider, do not move the person unless this is absolutely essential

26

Investigate cause of accident, record physical evidence and take steps to prevent recurrence.

27

Inform the SHE Department of such incidents.

28

Record and report the accident on the accident book form and send a copy to the SHE Department together with any supporting evidence/documentation.

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24

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REPORTING AND INVESTIGATION OF AN INCIDENT/NEAR MISS/LEARNING EVENT – PROJECT / SITE MANAGER / SHE ADVISER / MANAGER Where a near miss, learning event is observed, the process detailed in SHE-PRO-016 should be followed.

30

If appropriate to the circumstances the Project / Site Manager / SHE Adviser / Manager will complete First Alert report and circulate as appropriate.

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31

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PROCEDURES– CONTRACTORS (SUB/WORK PACKAGE), THIRD PARTIES, ETC Procedures above apply.

32

These contractors are expected to carry out their own reporting and investigation procedures but we must ensure that it is done. Where the contractor is obliged to report accidents, they shall be requested for a copy of the report to COMPANY site management who will forward to the SHE Department.

33

According to the severity or potential of the injury or the level of environmental damage the contractor may be requested to carry out a joint investigation. This will be decided in discussion with the Contractor.

34

Reporting/Investigating of Accidents to the General Public/Third Parties

35

Follow the procedure as Section 3.i to 3.iv above as appropriate to the category and ascertain the type of injury and hospital details, etc.

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Section 11: Health and Safety Page 8 Part 2.3.08: The Report and Investigation of Accidents and Incidents

ACCIDENT BOOK/REGISTER Site management shall control and verify entries made in the COMPANY accident book and ensure that copies are forwarded as soon as possible after they are made to the SHE Department.

37

All notified accidents shall be entered in the COMPANY accident book including all employees, contractors, visitors to site and accidents to members of the public.

38

Remember, some accidents, which seem minor at the time, may be important long after the particular contract is finished and hence full information becomes essential.

39

Accident books must be retained for at least three years from the date of the last entry in the book.

40

The accident book must be sent to archive at the end of the contract with the rest of the contract documents.

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36

The Project / Site Manager is responsible for the completion of the SHE Return and this shall be sent to the SHE Department as soon as possible after the month end but no later than the second working day of the following month.

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41

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MONTHLY SHE RETURNS

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In the event of a reportable disease being advised by a Doctor, the Project / Site Manager must: Ensure that the SHE Department is notified.

(b)

After consultation with the SHE Adviser / Manager carry out an immediate investigation and prepare a written report with emphasis on preventing recurrence of the problem with a copy to the SHE Department.

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(a)

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42

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DISEASES - PROCEDURES

(c)

After completing above, arrange with the SHE Adviser to complete and forward form F100A to the appropriate Labor Ministry Department with a copy to the SHE Department within 10 days. In the case of COMPANY employees, forward a copy to the Insurance Broker.

(d)

A disease needs to be reported only when a written statement prepared by a Registered Medical Practitioner diagnosing the disease is in line with the Qatar Regulatory Document (Construction) RIDDOR Section.

DANGEROUS OCCURRENCES (SPECIFIED BY RIDDOR) - PROCEDURES 43

If injury to person is also involved, carry out procedure under Section 3.1 to 3.4 as appropriate.

44

For all events, consult with the SHE Manager / Adviser for the full list of specified Reportable Dangerous Occurrences.

QCS 2014

45

Section 11: Health and Safety Page 9 Part 2.3.08: The Report and Investigation of Accidents and Incidents

All Dangerous Occurrences shall be investigated by the Site / Project Manager in conjunction with the SHE Department :

ALL DANGEROUS OCCURRENCES Do not interfere with the scene of the accident.

47

Notify the Contract Manager and SHE Department immediately and discuss whether reportable.

48

If appropriate contact the COMPANY Emergency Media Telephone Number.

49

Obtain written statements for witnesses where possible.

50

Obtain photographs of the area and record physical evidence.

51

Report accident on the form from the accident book with a copy to the Insurer.

52

Reportable Dangerous occurrences shall be reported by the SHE Department will inform the Qatar Administrative Authority. The Administrative Authority, Workplace Inspector will advise whether and when you can resume work in the area.

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In addition to the above:

The Manager, in consultation with the SHE Manager / Adviser, shall report the occurrence on First Alert report form and distribute as appropriate.

(b)

The Manager, in consultation with the SHE Manager / Adviser, to complete Form F100 and send to the Qatar Administrative Authority within 10 days.

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(a)

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DANGEROUS OCCURRENCES REPORTABLE UNDER RIDDOR

54

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REPORTING & INVESTIGATING ENVIRONMENTAL INCIDENTS - PROCEDURE To assist the reporting process, environmental incidents have been categorised and examples of each type of category are listed in Appendix 1 (guidance document).

55

For all environmental incidents, consult with the SHE Manager/Environmental Adviser for advice.

56

Following an environmental incident, complete the reporting requirements as detailed below : (a)

If it is a significant/serious incident then completes a First Alert form as per section 3.12 (note examples of types of environmental incidents requiring First Alert).

(b)

In addition, less serious incidents must also be recorded and reported monthly as per section 6.8, to enable COMPANY to monitor and measure environmental performance.

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Section 11: Health and Safety Page 10 Part 2.3.08: The Report and Investigation of Accidents and Incidents

(c)

Where deemed necessary, a formal Investigation report shall be completed as per section 3.13 and 3.5 in cases of Learning Events

FIRST ALERT PROCEDURES 57

COMPANY operates a ‘First Alert’ system to ensure that serious incidents are notified quickly to the relevant personnel.

58

A First Alert form should be completed for the following circumstances: Fatal accidents;

(b)

Major Injury accidents;

(c)

Over 3 Day Injury;

(d)

Dangerous Occurrences;

(e)

Following receipt of enforcement notices from any enforcing authority either by the Company or its sub-contractors;

(f)

All accidents and incidents, including those resulting in significant damage to the environment, where prosecution is likely or where substantial loss has occurred or where public attention is likely.

(g)

Significant Learning events (near misses).

(h)

Visits by a Regulatory Authority

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(a)

If however, doubt exists whether or not to send a First Alert then it should be sent. It is the responsibility of the Regional SHE Adviser / Managers to ensure the First Alert is circulated to respective COMPANY post holders. Further circulation will be agreed with the relevant SHE Managers.

60

All First Alerts shall also be copied to the COMPANY SHE Director.

61

First Alerts shall be sent as soon as possible after the accident/incident has become known to the Company and in any case WITHIN 24 HOURS.

62

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The Project/Site Manager shall contact the SHE Manager/Adviser for their site to provide support on the information required for the First Alert.

ACCIDENT/INCIDENT INVESTIGATION REPORTS 63

It is important that accidents/incidents are properly investigated by the Project Management Team to determine what has happened and any actions needed to improve performance.

64

It is of the utmost importance that actions arising from an investigation are fully closed out. This is the responsibility of the Project / Site Manager to produce a written report in conjunction with the local SHE Manager / Advisor.

65

Formal investigations will be necessary:

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Section 11: Health and Safety Page 11 Part 2.3.08: The Report and Investigation of Accidents and Incidents

(a)

for accidents/incidents reportable under RIDDOR;

(b)

where prosecution or other formal enforcement action is being taken/is considered likely;

(c)

where, although not reportable, there was potential for more serious consequences or there are wider lessons to be learned (such as near miss/learning event incidents)

(d)

Significant pollution/damage to the environment has been caused

The decision on whether to conduct a formal investigation should be taken in conjunction with the relevant SHE Manager / Advisor.

67

Reports on accident/incident investigations should be written in the format set out on the Accident/Incident Investigation Report form. (Notes for guidance for completing the AIR are also included with this form). In cases where witness reports are taken to support the investigation, these should also be included.

68

For any incident and subsequent investigation, a completed or interim report shall be issued within 7 days from the date of the incident.

69

Distribution of completed accident/incident investigation reports must include the COMPANY SHE Director. Any distribution outside COMPANY should be agreed with the SHE Director who will provide the necessary direction

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Section 11: Health and Safety Part 2.3.08: The Report and Investigation of Accidents and Incidents

Page 12

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2.3.8.4 Appendices

ENVIRONMENTAL INCIDENT TYPE

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EXAMPLE

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APPENDIX 1 – GUIDANCE ON CATEGORIES OF ENVIRONMENTAL INCIDENTS

Any Spillage of Fuel / Oil / Chemicals / Soap Oil etc. 3Day

Major

COMPANY Sub-Contractor / Other Hours/Employees Av. No. Direct Employees – DAY SHIFT

Contractor Employees Hours Worked – DAY SHIFT

Av. No. Contractor Employees – DAY SHIFT

Direct Employees Hours Worked – NIGHT SHIFT

Av. No. Direct Employees – NIGHT SHIFT

Contractor Employees Hours Worked – NIGHT SHIFT

Av. No. Contractor Employees – NIGHT SHIFT

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Direct Employees Hours Worked – DAY SHIFT

Training/Inductions

No. of Persons with Skill Cards – Direct Employees

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No. of Inductions – Direct Employees

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No. of Inductions – Contractors/Others No. of Supervisors Inductions – Direct Employees

No. of Toolbox Talk Attendees – Contractors/Others

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Proactive Indicators

Yes

No

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Do you hold Employee Safety Meetings

Total No. of Toolbox Talks Undertaken No. of Toolbox Talk Attendees – Direct Employees

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No. of Supervisors Inductions – Contractors/Others

No. of Persons with Skill Cards – Contractors/Others

No. of Employee Safety Meeting

No. of Representatives

No. SHE Advisor Inspections Undertaken – Sub-Contractors

No. of Issues Raised

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No. of SHE Advisor Inspections Undertaken – COMPANY

No. of Issues Closed Out

No. of Leadership Assessments Undertaken

No. of SHE Procedural Audits Carried Out

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No. of Project SHE Inspections Undertaken (Managers/Supervisors)

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SHE Procedure Ref. No.

Environmental Indicators Electricity (Kilowatt Hours)

Fuel Oil (Litres)

Waste Generated

Gas (Kilowatt Hours)

Water (Cubic Metres)

Construction

Demolition

Excavation

Construction

Demolition

Excavation

Project Waste Generated – Inert (tonnes) Project Waste Generated – Non Hazardous (tonnes) Project Waste Generated – Hazardous (tonnes) Waste Management Project Waste to Landfill (tonnes) Project Waste Recycled Off Site (tonnes) Material Re-Used Directly on the Project (tonnes)

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Section 11: Health and Safety Page 32 Part 2.3.08: The Report and Investigation of Accidents and Incidents

To be completed by Manager/Supervisors for damages to underground services Contract Location :

Manager :

Date of Incident:

Time of Incident:

1.

Type of damage (9)

2.

Where was the damage? (9)

Electric

Gas

Telecom

Water

…

…

…

…

Service

Main

…

…

Other (please state)

… Other (please state)

…

State type (e.g. PE, Ductile Iron, Steel, Lead, etc) :

For electric cables / telecom / fibre optic cable (if known) Street Lighting

State voltage of electric cable (if known) (9)

…

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5.

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4.

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For gas/water/drainage What diameter was the main or service? 3.

Was the cable in a duct?

… …

… …

No

No

…

…

Power Mode

Radio Mode

Genny Mode

…

…

…

7.

What mode did the team use? (9)

8.

Locator No:

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Was a cable locator used prior to excavation?

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…

Other (please state)

Yes

6.

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415v

Yes

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If yes, please state number of ducts…

240v

Calibration Expiry:

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What is the number of the locator and is it in calibration? Genny No: Calibration Expiry:

Yes

… … …

No

et

9.

Were trial holes dug?

Yes

…

No

The services had been marked i.e. crayon / spray paint / other

Yes

b)

Plans were issued

Yes

Plans were accurate and they cover the working area

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c)

10.

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Was there evidence to show :a)

No No

… … … … metres

If yes, at what depth were they dug?

Was the service … 11.

12.

13.

a)

Encased in concrete

Yes

b)

Under concrete

Yes

c)

Under tarmac

Yes

d)

Unmade ground (verge)

Yes

… … … …

No No No No

What was the depth of the underground service damaged? Were there any visible features above or below ground to assist in location of service e.g. covers/boxes, etc If yes, what were they?

… … … … metres

Yes

…

No

…

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Section 11: Health and Safety Page 33 Part 2.3.08: The Report and Investigation of Accidents and Incidents

Was assistance required from utilities before excavating? 14.

Yes

…

No

…

If yes, please give details … Name Address Telephone No. Contact Name

15.

16.

What caused the damage? (9)

Mechanical Plant

Power Hand Tools

Non-Powered Hand Tools

…

…

…

Other (please state)

…

State type (i.e. JCB 12” – Bucket, Breaker – Chisel, Shovel – Grafter, Fork, etc) :

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If the excavation was open at the time of the damage, state what measures had been taken to protect the damaged service:

rw

17.

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Give a brief description of how the damage occurred and sketch layout of site. (Show

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dimensions of excavation, position of damaged utility and location of relevant valve covers, boxes, manholes, metres, street lights, etc)

se

as

18.

Was a Sub-contractor responsible?

Please detail an assessment of repair costs (i.e. time taken on job, etc)

No

…

£

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20.

…

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Yes

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19.

If yes, please give details … Name Telephone No. Address

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21.

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What steps have you taken to prevent re-occurrence? (use additional sheet if required)

Supervisors Name (Print)

Signature

Street Works Qual

Date

Project Manager’s Close Out Are you satisfied that a full investigation has been completed?

Yes

…

No

…

Yes

…

No

…

State additional actions where necessary …

Is the action to prevent reoccurrence appropriate? State additional actions where necessary …

Where appropriate state what management action has been taken.

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Section 11: Health and Safety Page 34 Part 2.3.08: The Report and Investigation of Accidents and Incidents

Manager’s Name

Signature

Street Works Qual

Date

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(Print)

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Section 11: Health and Safety Page 35 Part 2.3.08: The Report and Investigation of Accidents and Incidents

REPORT OF AN INJURY OR DANGEROUS OCCURRENCE Form F100 Filling in this form This form must be filled in by a Contractor or other responsible person.

Part A

Part C

About you 1 What is your full name?

About the injured person

2 What is your job title?

1 What is their full name?

3 What is your telephone number? postcode?

2 What is their address and

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If you are reporting a dangerous occurrence, go to Part F to describe the incident.. If more than one person was injured in the same incident, please attach the details asked for in Part C and Part D for each injured person

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About your organisation

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4 What is the name of your organisation?

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3 What is their home phone number?

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5 What is its address?

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Part B

Female? 6 What is their job title

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About the incident

4 How old are they? 5 Are they Male?

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1 On what date did the incident happen?

7 Was the injured person (tick only

et

one box)

2 At what time did the incident happen?

one of your employees?

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(Please use the 24-hour clock eg 0600)

on a training scheme?

Give details:

3 Did the incident happen at the above address? Yes No

Go to question 4

on work experience?

Where did the incident happen?

Employed by someone else? Give details of the employer:

Elsewhere in your organisation – give the name, address and postcode At someone else’s premises – give the name, address and postcode In a public place – give details of Where it happened

self employed and at work? a member of the public?

Part D About the injury

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Section 11: Health and Safety Page 36 Part 2.3.08: The Report and Investigation of Accidents and Incidents

If you do not know the postcode, what is the name of the Construction Site? 1 What was the injury? (eg fracture, laceration)

4 In which department, or where on the premises, did the incident happen?

2 What part of the body was injured?

Part F

3 Was the injury (tick one box that applies) a fatality?

Describing what happened

a major injury or condition?

Give as much detail as you can: For instance

(see accompanying notes)

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remain in hospital for more than 24 hours? none of the above

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Part E

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About the kind of accident Please tick the one box that best describes what happened, then go to Part G.

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Contact with moving machinery or material being machined

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Hit by moving, flying or falling object

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Hit by moving vehicle Hit something fixed or stationary Injured while handling, lifting or carrying Slipped, tripped or fell on the same level Fell from height How high was the fall? Trapped by something collapsing Drowned or asphyxiated Exposed to, or in contact with, a harmful substance Exposed to fire Exposed to an explosion

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• the part played by any people

as

need resuscitation?

• the events that led to the incident

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4 Did the injured person (tick all the boxes that apply) become unconscious?

• the name and type of any machine involved

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an injury to a member of the public which meant they had to be taken from the scene of the accident to a hospital for treatment?

• the name of any substance involved

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an injury to an employee or self-employed person which prevented them doing their normal work for more than 3 days?

metres

If it was a personal injury, give details of what the person was doing. Describe any action that has since been taken to prevent a similar incident. Use a separate piece of paper if you need to.

QCS 2014

Section 11: Health and Safety Page 37 Part 2.3.08: The Report and Investigation of Accidents and Incidents Contact with electricity or an electrical discharge

Part G Your signature

Injured by an animal Physically assaulted by a person Date

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Another kind of accident (describe it in Part F)

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Section 11: Health and Safety Page 38 Part 2.3.08: The Report and Investigation of Accidents and Incidents

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Please continue on this page if necessary

QCS 2014

Section 11: Health and Safety Page 39 Part 2.3.08: The Report and Investigation of Accidents and Incidents

REPORT OF A CASE OF DISEASE Form F100A Filling in this form This form must be filled in by an employer or other responsible person.

Part B

About you

About the affected person

1 What is your full name?

1 What is their full name?

2 What is your job title?

2 What is their date of birth?

3 What is your telephone number?

3 What is their job title?

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Part A

4 Are they

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4 What is the name of your organisation?

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About your organisation

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5 What is its address?

female?

5 Is the affected person (tick one box) one of your employees? on a training scheme? Give

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details:

male?

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6 Does the affected person usually work at this address? Yes No

Go to question 7 Where do they normally work?

on work experience? employed by someone else?

Give details:

was the injury? (eg fracture, laceration)

7 What type of work does the organisation do? other? Give Details:

Section 11: Health and Safety Page 40 Part 2.3.08: The Report and Investigation of Accidents and Incidents

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Section 11: Health and Safety Page 41 Part 2.3.08: The Report and Investigation of Accidents and Incidents

Part C

Continue your description here

The disease you are reporting 1 Please give: • the name of the disease and the type of work 7

it is associated with; or

8

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• the name and number of the disease

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2 What is the date of the statement of the doctor who first diagnosed or confirmed the disease?

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3 What is the name and address of the doctor

Part E Part D Describing the work that led to the disease

Your signature Signature

Please describe any work done by the affected person which might have led to them getting the disease. If the disease is thought to have been caused by exposure to an agent at work (eg specific chemical) please say what that agent is. Give any other information which is relevant. Give your description here

Date

QCS 2014

Section 11: Health and Safety Page 42 Part 2.3.08: The Report and Investigation of Accidents and Incidents

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Please continue on this page if necessary

QCS 2014

Section 11: Health and Safety Part 2.3.09: Personal Protective Equipment (PPE)

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES .......................... 1

2.3.9

PERSONAL PROTECTIVE EQUIPMENT (PPE) ........................................... 1

2.3.9.1  Responsibilities................................................................................................ 4 

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2.3.9.2  Definitions ........................................................................................................ 4  2.3.9.3  Actions Required to Implement This Procedure ............................................. 5 

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2.3.9.4  Reference Documents ................................................................................... 12 

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2.3.9.5  Author ............................................................................................................ 12 

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2.3.9.6  Approvals ....................................................................................................... 12 

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Section 11: Health and Safety Part 2.3.09: Personal Protective Equipment (PPE)

Page 2

PROCESS MAP – COMPANY DIRECT WORK Project Manager 

Buyer 

 

 

COSHH Co‐ordinator 

SHE  Dept/Competent  Person 

Supervisor 

 

Operatives   

Ensure PPE procedure is established 1.3

Hold until specific PPE identified by Risk Assessment 3.2

Assist in assessing suitability or any need for specialist PPE, BA equipment to be ordered

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Specify and order PPE in accordance with Appendix 1

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.

Note Light Eye protection is not suitable for all operations

3.2, 3.4

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3.2, 3.4

Ensure stock is adequate and maintained

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3.5

3.16 Review this procedure and improve if appropriate

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Ensure an adequate issue and return system is implemented

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Ensure adequate instruction ion use, replacement and maintenance of PPE

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3.16

Issue PPE and record 3.16

Monitor effectiveness of procedure. Review if required or feedback to S.H&E Dept 1.3

Use/wear PPE as detailed by Risk Assessment/Method Statement. Provide feedback on effectiveness Monitor compliance of working practices of operatives against procedure 1.5, 1.6

1.8

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Section 11: Health and Safety Part 2.3.09: Personal Protective Equipment (PPE)

Page 3

PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish an adequate system is in place for the selection, storage, issue and maintenance of Personal Protective Equipment (PPE).

SCOPE

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This procedure covers all COMPANY projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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Section 11: Health and Safety Part 2.3.09: Personal Protective Equipment (PPE)

Page 4

2.3.9.1 Responsibilities SHE DIRECTOR 1

Authorises this procedure. MANAGING DIRECTOR

2

Agrees and communicates PPE requirements for their area of responsibility and sets the appropriate delegated authority to allow sign off of ‘exceptional’ risk assessments for any deviation of the mandatory PPE requirements set out in this procedure.

Ensures that works are carried out in accordance with this procedure and arrangements are monitored.

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3

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PROJECT/SITE MANAGER

Ensures that PPE is ordered in accordance with the specifications set out in this procedure.

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4

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BUYER

SUPERVISOR

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Either supervises the work activities or the sub/work package contractor undertaking those work activities and ensures the controls are in place that are required by this procedure.

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5

Provides advice and support in the application of this procedure and monitors others’ effectiveness to manage the activities.

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SHE ADVISER

Person identified as being competent to undertake a risk assessment in relation to the activity being undertaken.

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7

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COMPETENT PERSON

OPERATIVE/CONTRACTORS EMPLOYEES

8

To comply and co-operate with COMPANY/Employer in respect of this and any associated procedure and requirements therein.

2.3.9.2 Definitions PERSONAL PROTECTIVE EQUIPMENT 1

“Personal Protective equipment” (PPE) means all equipment which is intended to be worn or held by a person at work and which protects them against one or more risks to their health and safety, and any addition or accessory designed to meet that objective. Items such as fluorescent yellow waistcoats, safety harnesses etc are PPE as defined. Ordinary working clothes and uniform not specifically provided to protect the wearer’s health and safety are not PPE.

QCS 2014

Section 11: Health and Safety Part 2.3.09: Personal Protective Equipment (PPE)

Page 5

SUITABLE 2

“Suitable” means it is appropriate for the risk, user friendly, correctly fitted, effective and complies with design and manufacturing standards. OVERLAPPING REQUIREMENTS

3

N/A RESUME OF THE REQUIREMENTS

(b)

The PPE is suitable.

(c)

If two different types of PPE are worn, they do not adversely affect each other’s performance against the risk (i.e. they are compatible).

(d)

PPE is maintained (including replaced or cleaned), in efficient working order and in good repair.

(e)

Appropriate storage and accommodation is provided for PPE when not in use.

(f)

Employees are provided with adequate information, instruction and training about the use of the PPE, its limitations, the risk(s) it guards against and how to maintain it in efficient working order. Such information should be easily understood.

(g)

That PPE is properly used.

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The required employees are to:-

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PPE is provided but only as a “LAST RESORT” for employees exposed to a risk of health or safety whilst at work.

(a)

Use the PPE provided to them in accordance with any training and instruction given

(b)

Return the PPE to any accommodation provided for it after use

Report any loss of or obvious defect in the PPE to their employer.

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6

(a)

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5

The required employers to ensure that:

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2.3.9.3 Actions Required to Implement This Procedure

1

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PERSONAL PROTECTIVE EQUIPMENT

Places responsibilities on employers to provide suitable personal protective equipment to their employees whilst at work. There is a similar duty for the self employed. RISK ASSESSMENT

2

Prior to the selection of any Personal Protective Equipment (PPE) a risk assessment shall be carried out to identify the relevant PPE, proportionate to the risk involved. Any assessment should also take into consideration any overlapping requirements.

3

Refer to SHE-PRO-001 to assist with this process. The risk assessment shall also consider the requirements for specialist PPE, such as Breathing Apparatus. Further advice in this area can be sought from your local SHE Dept.

4

A guide to the standards required for common PPE is in Appendix 1.

5

The List at Appendix 1 covers:(a)

Type of protection

QCS 2014

Section 11: Health and Safety Part 2.3.09: Personal Protective Equipment (PPE)

(b)

Potential Health and Safety effects if not worn

(c)

Typical hazards

(d)

Relevant BS/EN

Page 6

CONTINUOUS ASSESSMENT COMPANY promotes the continual assessment of PPE in terms of fit for purpose and suitability and the users feedback on its effectiveness, comfort and compatibility should be encouraged by the relevant project management.

7

Any feedback on its effectiveness should then be reported to the SHE Department. This could then allow for items/types of PPE to be added to the approved list. Purchase of such unlisted PPE should initially not take place until there has been consultation with the SHE Department.

.

6

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When considering the type of PPE, ie gloves, respirators, foot protection etc. further information is available on the MSDS sheets as detailed in SHE-PRO-02. Information can be obtained through the COSHH Co-ordinator.

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CONSIDERING TYPE OF PPE

A stock of the appropriate PPE shall be available on site. This will be dependent on the contractual requirements (i.e. stipulated by clients) or as a result of risk assessment.

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9

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STOCK OF PPE

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The main types of protection that are in regular use with COMPANY are: Eye protection

(b)

Head protection

(c)

Hearing protection

(d)

Respiratory protection

(e)

Foot protection

(f)

Hand protection

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(a)

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TYPES OF PPE

MANDATORY PPE

11

COMPANY has a requirement in place for the mandatory wearing of the following items of PPE on all its projects: (a)

Head protection

(b)

Foot protection

(c)

Hand protection

(d)

Eye Protection

12

In addition where there are plant movements, Hi-Vis clothing must be worn in areas designated by the Project/Site Manager.

13

Mandatory requirements will be included in the Site Rules and communicated at Induction.

14

In exceptional circumstances an approved risk assessment may be undertaken to allow for deviation from the mandated PPE requirements. This would be at Director level.

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Section 11: Health and Safety Part 2.3.09: Personal Protective Equipment (PPE)

Page 7

EYE PROTECTION (SEE ALSO VII – MANDATORY REQUIREMENTS) 15

Particular operations may require the use of either glasses, goggles or full face masks etc. The SHE Department shall be contacted and will advise on the type required.

16

It is also critical that suitable and sufficient risk assessments identify the correct type of eye protection to ensure that Light Eye Protection (LEP) is not used in place of the eye protection that may be required, e.g. grinding or cutting operations where goggles would be required and not LEP.

17

It is COMPANY policy to issue prescription safety glasses to COMPANY employees when applicable. Anyone who considers they need prescription safety glasses should contact the local SHE Manager/Advisor who will advise on the process to be followed.

.

HEAD PROTECTION (SEE ALSO 3.7 – MANDATORY REQUIREMENTS) Safety helmets are only designed to last for 3 years and this figure may reduce dependent on the use, environment, storage arrangements etc., for example helmets must not be stored in direct sunlight as the sun rays degrade the plastic (e.g. if stored on the rear shelf of a car). Safety Helmets should be subject to regular inspection by the user, to determine their suitability for use up to the 3 year maximum.

19

To identify the “age” of a helmet there is identification on the underside of a helmet (usually under the peak), it is usually a stamped circular disc containing a number surrounded by 4 or 12 segments. The number represents the year of the helmet shell moulding and each segment containing a dot defines the month of the year. A shell marked with six dots surrounding a number 98 would represent a shell that was moulded in June of 1998. Some manufactures use different methods, reference should be made to the manufacturer’s guidance

20

Markings on the Helmet

21

Every helmet claimed to comply with the requirements of European Standard BS EN 397, shall carry a moulded or impressed marking giving the following information :

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number of European Standard BS EN 397

(b)

name or identification mark of the manufacturer

(c)

year and quarter of manufacture

(d)

type of helmet (manufacturer’s designation). This shall be marked on

et

both the shell and the harness

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(e)

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(a)

(f)

size or size range (in centimetres). This shall be marked on both the shell

(g)

and the harness

(h)

abbreviation for the material of the shell in accordance with ISO 472 (eg ABS, PC, HDPE etc)

HEARING PROTECTION 22

There are two basic types of ear defender used in construction; they are ear plugs and ear muffs. It is also possible to purchase more specialist type such as ear muffs with in built communication systems.

23

Both plugs and muffs give good attenuation and comfort, although ear muffs give better protection at frequency ranges HZ 1000-8000 e.g. high impact noise, hilti, piling hammers.

24

In some extreme cases it may be required to give double protection, ie muffs and plugs. In all cases the requirement is for assessment of noise and the selection of the most suitable

QCS 2014

Section 11: Health and Safety Part 2.3.09: Personal Protective Equipment (PPE)

Page 8

type of defender. Consultation with the SHE Department will help you choose the most suitable type. 25

There may also be operational constraints on the type of protection, for example plugs should not be the automatic choice if working with contaminated land and should definitely not be used when working in compressed air.

26

If there are medical reasons why a person cannot use certain types of protection then this should only be agreed to after a letter has been received from a doctor. RESPIRATORY PROTECTION Respiratory Protective Equipment (RPE), as with any other form of PPE, should be considered as a method of last resort in preventing or reducing exposure.

28

Before ordering RPE there must be prior consultation with the SHE Department who will assist you in assessing the risks and advise on the type of RPE to purchase/use.

29

RPE includes a very wide range of devices, from disposable filtration masks to self contained Breathing Apparatus (BA). Therefore choosing the right type of RPE is essential. Please refer to COSHH procedure for information on face fitting or RPE.

30

In the case of BA, please refer to your local SHE Department for advice.

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27

FOOT PROTECTION (SEE ALSO VII – MANDATORY REQUIREMENTS) The type of foot protection will depend on the particular circumstances and the identified types produced by means of assessing the risk. This includes the frequency of exposure and the likely severity of the injury.

32

The type and style is detailed at Appendix 1 and it should be recognised that in some circumstances personnel may be eligible for more than one type, e.g. when working in both dry and wet conditions.

33

As a minimum the protection afforded should be steel toe cap and mid sole protection.

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35

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Gloves must be carefully selected so as to be fit for purpose, taking into account use, comfort, dexterity, temperature protection and grip.

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HAND PROTECTION (SEE ALSO VII – MANDATORY REQUIREMENTS)

The general requirements of any glove must include:

(a)

Fit for purposes

(b)

Construction

(c)

Sizing

(d)

Storage requirements

(e)

Breakthrough properties

36

For whatever glove is being used on site, both product and technical information should be available.

37

Consultation with the SHE Department will provide further advice on type/selection. Where gloves are required to prevent a health risk, they will be selected as part of the COSHH assessment.

38

NB:

For further details on all the above protection see Appendix 1.

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Section 11: Health and Safety Part 2.3.09: Personal Protective Equipment (PPE)

Page 9

MINIMUM DRESS STANDARDS 39

The minimum acceptable dress on site when working is: (a)

Long Trousers (Waist to ankle. Shorts & ¾ length are not permitted)

(b)

Shirt, T Shirt, Polo Shirt, wearing of short sleeves may also have restrictions in terms of COSHH assessment requirements such as protection against irritants etc – Long sleeves preferred ( Vest, singlets are not permitted

(c)

Safety helmet

(d)

Safety footwear

CE MARKING All PPE manufactured and imported from the European Union should have CE marking indicating its conformity with the PPE directive. Items referred to within this document conform to the CE standard marking and site management will check compliance.

41

NB: NUISANCE DUST MASKS (mask or gauze pad) do not conform to the European Standard EN149 and are not CE marked. Therefore they are not classified as protective equipment and SHALL NOT be used on site.

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ISSUE AND USE

The COMPANY Personal Record/Issue Card logs shall be completed for the issue of protective equipment/clothing to confirm receipt by employees.

43

All PPE issued to COMPANY employees is issued/replaced free of charge .

44

Abuse or non use of PPE supplied is a disciplinary offence.

45

In addition to the issue of equipment the project manager shall ensure that there are procedures in place for the replacement, maintenance, means of reporting defects, storage and, if appropriate, return of PPE when not in use.

46

Where relevant adequate information, instruction and training proportionate to the risk shall be provided. This may range from instruction on how to fit and fit test RPE through to the mandatory legal requirement for training in the use of BA.

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47

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SUPPLIERS

Suppliers quoted within these procedures have no prior arrangements or contractual agreements and all purchases shall be made in accordance with COMPANY Procurement Procedures. CONTRACTORS, VISITORS AND LABOUR AGENCY PERSONNEL CONTRACTORS

48

It is a condition of contract that all contractors provide PPE to the appropriate BS/EN as required, and also be of the type identified by the Project or the contractors’ risk assessment.

49

The type identified for the Project will, where appropriate, be discussed at the initial safety meeting.

50

If the contractors do not supply the relevant PPE then COMPANY will supply the PPE and charge the contractor at cost, plus handling fee.

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Section 11: Health and Safety Part 2.3.09: Personal Protective Equipment (PPE)

Page 10

LABOUR AGENCY PERSONNEL

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Labour agencies are required by COMPANY contract conditions to ensure the personnel they supply to COMPANY possess the relevant PPE. Visitors shall comply with the directions of the Project Manager.

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Page 11

APPENDIX 1 - PPE PURCHASE LIST Type of Protection

Relevant BS/EN

Typical Hazards • • • • • • • • •

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BS 2092 BS EN 166 349B

• • • •

Falling objects Striking objects Sunlight UVA & B Restricted view

• • • • •

High noise levels Low frequency noise levels Mid frequency noise levels High frequency noise levels High impact noise levels

EN 352-1 EN 352-2 EN 352-3

• • • • • • • • • • •

Harmful dusts Inhalable dusts Respirable dusts Toxic dusts Gases Liquids or solids Micro biological Vapours Fumes Mists Oxygen deficiency

EN149 Pr EN 140 En 405

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EN 397

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Respiratory Protection Potential Health & Safety effects if protection not worn:• Upper tract respiratory problems ie rhinitis • Lower tract respiratory problems ie asthma, bronchitis • Toxic poisoning (various health effects) • Viral infections • Asphyxiation

Chemicals Liquids Gases Molten metal Hot solids Short circuit electrical Direct sunlight Laser beams Airbourne dust (large and small particles) Flying particles (high and low velocities)

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Eye Protection Potential Health & Safety effects if protection not worn:• Blindness • Eye injuries (various) • Cataracts • Headaches • Restricted vision • Eye strain • Arc eye Head Protection Potential Health & Safety effects if protection not worn:• Head injuries • Sunburn • Cuts, bruises • Fractures • Concussion • Unconsciousness Hearing Protection Potential Health & Safety effects if protection not worn. • Hearing damage • Noise induced hearing loss • Tinnitus • Increased stress levels • Communication problems

• • • • • • • • •

Falling objects Sharp objects Piercing objects Cements Oils Contaminated land Chemicals Water/mud Uneven ground

BS EN 345 and 346

Hand Protection Potential Health & Safety effects if protection not worn:• Hand injuries general • Cuts/lacerations • Dermatitis • Burns • Poor dexterity and grip (i.e. due to cold weather)

• • • • • • • • • •

Sharp objects Abrasives Chemicals Oils Cement Wood Lack of dexterity Cold/ Heat Weather Water

EN 420

High Visibility Clothing Potential Health & Safety effects if protection not worn:• Bruising • Fractures • Concussion • Unconsciousness • Death

• • •

Cars Mobile Equipment Heavy Equipment

EN 471 Class 3

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Foot Protection Potential Health & Safety effects if protection not worn:• Foot injuries/amputation • Burns • Dermatitis • Biological infection • Blood poisoning • Sprains & strains • Fractures • Bruising • Cuts

Notes: 1) 2)

This list must be read in conjunction with any relevant company procedure. When in doubt the SHE Department must be consulted to assist in any assessment or alternative PPE.

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2.3.9.4 Reference Documents FORMS 1

N/A

REFERENCE DOCUMENTS Qatar Regulatory Document (Construction) RD1.3 and RD 1.4

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Safety, Health and Environmental Risk Management and Written Safe Systems of Work – (SHE-PRO-001)

4

COSHH - (SHE-PRO-002)

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POSITION IN COMPANY

NAME

CONTACT DETAILS

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SECTION

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2.3.9.5 Author

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SHE Manager

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2.3.9.6 Approvals

Approved by:

NAME

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ......................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ..................................1

2.3.10 THE SAFE USE OF CRANES & OTHER LIFTING APPLIANCES (EXCAVATORS, TELE HANDLERS AND LORRY LOADERS) ...........................1

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2.3.10.1  Responsibilities .............................................................................................. 4 

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2.3.10.2  Definitions ....................................................................................................... 5 

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2.3.10.3  Action Required To Implement This Procedure ............................................. 6  2.3.10.4  Application of Procedures to Cranes under the Control of Contractors ........ 8 

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2.3.10.5  Guidance To This Procedure ......................................................................... 9 

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2.3.10.6  Reference Documents ................................................................................. 13  2.3.10.7  Author ........................................................................................................... 14 

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2.3.10.8  Approvals ..................................................................................................... 14 

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

Process Map Project Manager/Contractor

Ensure all those involved in planning, recording, permitting and carrying out lifting operations are competent. Ensure adequate arrangements are put in place, including for 1.2, 3.2, 3.8

Appointed Person

Specialist Contractor/Crane Supplier

Lift Supervisor

Ensure lifting equipment and accessories are suitable for the task and have adequate strength and stable in use 3.1, 3.9, Appendices 1 & 2

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All crane lifts must have an appropriate Lift Plan prepared by a qualified

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1.3, 3.3, 3.7, 3.9, Appendix 1

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Appointed Person assesses lifts and classifies as either standard or complex

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1.3

Classified complex lift due to nature of lift i.e. location, tandem lift, unusual load, high risk i 2.2

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Standard lift classified as crane lift with no extraordinary hazard

Appointed person interfaces with specialists engineers, designers, temporary works co-ordinators to assess options and limitations

Company supply relevant information and agree with specialist crane company the parameter for a complex lift 3.6

In cases of tower cranes, specialist advice on selection and type of crane is required taking into account site conditions, access, foundations and 3.5, 3.7

1.2

Appointed person prepares, reviews Lift Plan and ensures permits in place. NB additional permit required for multi positions 1.2, 3.3

Key

Activity Guidance

Slinger/Signaller & Operators

Tower crane thoroughly examined before use and lifting schedule in place 3.7

Crane lift supervisor made aware of operational requirements including any 1.4, 3.1, 3.9, Appendix 1

Slinger,/Signaller and operator(s) made aware of operational requirements including any restrictions 1.5, 1.6, 3.1, 3.4, 3.9, Appendix 1

Crane Lift Supervisor to inform appointed person of situation or 1.4

Stop and inform of any abnormal situations or changes in work practice from agreed method or sequence 1.6

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PURPOSE 1

The purpose of this procedure is to ensure the correct selection, safe use and maintenance of all lifting equipment and lifting accessories as prescribed in the Lifting Operations and Lifting Equipment (LOLER) section of the Qatar Regulatory Document (Construction). SCOPE

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This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

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2.3.10.1 Responsibilities 1

The following duty holders must be appointed for all crane operations in accordance with current guidance and their responsibilities are detailed below : SHE DIRECTOR

1

Authorises this procedure PROJECT/SITE MANAGER Their responsibilities are as follows: Ensure this procedure is implemented for all types of lifts.

(b)

Ensure appropriate measures are in place for the control of change for risk assessment/method statements.

(c)

Ensure the COMPANY nominate an authorised person to sign off Crane Permit to Lift.

(d)

Ensure all persons involved in the planning and carrying out of lifting operations are competent.

(e)

Ensure a COMPANY person is appointed to co-ordinate the relevant plans, permits, forms and associated paperwork for the COMPANY filing system.

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(a)

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The Appointed Person will ensure that :

The assessment and planning of lifting operations is undertaken and complies with the requirements of the COMPANY lifting operations procedure.

(b)

The Crane Team is appointed and all are made aware of authorities and responsibilities.

(c)

There is an effective line of communication back to him in the event he is not present at the lift.

(d)

Close liaison is maintained with the technical crane suppliers throughout the installation, operational and dismantling phases of tower cranes.

(e)

Lifting operations are reviewed following advice from the Crane/Lift Supervisor/Signaller/Slinger on any matters of change in arrangements, and that the Permit to Lift and Risk Assessment are amended accordingly.

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APPOINTED PERSON (LIFTING OPERATIONS)

LIFT SUPERVISOR 4

The Lift Supervisor will : (a)

Act as a key member of the Crane Team and report to the Appointed Person as leader of that team, including details of any change in activities or arrangements.

(b)

Ensure that the Slingers/Signallers, the Crane Operator and any other person involved in the lift are familiar with and follow the safe system of work and the details and limitations recorded in the lifting plan.

(c)

Ensure that Tower Crane Operators’ working hours do not exceed the operating criteria.

(d)

Ensure that Crane Operators are suitably trained and competent.

(e)

Ensure the safe working load (SWL) is never exceeded, other than for the express purpose of testing a crane under the supervision of a competent person. There are no exceptions to this.

(f)

Ensure cranes do not operate in any weather conditions that exceed the limit stated for that type of crane.

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

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(g)

Ensure that man-riding is never carried out unless it is part of the agreed safe system of work.

(h)

Ensure grab work, demolition balling or pile driving are only performed by machines specially adapted and intended for these purposes.

SLINGER/SIGNALLER The Slinger/Signaller will : Read, understand and comply with the lifting plan and take instruction from the Lift Supervisor.

(b)

Establish weights, balance loads and judge distances, heights and clearances.

(c)

Select the correct lifting gear in suitable condition for the loads to be lifted, reporting any defects where necessary.

(d)

Adopt correct slinging techniques.

(e)

Give precise and clear instructions to the Lifting Equipment Operator.

(f)

Initiate and direct the safe movement of the crane and load.

(g)

Signallers shall be identified on site by their orange hi-vis tabards and/or orange helmets.

(h)

Stop operations if any changes to the agreed method are undertaken or required.

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OPERATORS

Ensure they are in possession of and have been briefed on the Permit to Lift and have signed the relevant section.

7

Position the crane, as instructed, in accordance with the Permit to Lift.

8

Operate in accordance with the Permit to Lift.

9

Inform the Lift Supervisor/Signaller/Slinger if any problems arise which would affect the lifting operation.

10

Operate the crane in accordance with the crane’s operating instructions.

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2.3.10.2 Definitions

STANDARD LIFT 1

Any lift using lifting equipment. 2.2

Complex Lift

2

A lift where the lifting operation requires more than one crane to lift the load, or cranes using load enhancement attachments (super lift etc), or the lift is to take place at a location with exceptional hazards, e.g. chemical plant or lifting loads on or near live equipment, including Rail Infrastructure. CONTRACT LIFT

3

COMPANY may enter into a contract with a third party (usually a crane hire company) who will undertake the work on its behalf. Before entering into such a contract, COMPANY has a duty to satisfy itself that the third party has the necessary competence to carry out the work in accordance with the requirements of BS 7121.

4

In a Contract Lift the crane hire company will plan the lift, select a suitable crane, specify the slinging and signalling arrangements, supervise the lift and be responsible for the lifting operation.

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

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CRANE HIRE ARRANGEMENTS 5

In a crane hire arrangement (including tower cranes), the crane and operator will work to the client’s instructions. Under this arrangement, COMPANY will plan the lift and specify the slinging and signalling arrangements, supervise the lift and be responsible for the lifting operation. LIFTING EQUIPMENT Lifting equipment means work equipment used to lift or lower loads (cranes, hoists, tele handlers, vehicle mounted lifting arms i.e. ‘Hiab’ etc) and includes the attachments for the anchoring, fixing or supporting of lifting equipment.

7

Should an excavator be used for lifting materials, other than for excavated material or fill, then by definition it becomes lifting equipment (eg. an excavator used to lift and lower a manhole section in position).

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Lifting accessories are items of work equipment used to attach loads to lifting equipment, eg. chains, shackles, strops, slings, eye-bolts, spreader beams, etc.

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LIFTING ACCESSORIES

2.3.10.3 Action Required To Implement This Procedure

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Lifting operations if not properly planned, managed and executed can result in accidents, serious incidents or fatalities.

The Lifting Operations and Lifting Equipment requires the appointment of Duty Holders to ensure: All lifting operations are properly planned, managed and executed.

(b)

Those involved in lifting operations are competent.

(c)

All crane lifts must be planned and approved by an Appointed Person.

(d)

The risks from lifting operations are assessed and lifting equipment and lifting accessories selected and used are suitable for the task. When in use, the equipment must be stable and the safe working load of equipment and accessories MUST NEVER be exceeded.

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GENERAL REQUIREMENTS

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(e)

Lifting equipment is inspected, maintained and thoroughly examined as required.

(f)

Lifting accessories (eg. chains, shackles, strops) are thoroughly examined every 6 months.

(g)

Any lifting accessory found not to have a current test certificate should be taken out of service immediately and be quarantined and clearly marked for re-testing or disposal.

(h)

Any defects found must be reported to the person in control of the lifting operation immediately so that appropriate action can be taken to repair or replace the equipment or otherwise ensure that potential dangerous equipment is withdrawn from use as soon as possible.

(i)

The safe working load must be marked on the lifting equipment. Where the configuration of the lifting equipment can be altered, affecting the safe working load, there must be adequate information to determine the safe working load in the different configurations.

(j)

Lifting equipment and accessories that are used for lifting persons must be marked to indicate this fact.

(k)

Consider the positioning and installation of lifting equipment, site conditions for proximity hazards, eg. overhead cables, space availability, and suitability of the ground or foundations eg. for outriggers in consultation with the manufacturer’s information.

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

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(l)

Ensure that there is a plan in place that also considers a safe system of work to prevent persons being trapped, eg. physical barriers to prevent access to restricted areas. Refer to theTemporary Works Co-ordinator if necessary.

(m)

The COMPANY Regional SHE Adviser is advised in advance, of any intention to carry out man-riding. (See also Appendix 1 – General Rules for the Use of Cranes).

(n)

Where there is more than one Appointed Person allocated to a project, then appropriate communications to co-ordinate any interfaces should be put in place and a ‘lead appointed person’ nominated.

3

See also:

Appendix 1 – General Rules for the Use of Cranes.

4

Appendix 2 – Table of examinations and inspections. LIFTS OTHER THAN CRANE LIFTS

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Other than crane lifts, numerous operations fall under the category of lifting operations as per the Lifting Operations and Lifting Equipment (LOLER). These may include : Fork Lift Trucks

(b)

Excavators (used as lifting devices).

(c)

Hoists & material lifting equipment (all types).

(d)

Hiab (or vehicle mounted lifting arm) operations. See SHE-FRM-10-06

(e)

Scaffold Pulley Wheels (Gin Wheels).

(f)

Working platforms i.e. MEWP’s, Mast Climbers

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(a)

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For lifting appliances other than cranes or Hiab, the checklist in form SHEFRM-10-05 should be considered.

7

Where the above does not cover the type of lift or equipment involved, the person managing the lift should consult with the manufacturer, supplier or a member of the SHE team to establish and record a safe system of work. CRANE LIFTS

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A Lift Plan must be received from the Appointed Person responsible for a Contract Lift carried out by a third party. Note: Tthe lift plan must include a detailed layout plan.

9

All lifting plans must be verified using the ‘Control of Lifting Operations – Permit to Lift Checklist’ to ensure all associated documents are included and authorised by the Appointed Person.

10

Once these checks are signed off the ‘Control of Lifting Operations – Permit to Lift’ can then be issued by the nominated person to authorise commencement of lifting operations. Note that in cases where the crane moves location (multiple crane position) around site then the Permit must be used for multiple positions (SHE-FRM-10-02).

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SLINGING PLANS 11

During standard lifting operations, the following slinging plan shall be followed by the Signaller/Slinger as part of their duties : (a)

Assess the weight of the load.

(b)

Choose the correct lifting equipment and control the lifting operation.

(c)

Ensuring lifting equipment is fit for use by carrying out pre-use checks.

(d)

Ensure that any physical controls ie. barriers are in place and nonessential personnel are kept out of the immediate working area of the operation.

(e)

Check the anticipated path of the load.

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

(f)

Prepare a place to set down the load.

(g)

Fit the lifting equipment to the load together with tag lines as necessary.

(h)

Make the lift (a trial lift may be necessary to establish centre of gravity).

(i)

Release the lifting equipment after the lift has been completed.

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12

Clear up.

13

Where appropriate, return lifting equipment to a suitable secure storage location.

14

Be familiar with any appropriate communication arrangements, documentation or operational requirements such as risk assessments, method statements or Permit to Lifts.

2.3.10.4 Application of Procedures to Cranes under the Control of Contractors When contractors provide cranes for their own use and operate them under their own control, then the principles of this procedure shall apply, however COMPANY will retain permit control.

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These requirements shall be discussed at the initial safety meeting with contractors. It shall be agreed at that meeting:

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When a method statement is required from the Contractor.

(b)

Who the Contractor has nominated as his competent Appointed Person.

(c)

The Contractor’s Appointed Person shall prepare a Crane Lift Plan (it will be necessary for ourselves to provide details of the ground conditions). COMPANY shall complete the Permit to Lift Checklist and Permit to Lift.

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SPECIAL OR COMPLEX LIFTS

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(a)

Special lifts include Tandem, Complex, Floating Lifts etc. Additional advice must be sought from the SHE team during the planning of such lifting operations.

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Where possible this should be arranged as a contract lift.

5

Certain crane applications, such as handling temporary pile casings or piling hammers/extractors can be controlled by a trained Signaller/Slinger provided that a detailed risk assessment/method statement has been produced by the Appointed Person, and it is worked to, and the Signaller/Slinger has been specifically instructed in its application.

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Complex lifts may be common and repetitive during piling operation ie. Tandem Lifts, Diaphragm Walls, Topping and Tailing Loads etc. Where it has been identified by the Appointed Person that this is the case, the Appointed Person shall be in attendance for the duration of the first lift. Once satisfied the Lifting Operation, Risk Assessment and Method Statement are correct they may delegate their supervisory duties to the Crane/Lift Supervisor for the remainder of the operation. Thereafter the Appointed Person will be required to monitor the lifting operation at intervals agreed with the Project Manager. Where changes to lifting operation, Risk Assessment/Method Statement are required, the Appointed Persons must be notified immediately and shall review and revise the lifting operation, Risk Assessment/Method Statement for the duration of the lift. Once satisfied, the Appointed Person can once again delegate the supervisory duties back to the Crane/Supervisor.

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TOWER CRANES 7

Due to the high risk nature of tower crane selection, erection, use, maintenance and dismantling operations, specialist advice must be sought.

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The Appointed Person must ensure there is an appropriate plan/lifting schedule in place for lifting operations. A typical example of a tower crane lifting schedule is included in the Lifting Plan and Schedule (SHE-FRM-10-03).

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

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9

Where more than two tower cranes are operating within the same radius zone automatic proximity warning devices must be fitted, ie. anti clash systems,

10

Where tower cranes are operating, systems should be in place which take account of protestors, unauthorised entry, etc. Controls should include : For internal cranes, first/base section of the mast, in the region of 4 m. high, or to the underside of the upper floor, can be covered with heavy gauge 50 mm. squared (maximum) weld mesh secured with either wire or zip ties (not welded). Access for the crane driver can be in the form of an outward opening lockable door, with a turnbuckle on the inside with key access from the outside. Keys can be held by the crane driver and the Slinger/Signallers for use in the event of an emergency. The gate is to remain closed at all times whilst the driver is up the crane.

(b)

For external cranes, a 2.4 m. high plywood hoarding with a security fan, independent of the crane, gated as above, with mesh viewing panels to give additional natural lighting to facilitate safe access/egress.

(c)

Where the building is progressed around the tower crane, 2 m. high double clipped demountable Heras type fencing to be placed around the floor aperture at each floor slab level as the building progresses.

(d)

Lockable access doors to the cab/jib installed and padlocked shut when the crane driver vacates the crane.

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When the crane driver vacates the crane, the machine to be locked off, isolated and secured into free slew either from the cab or from the isolator situated at the base.

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(a)

COMPANY must ensure that suitable arrangements are put in place for emergency situations (rescue from tower crane, crane failure etc). Any such arrangements shall be subject to liaison with emergency services and appropriate rescue practices carried out to test any agreed arrangements.

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EMERGENCY ARRANGEMENTS

A list of general rules for the use of cranes is included at Appendix 1 and shall be made known to persons involved in lifting operations

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MINIMUM TRAINING REQUIREMENTS 1

Appointed Person must hold training certification following attendance and successful completion of a recognised Appointed Persons (Lifting Operations) training course.

2

Lift Supervisors must have received suitable and sufficient training. Slinger/Signaller must have received suitable and sufficient training certification for Slinger/Signaller.

3

Mobile or Tower Crane Operator must have received suitable and sufficient training certification for crane operation.

4

Pedestrian Operated Tower Crane Operator must have received suitable and sufficient training certification for crane operation.

5

Other Lifting Equipment, operators must hold suitable training certification relevant to the category of lifting equipment being used.

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Lifting Equipment and Accessories – Testing (see Appendix 2)

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

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The implementation of LOLER and BS 7121 Part 2:2003: Code of Practice for Safe Use of Cranes - Inspection, Testing and Examination’, provides the opportunity for either a “specified period” or an “examination scheme” approach to the 12 monthly thorough examination.

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If the examination scheme approach is to be used, the owner must produce a scheme in consultation with the manufacturer or another competent engineer.

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Mobile cranes with a rated capacity of less than 500 tonne that are not thoroughly tested in accordance with an examination scheme should be load tested every 4 years.

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Any lifting accessory found not to have a current test certificate should be taken out of service immediately and be quarantined and clearly marked for re-testing or disposal.

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

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APPENDIX 1 - GENERAL RULES FOR THE USE OF CRANES The following rules apply to all COMPANY sites and shall be made known to all persons involved in lifting operations : Cranes shall only be used for vertical lifts.

(b)

The weight of the load (including lifting gear, etc.) shall be confirmed before lifting.

(c)

A common lift schedule for tower cranes to be produced.

(d)

The safe working load shall never be exceeded; if the Rated Capacity Indicator is activated this shall be investigated.

(e)

When lifting a load for the first time the crane stability shall be checked when the load is just off the ground.

(f)

No operation shall be carried out where high winds affect the stability of the load or the crane. Limits on wind speeds shall be determined (i.e. by reference to the operator’s manual). The means for determining wind speed shall be by use of an anemometer fitted to the crane or available on site.

(g)

An audible alarm shall be capable of being heard at the crane’s maximum operation radius.

(h)

No crane shall be left unattended with the load suspended or the engine running.

(i)

The crane shall be left secured when unattended.

(j)

Persons shall only be lifted by a crane in power lowering mode and automatic brakes. Cranes with keys to set power lowering shall be locked in this mode and the key retained by the Appointed Person or Project/Site Manager whenever persons are to be lifted.

(k)

Crane Selection for Carriage of Persons: The following points are mandatory:

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(a)

Cranes with the “traditional manually operated slipping friction clutch will not be used

(ii)

Cranes with hydraulically driven permanently engaged clutches are preferred.

(iii)

Cranes must be used in a power load lowering mode. Cranes which have a free fall mode must be ‘locked out’ of free fall with a key operated selector and indications of this shown externally on the crane and within the cab, by light or sound. The keys must be held secure by the Project/Site Manager or other Appointed Persons whilst the crane is engaged in man riding duties.

(iv)

The cranes must have automatic brakes which will be automatically applied if the hoisting lever is not in the operating position.

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(v)

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(vi)

Cranes with latchable controls must have the latching mechanisms removed, ie. controls must automatically return to the neutral position when released.

(vii)

Lifting equipment used shall comply with relevant Qatar Regulatory Document (Construction) together with the relevant British Standard.

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(viii) Each crane must be individually assessed and a technical statement, with appropriate information, obtained from the owner as to its suitability for the carriage of persons. This statement must be appraised by a technically competent person and agreed prior to the commencement of man-riding. (ix)

Technical assistance is available from the SHE Manager/Team.

(x)

Overhoist device shall be fitted for all man-riding operations or where an overhoist risk exists.

(l)

Cranes shall not slew within 600 mm. of any fixed object that may cause a trap.

(m)

Only trained and certificated Signaller/Slingers shall direct crane drivers. If more than one Signaller is appointed only one shall have authority to direct the Crane Driver and that Signaller shall be known to the Crane Driver.

(n)

Site conditions, both underfoot and overhead, shall be checked for hazards before a crane is used. This includes checking access to and egress from the site before attendance.

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APPENDIX 2 - TABLE OF INSPECTION AND EXAMINATIONS TYPE OF EQUIPMENT Mobile cranes and tower cranes

INSPECTION REQUIREMENTS

Daily pre-use checks and weekly inspection by trained operator. Daily pre-use checks and weekly inspection by trained operator.

Lorry mounted cranes

Daily pre-use checks and weekly inspection by trained operator.

Excavator

Weekly inspection by trained driver.

Mobile elevating work platforms (MEWPs)

Daily pre-use checks and weekly inspection by trained operator.

Passenger and goods lifts

In accordance with the manufactures’ instructions.

Scissors lifts (fixed)

Refer to manufacturers’ instructions.

As above and initial test and examination before use required 12 monthly by competent person 12 monthly by competent person

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In accordance with the manufactures’ instructions. In accordance with the manufacturers’ instructions.

Visually check for obvious defects in accordance with training / experience immediately prior to use.

6 monthly by competent person 6 monthly by competent person 12 monthly by competent person 6 monthly competent person 12 monthly by competent person 12 monthly by competent person

6 Monthly by competent person.

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Overhead cranes (motorised or manual) Vehicle tail lifts, maintenance lifts Lifting chains, chain slings, spreader beams, lifting frames ring hooks, shackles, swivels, eyebolts, turnbuckles, wire ropes & slings, strops, fibre ropes, slings & all textile based slings.

Daily pre-use checks and weekly inspection by trained operator. Weekly inspection by trained driver.

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Fork lift trucks

6 monthly by competent person

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PERIOD OF THOROUGH EXAMINATION 12 monthly* by competent person (6 monthly if used for lifting persons)

Flood lighting winches

None.

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Hydraulic jacks and screw jacks

Periodic visual inspection depending upon usage. Periodic visual inspection depending upon usage.

Fixed lifting beams

12 monthly by competent person 12 monthly by competent person 12 monthly by competent person

Tie down straps for lorry loads.

Weekly visual inspection by trained Not required driver. Visual inspection of all webbing 6 monthly by competent stitching and attachments every Body harness person month, and before use. * Can be a specified examination scheme in lieu of the 12 monthly thorough examination for cranes. Equipment such as pallet trucks, sack barrows and manhole cover lifters do not require a thorough examination under LOLER but shall be subject to regular visual inspections as required by the Provision and Use of Work Equipment - PUWER (refer to separate procedure and guidance).

QCS 2014

Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

Page 13

2.3.10.6 Reference Documents PROCEDURES FORMS Site/crane Permit to Lift Part 1 (SHE-FRM-10-01)

2

Site/Crane Permit to Lift Part 2 (Multiple Operations) (SHE-FRM-10-02)

3

Control of Lifting Operations - Lift Plan and Schedule (SHE-FRM-10-03)

4

Control of Lifting Operations – Pre-Permit to Lift Checklist (SHE-FRM-10-04)

5

Lifting Appliance Use for Loading (Tele Handler etc) (SHE-FRM-10-05)

6

Lorry Mounted Crane Checklist (Hiab) (SHE-FRM-10-06)

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FURTHER REFERENCE

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Lifting operations are properly planned and appropriately supervised. Detailed information on all these issues can be found in: Qatar Regulatory Document (Construction) RD1.3 and RD1.4

(b)

BS 7121-1:2006 Code of practice for the safe of cranes – Part 1: General

(c)

BS 7121-2:2003 Code of practice for the safe of cranes – Part 2: Inspection, testing and examination

(d)

BS 7121-3:2000 Code of practice for the safe of cranes – Part 3: Mobile Cranes

(e)

BS 7121-4:2010 Code of practice for the safe of cranes – Part 4: Lorry Loaders

(f)

BS 7121-5:2006 Code of practice for the safe of cranes – Part 5: Tower Cranes

(g)

Management of temporary works and equipment is covered in QCS Section 1, Part 14

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QCS 2014

Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

2.3.10.7 Author SECTION

POSITION IN COMPANY

NAME

CONTACT DETAILS

SHE Manager

POSITION IN COMPANY

SHEQ Director

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Approved by:

SIGNATURE & DATE

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NAME

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2.3.10.8 Approvals

Page 14

QCS 2014

Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

FORM SHE-FRM-10-04 CRANE/PERMIT TO LIFT CHECK LIST COMPLETED

Page 15

YES …

Contract : Location : Task/Method Statement No. (If applicable): Appointed Person : Employed by:

Date and Time of Visit :

…

Standard Lift

Contract Lift …

…

Complex Lift

Single Crane Position † Complete Part 1 only

Multiple Crane Positions † Complete Parts 1 & 2

Description of Works :

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LOAD DETAILS Max. Size of Load : Max. Lift Height :

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Max. Weight : Max. Radius : Others e.g. Unusual Centre of Gravity, Lifting Points etc. :

CRANE DETAILS

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Capacity and Type :

Max. Boom Length To Be Used For Lift :

Counterweight Req :

Hook Block Reeving (No. of Falls) :

Outrigger Spread (centre to centre) :

m. x

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Max. Available Boom Length : m.

Outrigger Pad Size (without mats) :

Max. Outrigger Load:

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SITE SURFACE CONDITIONS

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Access for Crane : Access for Transport : Lifting Position : Laydown Area : Safe Ground Bearing Capacity Under Outrigger : Assessed by : Proximity Hazards, provide details and attach sketch (eg overhead lines, public roads, drains, ground conditions etc) : A temporary works design for the lifting platform must be in place and signed off prior to setting up/commencing lifting operations. (Permit part 2 shall be completed for all crane positions/repositions of the crane.)

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CRANE ACCESSORIES REQUIRED (State type and safe working load) Chains : Shackles : Outrigger Mats (state size) :

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Wire ropes : Web Slings : Beams : Others (including specialist equipment) :

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Operational Requirements e.g. road closures/possessions/site clearance : Permit Valid From

To

CRANE TEAM Name Appointed Person Crane Supervisors Crane Operator

Qualifications

Signature

Date

No. Expires: No. Expires: No. Expires:

Signaller/Slinger

No. Expires Where contractors are required to complete this form, assistance shall be given by COMPANY Authorised Person who shall agree the details entered on the form and sign below. Lifting operations must not commence until this form has been signed by Details agreed on behalf of COMPANY COMPANY Authorised Person. Distribution: Site File … Appointed Person … Crane Operator …

Crane Supervisor …

Signature

Date

If for any reason the details contained within this permit cannot be adhered to, the lifting operation must not continue, the Appointed Person must be notified immediately.

QCS 2014

Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

Page 16

ARRANGEMENTS FOR MULTIPLE CRANE POSITIONS I agree that the crane described in part 1 may be re-positioned within the constraints defined within the Lift Plan provided that each time it is set up in a new position the items in the list below are checked and signed for by the Crane Supervisor. When the crane is being operated by a Contractor, each entry shall be countersigned by an COMPANY person, authorised by the Project Manager. The signature(s) shall be entered on this form prior to allowing the crane to operate in the new position.

.............................................................................

........................

Appointed Person

Date

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Additional items to be inserted by AP, if required

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Mats as Defined in Lift Plan Correctly Placed Under Each Outrigger

All Outriggers on Crane Platform and Within Designated Lifting Area Defined in Lift Plan

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Date

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Time

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Position Ref. as Lift Plan

Outriggers Extended to Spread Stated in Lift Plan

This form shall remain in the crane cab during lifting operations and be returned to the COMPANY Project Manager on completion of the lifting operations as described in part 1.

Crane Lift Supervisor Signature

COMPANY Authorised Signature

QCS 2014

Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances LIFT PLAN AND SCHEDULE

Page 17

This Lift Plan is specific to the lifting operations described in the “Scope”. It is not and should never be considered “Generic”

Contract: Date of Lifting Operation: Lift Plan Ref or Activity: Appointed Person Preparing this Lift Plan: Signed:

.

Date:

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Lift Supervisor: Purpose

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The crane overturning The load falling from the crane The load or machine striking someone or any other identified hazard

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1. 2. 3.

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The purpose of this lifting plan is to identify the control measures necessary to negate the primary hazards of :

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Scope of Works

Company Name:

Telephone:

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Contact Name:

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Address:

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Details of Crane Hire Company

Details of Crane Operator Qualifications and Operating History:

Load Details Max Size of Load: Other Details (centre of gravity, lifting points, packaging, pallets etc): Max Weight:

QCS 2014

Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

Page 18

Details of Crane Capacity and Type: Height (Ground – Jib Head): Radius: Main Jib Length: Fly Jib Length: Total Jib Length: Safe Working Load: Actual Working Load:

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Out Rigger Spread: Counterbalance Weight:

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Ground Conditions (CBR, Strata), Temporary Works Design in Place and Checked Off (where appropriate) : Out Rigger Loadings:

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Lifting Accessories & Configuration

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Spread Mat Requirements: Note: Where operating (Jib) height equals or exceeds 10m at any time, the Appointed Person must advise and consult with the Manager from any airport/airfield with 6km of the site. Airport/Airfield Requirements:

Equipment Details:

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Safe Working Load:

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Type (e.g. spreader beam):

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Sketch of Slinging Method:

(Note: will configuration affect SWL?)

QCS 2014

Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

Page 19

Site Conditions and Hazards

The following non-exhaustive list should be considered during the lift plan along with any other factors which could affect any aspect of the lift. Excavations, embankments, overhead and underground services or obstructions, culverts, drainage, manhole/inspection chambers, buildings, stationary objects, scaffolding, plant and equipment, roads, rivers, railways, personnel and public, other cranes, environmental considerations. Hazard

Control

.

Strength and Stability

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Ground conditions must be suitable and sufficient and remain so during crane lifts to take the anticipated loads. Include details of the ground conditions and any additional works required to the ground, including spreader mats specification and any testing regime required e.g. CBR tests. A temporary works design must be in place and checked off before any lifting operation or crane set up takes place.

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Weather / Environmental Considerations

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Indicate in this section detail of wind speeds / environmental conditions that have been referenced / anticipated for the duration of the lifting operations.

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Access

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Include any special travelling routes, road closures / highways notifications, access problems.

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Third Party Considerations

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Over-sailing, works adjacent to railways, noise and restriction of view.

Emergency / Breakdown Procedures

Signalling

Indicate whether hand signals or radios are to be used. Also indicate signalling source and radio frequency/channel. This section can also include any unique slinger/signaller identification (i.e. different colour helmet / hi-vis) if required.

QCS 2014

Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

Page 20

Site and Crane Layout Plan

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Safe System of Work - Methodology

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Include crane position, lay-down / rigging area, position of delivery vehicles, landing points, banksman positions, ground and overhead hazards and exclusion zones. If required use elevation drawings.

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Include pre-lift, lift and post lift.

QCS 2014

Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

Page 21

Lift Team The details of this Lift Plan along with any other associated Risk Assessment, Method Statement or Safe System of Work have been brought to the attention and explained to the persons listed below who have acknowledged that they understand the contents, hazards and associated control measures. Other Relevant Documentation (list and attach)

Position

Name

Signature

Date

Site/Project Manager:

.

Lift Supervisor:

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Crane Operator:

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Slinger / Signaller:

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Others:

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This plan is specific to the lift as detailed in the scope of works.

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In the event of any changes to circumstances, personnel or equipment, the plan should be reviewed and revised by the Appointed Person and any changes re-communicated to the lift team.

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Lifting Accessories SWL Used

Comments

Loading platform

Forks & netting

2.5 Tonne

Forks must be slid fully home and netting wrapped around load after having lifted the pack approx 300mm from original position.

pour

Drop chain

3 Tonne

Drop chain only to be used, not longer chains hooked back up to main lifting ring

Max Weight

Crane Used

Lifted From

Lifted To

Pallets of Bricks/blocks

2 tonne

tower

Lorry or store

2 tonne

tower

RMC truck

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Item to be Lifted

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SCHEDULE OF LIFTS (Common Lifts) :

Concrete skip

Page 22

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Section 11: Health and Safety Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

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QCS 2014

QCS 2014

Section 11: Health and Safety Page 23 Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

This checklist must be completed fully before the permit to lift is issued. Contract: Date of Lifting Operation: Lift Plan Ref or Activity:

1

Check

Yes

Has a Lift Plan been produced by an Appointed Person and accepted by COMPANY? Has the correct crane, as stated in the Lift Plan, been supplied, complete with manufacturer’s operating manual including a maintenance inspection checklist and duty charts?

3

Is a current report of last thorough examination of the crane (within the last 12 months or 6 months in the case of man-riding operations) available?

4

Are current 6 monthly test/thorough examination certificates for all lifting equipment / accessories available on site and their ’ID’ numbers checked.

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Have all maintenance inspections, including last daily / weekly checks been carried out and recorded, and evidence of PPM scheme available? Last recorded entry in register:

6

Is the Crane Driver’s training certification available and current for the category of crane being operated? (Check that the Driver has experience of this type of crane or operation e.g. grabbing or balling operations.)

7

Is the Banksman/Slinger’s certificate of training / competence available and current?

8

Has the Crane / Lift Supervisor been appointed?

9

Is the crane sited in the position identified in the Lift Plan?

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5

Have all risks from obstructions, such as foul sewer and surface water drain manholes, overhead cables or adjacent structures, been identified and suitable precautions implemented?

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10

No

.

No.

11 12

Are the lifting accessories suitable for the task and as identified within the Lift Plan, is there safe access to sling the load and will the load(s) be stable while being slung / unloaded and are any lifting points on the load identified and correct? Has the ‘Crane Lift Team’ (and others that may be affected) been made aware of the requirements in the Lift Plan, received an induction, and signed acknowledgement of the content of the Plan and the operations associated control measures? A complete copy of the Lifting Plan and associated crane documentation must be retained in the site safety file and be ready for inspection at any time.

If the answer to any of the above questions is ‘NO’, the Permit to Lift must not be issued until the query has been resolved. Site / Project Manager Completing this Checklist: Date:

Signature:

QCS 2014

Section 11: Health and Safety Page 24 Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

Operator’s Confirmation I have carried out all statutory and maintenance inspections as detailed above. Operator’s Details __________________________________________________

Signature:

__________________________________________________

Crane Type:

__________________________________________________

Qualifications:

__________________________________________________

Registration No :

__________________________ Date: ___________________

Crane Operator

Site File

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Distribution :

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Name (print):

QCS 2014

Section 11: Health and Safety Page 25 Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

DELIVERIES Vehicle Registration Number (as applicable):

Type of Plant/Equipment: Project Name: Supplier:

Driver Name:

Delivery For:

Date:

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CHECKLIST

Yes

No

…

…

Is the driver’s qualifications correct for the required task?

2.

Is a current 12 month certificate of thorough examination in place for the Appliance?

…

…

3.

Is the common Lift Plan in place?

…

…

4.

Are certificates in place for lifting accessories?

…

…

5.

Does the driver understand the requirement to have assistance loading/unloading transport vehicles?

…

…

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Location:

Defects Found:

Comments:

Signature: On completion file.

Date:

QCS 2014

Section 11: Health and Safety Page 26 Part 2.3.10: The Safe use of Cranes & Other Lifting Appliances

DELIVERIES Type of LORRY MOUNTED Vehicle Registration Plant/Equipment: CRANE (HIAB) Number: Project Name: Supplier:

Driver Name:

Delivery for:

Date:

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CHECKLIST Yes

No

…

…

…

…

…

…

…

…

Is the driver’s qualifications correct for the required task?

2.

Is a current 12 month certificate of thorough examination in place for the ‘HIAB’?

3.

Is the common lifting plan in place?

4.

Does the above include the operation in hand?

5.

Does the driver understand that a lift must not take place if they are beneath the load, is this identified in the plan (Item 3)?

…

…

6.

Does the driver understand the ‘No Lone’ working rule relative to the loading and unloading of the wagon?

…

…

Location:

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1.

Defects found:

Comments:

Signature: On completion file.

Date:

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ..................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ............................ 1

2.3.11 PERMIT TO WORK SYSTEMS ......................................................................... 1 2.3.11.1  Responsibilities .............................................................................................. 4  2.3.11.2  Definitions ...................................................................................................... 4 

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2.3.11.3  Action Required To Implement This Procedure ............................................ 5  2.3.11.4  Guidance to this procedure............................................................................ 7 

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2.3.11.5  Reference Documents ................................................................................... 9 

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2.3.11.6  Author........................................................................................................... 10 

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2.3.11.7  Approvals ..................................................................................................... 10 

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 2

PROCESS MAP Project Site/Manager

Authorised Person

SHE Advisor

Supervisor

Liaise with Project manager to ensure suitable persons are appointed to control permits on sale

Appoint an Authorised Person to control permits for the project

3.1, 3.3

3.1

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When necessary produce and update a suitable map or plans for the permits being d 3.1

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Ensure that the Appointed Person is trained to carry out

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For some activities, the contract may run their own permit system. When this is the case, the PM/SM will issue an overriding permit to enable the system to be run 3.3

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Issue and sign off Company permits – after ensuring necessary checks have been carried out and

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3.1

In conjunction with the Authorised Person, assess and confirm the competency of the individual undertaking the task 3.3

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In conjunction with the task supervisor, assess and confirm the competency of the individual undertaking the task 3.2

Monitor the Permit to Work system and advise the relevant person of any change required so that an appropriate review can be made of the Permit requirement and issue

3.1

Key Activity Guidance

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 3

PURPOSE 1

The purpose of this procedure is to assign responsibilities and establish a safe system of work to control hazards (which under normal circumstances are difficult to control), by means of a recognised permit system. SCOPE

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This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 4

2.3.11.1 Responsibilities SHE DIRECTOR 1

Authorises this procedure. CONTRACTS MANAGER

2

Ensures that the authorised person(s) are appointed. PROJECT/SITE MANAGER Ensures this procedure is established on the project under their responsibility and where applicable a permit to work system is applied.

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3

Has responsibility for the overall co-ordination and signature for the permit to work system

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4

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AUTHORISED PERSON

5

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SHE ADVISER/MANAGER

Provides advice and support in the application of this.

Work in accordance with this procedure.

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CONTRACTORS

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2.3.11.2 Definitions

HAZARD/ ASPECT/IMPACT

Something with the potential to cause harm, this can include substances, workplaces, machines, tools, etc and includes the potential to harm/damage the environment including the potential of causing a statutory nuisance.

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2

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RISK

Is the likelihood that the potential harm from a particular hazard is realised.

Risk = consequence x probability and is classed as either Acceptable or Unacceptable, depending on the results of the quantifying matrix. METHOD STATEMENT PERMIT TO WORK SYSTEM 3

The arrangements, confirmed by a written permit, by which a competent person/s satisfies that all necessary precautions have been taken and provisions made to secure the safety of persons associated with an activity. PERMIT TO WORK

4

A permit is a signed document that provides assurance that work may safely take place. It does not replace any requirements for risk assessments or method statements

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 5

2.3.11.3 Action Required To Implement This Procedure 1

In order to control hazards which under normal circumstances are difficult to control such as fire, dangerous substances electrical equipment, confined spaces, excavations etc. A formal written procedure shall be used to ensure a safe place of work/safe system of work strategy and full compliance with current legislation.

2

Permit to Work Systems Shall be used on COMPANY Projects in the following circumstances: Work on/test on electrical equipment which could give rise to risk of injury or death from electrical shock or burn, including commissioning work and, particularly, work involving exposed live conductors operating at dangerous voltages. (USE ELECTRICAL PERMIT FORMS).

(b)

Welding, flame cutting, use of ignition sources, or work on electrical equipment which could give rise to an incentive spark. (USE HOT WORK PERMIT FORM).

(c)

Work in confined spaces or at any poorly ventilated place where toxic/flammable gases, fumes, or vapours are likely to be present in dangerous concentrations, or where there may be oxygen deficiency or oxygen enrichment. (USE CONFINED SPACE PERMIT FORM).

(d)

Permit to excavate to be produced prior to any ground being broken. Information relative to services etc. shall be identified on the permits. (USE EXCAVATION WORK PERMIT).

(e)

Controlling access to complete or specific areas. (USE WORK ACCESS CONTROL PERMIT FORM).

(f)

Any other clearly dangerous circumstances e.g. site radiography where formal coordination of people and precautions is necessary in order to secure safety. (BESPOKE PERMIT FORM TO BE PRODUCED REFER TO SHE DEPARTMENT FOR ASSISTANCE).

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(a)

Only competent persons fully conversant with the COMPANY and/or client permit to work procedures shall be appointed as an Authorised Person by the Project/Site Manager

4

The Project / Site Manager responsible for the Project will ensure that the Authorised Person(s) have received suitable and sufficient training in order to execute their duties in this procedure, and should take into account the practical experience of the proposed Authorised Person of the particular plant, equipment and/or situation involved.

5

The Authorised Person shall ensure that on large sites, particularly where more than one permit system is operating, a suitable map(s) or plan(s) shall be produced and posted at a focal point(s). The map/plan shall where appropriate indicate the type of permit operating in, what areas, and shall make clear that only personnel covered by the permit shall enter those areas. The map or plan shall be updated, and removed immediately all work which demands a permit is closed.

6

N.B. Where more than one permit is issued on plant or an operating system a cross referencing procedure shall be adopted to ensure safety.

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GENERAL

HOT WORK PERMITS 7

The Authorised Person shall ensure that conditions are safe for work to be carried out, and where necessary, carry out, or arrange for atmospheric tests to ensure safety. Additionally, the Authorised Person shall ascertain the presence, nature and properties of any flammable, combustible, or explosive agent involved in the work (e.g. LEL, UEL, WEL, Flash Point, Density, Threshold of Smell, etc).

8

In addition the Authorised Person shall consider the possible sources of ignition such as:

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 6

(a)

Matches, lighters, cigarettes, etc.,

(b)

Oxyacetylene and other gas welding, cutting and burning, Electrical arc welding

(c)

Electrical sparks from electric motors, circuit breakers, capacitors etc.

(d)

Static Electricity

(e)

Percussive Sparks from metal tools etc.

(f)

Solar refraction

(g)

Any other source of ignition

WORK IN CONFINED SPACES Before signing this Form the Authorised Persons shall be sure he knows the exact nature and properties of any gases, liquids, vapours, solids or sludges present in the confined space (LEL, UEL, OEL, WEL, density, flash point, threshold of smell etc.).

10

The Authorised Person should carry out or arrange to carry out air tests if breathing apparatus is not worn by operatives entering the confined space and ensure that any working, escape or rescue respirator or breathing apparatus is suitable for the hazard involved, users have been instructed in correct usage and the time for which it will remain effective.

11

If breathing apparatus is to be worn, the Authorised Person must ensure that the operative is attached to a trained observer outside the confined space by means of a lifeline and harness and that any necessary rescue equipment is in position, and that operatives never work unattended in confined spaces.

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WORK INVOLVING THE PRESSURE TESTING OF PLANT AND EQUIPMENT Pressurisation of air and gases produce a much greater hazard if a vessel or pipe bursts than when hydrostatic pressurisation is used. Therefore, hydrostatic testing shall be used whenever practicable.

13

All tests shall be carried out in full consultation with the relevant Designer. If for technical reasons air or gas pressure testing is unavoidable the Project / Site Manager shall obtain formal permission to carry out such testing from the relevant Designer and safety procedures agreed with them.

14

Where the risk of an explosion or injury through pressure testing is evident the Project / Site Manager shall ensure that the Authorised Person ultimately signing the permit is a trained and experienced engineer who fully understands the hazards involved.

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OUT OF HOURS PERMIT

15

This is a delegation of control permit (it does not delegate responsibility which will still rest with the Project / Site Manager) and is intended to be used on projects where a contractor wishes to work outside normal site hours and no COMPANY supervision is available. It must only be used where the risk from the activity has been assessed as acceptable and can only be used for Single Contractor Works, where co-ordination between more than one contractor is an issue an COMPANY Manager or Supervisor must be in control of the site. WORK ACCESS CONTROL PERMIT

16

Where an access Control permit is to be used before issuing the permit the Authorised Person must ensure clear demarcation of the area is in place by means of notices and barriers so that personnel know the existence of such an area and its limits.

17

A means of identifying personnel permitted to enter the restricted area, must be established by the Supervisor of the works (The permit shall list the names of those permitted in the restricted area).

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 7

ACTIVITIES UNDERTAKEN BY COMPANY Whenever COMPANY operates a permit to work system the Project / Site Manager shall liaise with the SHE Department and agree who shall have responsibility for overall signature of the particular permit to work form. In all cases such persons shall be appointed in writing as Authorised Persons.

19

The Authorised Person who signs the Permit to Work shall assess the persons who are to carry out the work and decide in conjunction with the supervisor in charge of those persons whether they are competent to undertake the work safely.

20

The Authorised Person has a clear responsibility to satisfy themselves that the precautions required by any particular permit to work they issue are in place before work is authorised, and must be aware of any risk assessments and controls identified therein associated with the activity to be undertaken.

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ACTIVITIES UNDERTAKEN BY CONTRACTORS

In some circumstances sub/work package contractors may wish to operate their own permit to work systems, and it may be that COMPANY will require some contractors to control their own works by a permit system. In these cases the following actions should be undertaken.

22

The Site Manager will issue an over riding permit of the appropriate type authorising the Contractor to control the works in accordance with an agree permit system, this permit shall be reviewed regularly by the Project Site Manager to verify it is still appropriate and updated as necessary. The review shall be at intervals not exceeding 7 days.

23

The Project Site Manager shall liaise with the SHE Department and agree who from the Contractors team shall have responsibility for overall signature of the particular permit to work form. In all cases such persons shall be appointed by the Contractor in writing as Authorised Persons and this appointment `notified to the Project Site Manager.

24

The Contractors Authorised Person who signs the Permit to Work shall assess the persons who are to carry out the work and decide in conjunction with the supervisor in charge of those persons whether they are competent to undertake the work safely.

25

The Contractors Authorised Person has a clear responsibility to satisfy themselves that the precautions required by any particular permit to work they issue are in place before work is authorised, and must be aware of any risk assessments and controls identified therein associated with the activity to be undertaken.

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21

2.3.11.4 Guidance to this procedure 1

In some circumstances, particularly where COMPANY is modifying or enlarging an existing plant, the client may require his own permit to work system to be used and that sub/work package contractors working on the site be subject to it. AUTHORISED PERSONS

2

All Authorised Persons shall be aged over 21 years.

3

Authorised Persons shall formally accept and not delegate their duties.

4

Authorised Persons shall be identified in the SHE Management Plan. TYPES OF PERMITS AND THEIR APPLICATION ELECTRICAL WORK PERMITS

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 8

5

Electrical work is subject to the Electricity at Work Regulations. The procedures for complying with them are contained in SHE-PRO-004 together with any COMPANY Electrical Safety Instructions

6

All work on electrical equipment that has the potential to be energised at a dangerous voltage shall be covered by a permit to work and the necessary signs displayed. HOT WORK PERMITS

The permits are for use where hot work on plant or equipment is required and a permit for general hot work within buildings where flammable materials are liable to be present. The advice of the SHE Department shall be sought when determining which the appropriate permit to be used in is circumstances where there is any doubt, and should be used where one or more of the following are present in significant quantities:

(b)

Flammable liquids (particularly highly flammable liquids whose flash points lie below 32ºC). It should be remembered that vapours from such liquids are normally heavier than air, and may collect in sumps, drains etc

(c)

Flammable gases or vapours where the concentration involved could approach or exceed the lower explosive limit. (NB whilst methane is lighter than air, most other hydrocarbon gases are heavier than air e.g. propane, butane).

(d)

Flammable dusts (particularly organic dusts like grain, wood, sugar, etc. Also certain metal and other inorganic dusts which are explosive e.g. aluminium. It should also be remembered that a relatively minor initial explosion may disturb lying dust and give rise to a catastrophic secondary explosion.

(e)

Solid organic and other materials, for instance timber structures or combustible insulation materials such as paper, polystyrene, polyurethane foam, etc.

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(a)

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The permit shall also be used in circumstances where (a)

Dangerously hot plant (e.g. steam heated) has to be isolated to avoid burns, scalds, etc., to personnel working on that plant.

(b)

Metal cutting is being undertaken either by gas or mechanical means

(c)

Welding or brazing operations are required

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8

The objective of these permits is to allow work that may give rise to a source of ignition in circumstances where there is risk of fire and/or explosion, and/or burns to personnel.

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10

The presence of potentially dangerous sludges or deposits shall also be considered which may, when disturbed, give rise to hazardous gas etc. Further hazards may also arise from flammable liquids, gases, and vapours, introduced by the work itself, or the ingress of steam or corrosive/hot liquids etc. or lack of oxygen.

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WORK IN CONFINED SPACES

The objectives of the permit are to minimise these hazards, and secure compliance with the Qatar Regulatory Document (Construction). EXCAVATION WORK PERMIT

11

See procedure SHE-PRO-003 for the procedure to be adopted for excavation work. Work Access Control Permit

12

This permit shall be used where it is necessary to control the access of personnel to certain work areas for the following reasons: (a)

To prevent damage and vandalism to installed plant within a particular area.

(b)

To know the exact whereabouts of personnel on "high security" sites at given times.

(c)

To restrict personnel who enter potentially hazardous areas to a limited number, all with appropriate specialist knowledge and training.

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 9

WARNING SIGNS AND TAPES The following warning signs/tapes shall be used where applicable. Danger Permit to Work Area Entry Forbidden Except to Authorised

(b)

Persons

(c)

Scaffolding Incomplete Do Not Use

(d)

Caution Men Working on Apparatus

(e)

Danger Keep Away Exposed Live Conductors

(f)

Danger No Unauthorised Person to Touch This Switchgear

(g)

Danger No Smoking or Naked Flames

(h)

Danger Plant Equipment Under Test Do Not Touch/Operate

(i)

Caution Risk of Ionising Radiation (Provided by Specialist Contractor)

(j)

Restricted Work Area Entry Only to Listed Workmen on COMPANY Access Permit

(k)

Danger Buried Cables

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(a)

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13

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2.3.11.5 Reference Documents

Confined Space Entry Work Permit (SHE-FRM-11-01)

2

General Permit to Work (SHE-FRM-11-02)

3

Hot Work Permit General (SHE-FRM-11-03)

4

Hot Work Permit Plant and Equipment (SHE-FRM-11-04)

5

Pressure Test Work Permit (SHE-FRM-11-05)

6

Work Access Control Permit (SHE-FRM-11-06)

7

Permit to Work on Test Electrically Isolated Apparatus

8

(SHE-FRM-11-07) Permit to Test Electrically Live

9 10

Out of Hours Work Permit (SHE-FRM-11-09)

11

Permit to Excavate (SHE-FRM-3-02)

12

Site Crane Permit to Lift (SHE-FRM-10-02)

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FORMS

Apparatus (SHE-FRM-11-08)

REFERENCE DOCUMENTS 13

Qatar Regulatory Document (Construction) RD1.5

14

Safety, Health and Environmental Risk Management and Written Safe Systems of Work (SHE-PRO-001)

15

Safe Working in the Vicinity of Buried and Overhead Services (SHE-PRO-003) Electricity at Work (SHE- PRO-004)

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 10

16

The Safe use of Cranes and Other Lifting Appliances (Excavators, Tele Handlers and Lorry Loaders (SHE-PRO-010)

17

Fire Precautions During Construction Work in Buildings (SHE-PRO-013)

2.3.11.6 Author SECTION

POSITION IN COMPANY

NAME

CONTACT DETAILS

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SHE Manager

POSITION IN COMPANY

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NAME

SHEQ Director

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Approved by:

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2.3.11.7 Approvals

SIGNATURE & DATE

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 11

Contract: …………………………………………………………………Permit No: ……………………………. Location: ……………………………………………………………………………………………………………………… Description of Work: ……………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………… Valid From …………..…hrs on (Date)…………..……To……..…. .hrs on (Date) ……..………(Max 1 shift) Hazard Restrictions, Comments: ……………………………………………………………………………….

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REQUIRED Mandatory Mandatory Mandatory Mandatory Mandatory Mandatory Mandatory Mandatory Mandatory

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MANDATORY CONTROL MEASURES Supervision – Nominated and Completed Means of Communication Instruments to detect adverse atmospheres Gas Purging Forced Air Ventilation Intrinsically Safe Lamps or Lighting Removal of residues (without causing additional hazards) Suitable Access/Egress arrangements including emergency evacuation Emergency Rescue equipment and procedure

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PERMIT MUST NOT BE ISSUED OR WORK COMMENCED UNTIL ALL THE CONTROL MEASURES ABOVE ARE IN PLACE OPTIONAL CONTROL MEASURES Isolation (Gases, Electrical, Mechanical) RPE Full BA, Escape Breathing Apparatus or External Air Feed Fire Precautions (Intrinsically safe lamps etc) Task and Emergency Lighting Additional permits for specific activities i.e. hot work ISSUE OF PERMIT

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REQUIRED YES NO YES NO YES NO YES NO YES NO YES NO

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I confirm that all atmospheric checks have been made and all persons required to enter the Confined Space for any reason are medically fit and have proof of having received the relevant training in Confined Space Entry to the correct category.

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Authorised Person: …………………………… Signed: …………………………………Date:………………. Names of persons entering the Confined Space are attached RECEIPT OF PERMIT I confirm that work by myself or by any person under my control in the Confined Space will be carried out in accordance with this permit, all statutory requirements and company safety policy. All persons entering the Confined Space will receive information and instruction in the requirements of this permit and safety measures necessary prior to entry into the Confined Space.

Competent Person: …………………………… Signed: …………………………………Date:………………. CLEARANCE (Competent Person Confined Spaces) I certify that all persons have been withdrawn and warned that it is no longer safe to enter the Confined Space above and that all tools and equipment have been removed.

Competent Person: …………………………… Signed: …………………………………Date:………………. CANCELLATION – AUTHORISED PERSON I acknowledge receipt of the clearance of this Permit. THE PERMIT IS NOW CANCELLED

Name: …………………………………… Distribution: White copy – Workplace recipient copy)

Signed: …………………………………Date:………………. Pink copy – Distribute as required

Blue copy – Retain in book (file

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 12

This Permit is valid only for the period specified Contract Name:

Contract No:

Location of works:

Description of works:

Part 1

Permit No:

Names of persons in working party:

Part 2 Details of work to be carried out (risk assessment, method statement, etc, to be attached)

Y N

.

Other

Action to be taken

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N N N N N N N

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Y Y Y Y Y Y Y

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Part 4 Other hazards Heat source Steam Electricity Noise Work at height Mechanical power Others (specify)

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Part 3 Precautions to be observed (e.g. other permits, lock off, access control) Protective clothing Y N Breathing Y N Gloves Y N required apparatus Safety helmet Y N Eye protection Y N Ear Y N defenders Safety harness Y N Wellingtons Y N Overalls Y N Safety boots Y N Face mask Y N RPE Y N

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Part 5 Issue of Permit: I hereby certify that the precautions detailed above have been carried out and that it is safe to commence work. Signed: Name: (Authorised person) (Print) Date: Time: Valid from: Valid to:

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Part 6 Receipt of Permit: I hereby declare that I accept responsibility for carrying out work detailed in this permit including all precautions noted. Name: Signed: (Authorised person) (Print) Date: Time: Part 7 Clearance of Work Area I hereby declare that the work for which this permit was issued is now complete and that all employees under my control have been withdrawn. All equipment, tools, material and gear has been removed. All guards have been replaced and the area has been checked as safe. Signed: Name: (Authorised person) (Print) Date: Time: Part 8 Permit cancellation I declare that this permit and all copies of it are cancelled Signed: Name: (Authorised person) (Print) Date: Time: Distribution: copy)

White copy – Workplace recipient

Pink copy – Distribute as required

Blue copy – Retain in book (file

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 13

Contract: …………………………………………………………Permit No: ………………………. Location: ………………………………………………………………………………………………… Description of Work: …………………………………………………………………………………………………………… …………………………………………………………………………………………………………… Valid From ………………hrs on (Date)…………………. To ……….hrs on (Date) ……………… Hazard Restrictions, Comments: ……………………………………………………………………..

CONTROL MEASURES

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…………………………………………………………………………………………………………… REQUIRED

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Combustible materials to be removed from the working area Suitable Fire Fighting Equipment (FFE) is in position Person received appropriate fire safety training No combustible liquids, vapours, gases or dusts within the work area Work location has been thoroughly examined Exposed wooden flooring or skirting etc, covered to prevent ignition Gas cylinders secured upright and flash back arrestors fitted Hot work to cease one hour before end of shift Operatives familiar with emergency procedures Screens positioned when welding, cutting or grinding operations

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ISSUE OF PERMIT I confirm that all persons carrying out hot work have been made aware of the contents of this permit Authorised Person…………………………….Signature……………………

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RECEIPT OF PAYMENT I confirm that work by myself or by any person under my control carrying out hot work will do so in accordance with this permit, all statutory requirements and company safety policy. All persons involved will receive information and instruction in the requirements of this permit and safety measures necessary prior to work commencing. Competent Person…………………………….Signature……………………

Weekly Issue Fire Watch Checks

Day Mon Tues Wed Thur Fri Sat Sun

Initial

Initials confirm temporary cancellation for weekly issue

FINAL CANCELLATION – Sub-contractor Representative

I confirm that all sources of ignition have been removed and the relevant fire watch stood Name……………………………………………………… Signed ......................................... Date……………

FINAL CANCELLATION – Authorised Person

I acknowledge receipt of the cancellation of this Permit. THE PERMIT IS NOW CANCELLED Name .............................................................................. Signed .......................................... Date…………...

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 14

Permit Serial No. Date of Issue Hot Work Permit - Plant/Equipment 1. Details of location and work to be carried out Plant/equipment no. 2. This permit is valid from hrs on (date) to hrs on (date) 3. Description of fire/explosion/hazards involved: Quote flammable gases, liquids, vapours involved, and give lower and upper explosive limits etc. or steam 4. Description of other hazards: Give details of noise, toxic dangerous chemicals, steam, hot liquids etc. Quote OELs where applicable YES

NO

Comment

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Precautions Valves (designate) padlocked off Total disconnection Spades fitted Open-ended pipes/vessels sealed Fire-fighting systems locked off Other isolation methods (specify) Drains, sewers within 25 metres sealed Mechanical ventilation Flame-proof electrical equipment or equivalent Fire blankets 'Don't Touch' labels Local electrical circuits isolated Dangerous machinery isolated/guarded Earthing against static electricity Smoking/naked lights prohibited Danger area demarcated Operators instructed in hazards and precautions Caution signs posted Standby fire-fighting equipment

Explosimeter reading:

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Atmospheric tests (not for steam) Reading taken by Print Name

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Other necessary precautions (including breathing apparatus) 6.

Date: Time:

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Title Gas detector reading Specify gases Authorisation I have personally checked the above conditions and consider it safe to carry out this work Authorised person Print Name Title: Signature: Date: Time: Acknowledgement I understand the hazards of this work and the precautions to be taken. These have also been fully explained to the operatives carrying out this work, and I consider them competent to do it safely. I will return my copy of this permit to the authorised person when this work has been safely completed Competent supervisor Print Name Title: Signature: Date: Time: Time extension Subject to the following precautions Mark N/A if none are required the expiry time of this permit is extended from hours on (date) to hours on (date) Signed Authorised person Date: Cancellation I have completed the work detailed in this permit, and have restored the location to a safe condition. I have returned my copy (white) of this permit to the authorised person Signed Competent supervisor Date: I accept that the work has been safely completed. The top (white) copy of this permit has been destroyed Signed Authorised person Date: Time:

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9.

10. 10.1

10.2 Notes a) b) c)

Permit is automatically suspended upon sounding of emergency alarms, instructions via public address system etc. Check with authorised person before recommencing work. Where the authorised person is also the competent supervisor he should sign all parts of the form and issue the top original (white) copy to himself as a check on procedure. Signatures for paragraphs 10.1 and 10.2 to be placed only on duplicate (blue) copy which is to be retained for record purposes.

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Permit Serial No………………………………….

Date……………………………

1.

Details and location of plant to be pressure tested:

2.

This permit is valid from: .........................

3.

Page 15

hrs on (date) ……………………to

…………………hrs on (date) …....................

Nature of pressure test: Hydrostatic

4.

Gas

Air

Pressure involved………………….

Description of any other hazards associated with pressure test (noise, hot liquid, steam, toxic/corrosive agents etc.): Precautions

6.

Authorisation

Applicable Yes No

Comment

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5.

7.

Time (hrs)………………….

Date………………………………

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Signed ……………………………………

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Authorised Person : Print Name…………………………………………Title………………………….............

Acknowledgement:

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I understand the hazards of this work and the precautions to be taken. These have also been fully explained to the operatives carrying out this work, and I consider them competent to do it safely. I will return my copy of this permit to the authorised person when this work has been safely completed. Print Name………………………………………Title…………………………..........

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Competent Supervisor:

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Signed …………………………………………………Time (hrs)…………………. Date………………………… Time Extension: Subject to the following precautions – Mark N/A if none required

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8.

The expiry time of this permit is extended from …........................ hrs on (date) …………………………

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To …........................hrs on (date) …………………………

9.

Cancellation:

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9.1 I have completed the work detailed in this permit, and have restored the location to a safe condition. I have returned my copy (white) of this permit to the authorised person. Signed Competent Supervisor…………………………………….. Time (hrs)…………………. Date…………………………………….. I accept that the work has been safely completed. The Top copy (white) of this permit has been destroyed. Signed Competent Supervisor…………………………………….. Date……………………………………..

Time (hrs)………………….

Notes a) Permit is automatically suspended upon sounding of emergency alarms, instruction via public address system etc. Check with authorised person before recommending work.

Distribution:

White copy Pink copy Blue copy

b) Where the authorised person is also the competent person, he should issue the top copy (white) to himself as a check on procedure.

-

Workplace recipient Distribute as required Retain in book (file copy)

c) Signature for paragraphs 9.1 and 9.2 to be placed on duplicate copy (blue) which is to be retained for record purposes. Top copy (white) to be destroyed to prevent re-issue.

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 16

1.

Project:

2.

Description of controlled work area:

3.

The above work area has been demarcated in the following manner:

4.

This permit is valid from: …................ ……….….hrs on (date) ………............

5.

The person(s) designated below is hereby authorised to enter and work in the controlled area described in 2. above

Name and initials

Title

Name and initials

Title

Name and initials

Title

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Title

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Name and initials

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hrs on (date) ………………. to

Special conditions (if any):

7.

I hereby agree to return my copy of this permit to the authorising person in 8. Below immediately after the expiry time /date at 4. above

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Signed Work Access Controller…………………………… Notes

Date……………….

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Signed person requesting access…………………………..

a) Top copy (white) to be issued by Works Access Controller to person requesting

Distribution:

White copy Pink copy Blue copy -

b) Duplicate copy (blue) to be retained in file

Workplace recipient Distribute as required |Retain in book (file copy)

Date……………….

QCS 2014

1.

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 17

Details of apparatus and work on/test* to be done: Contract No:…………………………………….. Location:………………………………………………………………….. Precautions and authorisation

2.1

Isolation: State isolation point(s), whether or not isolators have been padlocked off, fuses drawn, etc.

2.2

Warning notices and access control: State where caution/danger notices have been posted and if appropriate, how work area has been fenced off.

2.3

Prove apparatus dead: State what tests have been made, where and with what instruments.

2.4

Earthing: State where apparatus has been earthed and, for testing, which earths may be removed.

2.5

Other precautions: Specify if required for special circumstances.

2.6

Validation period: This permit is valid from ……hrs on (date)………to……..hrs on (date)……… I hereby declare that the above precautions have been taken and made known to the competent person in charge of the work. I consider that the apparatus specified in paragraph 1 is safe to work on/test*

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2.

3.

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Signed (Authorised Person)…………………………Time (hrs)………………Date………………… Acceptance and receipt of Top copy (White) by competent person

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I acknowledge receipt of this permit and understand the safety precautions described above. Neither I nor the men under my control will work on/test* any other electrically dangerous apparatus. I will return this permit to the authorised person when the work on/test is complete.

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Signed (Authorised Person)………………………… Time (hrs)………………Date………………… Cancellation

4.1

I hereby declare that the work on/test*- detailed in paragraph 1 has been completed/stopped, earths removed, and men/gear withdrawn. The apparatus is now in safe condition.

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4.

4.2

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Signed (Authorised Person)………………………… Time (hrs)………………Date………………… I hereby declare this permit cancelled. The top copy (white) has been returned to me by the competent person and destroyed. The apparatus detailed in paragraph 1 may be reconnected for service.

Signed (Authorised Person)…………………………Time (hrs)………………Date………………… Notes a) Where the authorised person is also the competent person, he should sign all parts of the form and issue the top (white) coy to himself as a check on procedure.

b) Top copy (white) is to be retained by competent person whilst work on test is going on and returned to authorised person for destruction when work is complete.

Distribution: Top Copy – White 2nd Copy - Blue This form is intended to be used in a PAD format only

c) Signature for paragraphs 4.1 and 4.2 to be placed only on duplicate copy (blue) which is to be retained for record purposes. Top copy (white) to be destroyed to prevent re-issued.

QCS 2014

1.

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 18

Details of apparatus and test to be done Contract No.

Location

2.

Reasons why test cannot be carried out with apparatus isolated

3.

Person(s) involved in test Only authorised or competent persons may work on/test live apparatus at or above 55 volts AC/DC Competent person name and initials Observer name and initials Precautions and authorisation

4.1

Safety equipment: The following safety equipment will be provided and used throughout the test Max safe voltage

insulating rubber boots

Max safe voltage

insulating rubber mats

Max safe voltage

insulating push bars

Max safe voltage

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Other tools and equipment: State type and when to be used

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insulating rubber gloves

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4.

Adjacent live equipment: The following precautions are to be taken to ensure that the persons named in paragraph 3 cannot come into contact either adjacent live equipment

4.3

Danger and caution notices have been posted at

4.4

Atmospheric conditions: The following precautions are to be taken to avoid danger from wet and humid conditions

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4.2

From 4.6

hrs on (date)

to

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Validation period: This permit is effective

hrs on (date)

Authorisation: I declare that all precautions specified in paragraph 4 are in force and that the test described in paragraph 1 may now begin. Signed Authorised person

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Important: No electrical test is to be carried out in potentially flammable atmospheres unless a hot work permit is in force

Time

hrs

Date

Acceptance by competent person and observer

5.1

I acknowledge receipt of the top (white) original of this permit and understand/will use the safety precautions listed in paragraph 4. I will work only under the surveillance of the observer, and will return this permit to the authorised person when the test is complete.

5.2

I acknowledge receipt of the first (pink) copy of this permit and will monitor the safe progress of the competent person. I have been instructed what to do in the case of emergency, and will return the permit to the authorised person when the test is complete.

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Signed Observer 6.

hrs

Date

Time

hrs

Date

Clearance I hereby declare that the test described in paragraph 1 is complete. The apparatus is safe and tools/gear have been withdrawn. Signed Competent person

7.

Time

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Signed Competent person

Time

hrs

Date

Cancellation For cancellation complete blue copy I hereby declare this permit cancelled. I have received back respectively from the competent person and the observer the white original and pink copy of the permit. These copies have been destroyed. Signed Authorised person

Time

hrs

Date

NOTES a) Top original (white) and first copy (pink) to be issued by authorised person to competent person and observer respectively and retained by them during the work/test. Both copies to be returned to authorised person for destruction on completion of test.

b) Where the authorised person is also the competent person he should issue the top original (white) to himself as a check on correct procedure.

QCS 2014

Section 11: Health and Safety Part 2.3.11: Permit to Work Systems

Page 19

CONTRACT: ......................................................................................Permit No. ................ LOCATION: .................................................................................................. DESCRIPTION OF WORK: .............................................................................. DATE & DURATION OF WORKS:

/

/

Hours: ........................

.

IS THE WORK TO BE CARRIED OUT A HIGH RISK ACTIVITY (e.g. Steel erection, roofwork, cladding, asbestos removal, work at height, excavations over 600mm deep etc.) Refer to initial risk assessment Construction Phase Safety Plan. (circle appropriate risk rating)

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HIGH

LOW

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If the work is high risk or multi discipline, COMPANY supervision must be on site at all times.

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Name and position of competent person supervising work activities. (person named must stay on site at all times) Name ................................................Position ..............................

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FURTHER CONTROL MEASURES

Safety Courses attended

YES OR

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Is there a first aid trained person on site? Is there access to welfare and washing facilities? Can the emergency services be called? Is there sufficient lighting and access to work areas? Have emergency contact numbers been passed to the supervisor? Are all staff inducted and aware of fire and emergency procedures? Have all applicable risk assessments / method statements been accepted? Confirm tool-box talk has been held to communicate this permit? Are there any specific environmental considerations i.e. consented noise levels IF NO IS INSERTED IN THE RESPONSE BOX THEN THE WORK MUST NOT CONTINUE

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OTHER SITE SPECIFIC CONTROLS:

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Site Manager: ................................................... Contract Manager: .........................................

Signed: ............................................................ Date Approved: .....................................................

RECEIPT OF PERMIT I confirm that work by myself or by any person under my control carrying out work out of hours or without on-site COMPANY supervision will do so in accordance with this permit. All persons involved will receive information and instruction in the requirements of this permit and safety measures necessary prior to work commencing Named Supervisor:

Sub-contractor:

Signature:

Date:

Works Completed:

YES

/ NO

Permit Return Date:

Further Permit Required:

YES

/ NO

Site Manager Signature:

*Out of hours

QCS 2014

Section 11: Health and Safety Part 2.3.12: Control of Working at Heights

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ........................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ............................ 1

2.3.12 CONTROL OF WORKING AT HEIGHTS ......................................................... 1

2.3.12.1  Responsibilities .............................................................................................. 4 

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2.3.12.2  Definitions ...................................................................................................... 4  2.3.12.3  Procedure ...................................................................................................... 5 

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2.3.12.4  Reference Documents ................................................................................... 7 

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2.3.12.5  Author............................................................................................................. 7 

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2.3.12.6  Approvals ....................................................................................................... 7 

QCS 2014

Section 11: Health and Safety Part 2.3.12: Control of Working at Heights

Page 2

Process Map Scaffold/Work at Height Coordinator

Project Manager/Contractor

SHE manager/Adviser

To ensure this procedure is established and prior to tender ensure detailed scaffold specification is produced, including for all production etc.

Contractor

Operatives

Provide details, including Design as appropriate to Project/Site Manager 1.5

1.2, 3.1

Prior to erection of scaffold, appoint scaffold Co-ordinator

Provide support and identify requirements for training 1.3

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Ensure work at height/scaffold requirements are discussed at contractor pre-start monitoring

Understand scaffold specification and comply with defined duties including ensuring the availability of risk assessment and method statements

Erect/Inspect scaffold and protection in accordance with this procedure

1.5, 3.3

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3.1

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Arrange for scaffold Co-ordinator to attend scaffold inspection course, if required

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3.1

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3.1

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Check scaffolders training certificates and retain copies

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3

Ensure scaffold inspected after erection and every 7 days. Record using Company Register or similar ti t d d 3.2, 3.3

Monitor that scaffolding etc. Erected by Company or Sub/Works Package Contractor are safe and inspected 3.2

Receive scaffold handover certificate from scaffolding contractor etc. 3.4

Key

Activity Guidance

Provide the appropriate certificates 3.2

QCS 2014

Section 11: Health and Safety Part 2.3.12: Control of Working at Heights

Page 3

PURPOSE 1

The purpose of this procedure is to control the hazards and associated risks of working at height by ensuring proper design and safe systems of work including the requirements for statutory inspections. SCOPE

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This procedure covers all COMPANY Projects projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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QCS 2014

Section 11: Health and Safety Part 2.3.12: Control of Working at Heights

Page 4

2.3.12.1 Responsibilities SHE DIRECTOR 1

Authorises this procedure. PROJECT/SITE MANAGER

2

Ensures this procedure is established and that works are carried out in accordance with this procedure. SHE MANAGER/ADVISOR

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Provides advice and support in the application of this procedure and monitors others’ effectiveness to manage the activities.

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SCAFFOLD/WORK AT HEIGHT CO-ORDINATOR

Ensure duties are carried out in accordance with this procedure

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To provide all relevant information including where appropriate design details, specifications and calculations to COMPANY and to work in accordance with this procedure and any other information/rules provided in relation to this procedure.

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CONTRACTOR

EMPLOYEES

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To work in accordance with this procedure and any other information/rules provided in relation to this procedure.

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2.3.12.2 Definitions

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This procedure has been prepared to control the risk of falls, falling objects and collapse of all work places and is particularly aimed at scaffolds, working platforms, and personal fall protection systems.

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SCOPE AND SUMMARY OF WORK AT HEIGHT

THE REQUIREMENTS 2

The control of scaffolding and working at heights are contained in the Qatar Regulatory Document (Construction) Work at Height Section, relevant British or International Standards and Codes of Practice, National Access and Scaffolding Confederation Current TG20 for Technical Guidance on the use of BS EN/2811-1. The current NASC SG14 Guidance for Preventing Falls in Scaffolding and False work. PERSONAL FALL PROTECTION IS

3

A fall prevention, work restraint, work positioning, fall arrest or rescue system, other than a systems in which the only safeguards are collective safeguards, or,

4

Rope access and positioning techniques.

QCS 2014

Section 11: Health and Safety Part 2.3.12: Control of Working at Heights

Page 5

2.3.12.3 Procedure MANAGEMENT RESPONSIBILITIES The Project/Site Manager will appoint a Scaffold Co-ordinator to ensure the proper control of all scaffolding, working platforms, working restraint mitigation. If no appointment is made the Project/Site Manager will assume the duties himself.

2

Specific details in relation to contractors scaffold etc and working at height shall be discussed at the initial SHE meeting SHE-PRO-007.

3

The person appointed will be site based and competent to carry out his duties. Training where necessary shall be arranged through the regional Training Coordinator.

4

Erection and dismantling of scaffolds shall be carried out in accordance with the National Access and Scaffolding Confederation (NASC) Guide (SG4).

5

Ensure all risk assessments and method statements have been prepared in relation to the erection use and maintenance of scaffolds

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USE OF SCAFFOLDS, WORKING PLATFORMS, PERSONAL FALL PROTECTION AND WORK RESTRAINT MITIGATION MEASURES PROVIDED BY COMPANY COMPANY retain the responsibility for ensuring that any such equipment it provides for use by its own personnel or others is safe for proper use.

7

Sub or Work Package Contractors have a responsibility to check any equipment/scaffold etc. provided for their use is safe before they use it and that their operatives are adequately trained.

8

COMPANY has a responsibility to ensure that any workplace that is part of a scaffold is safe before others under COMPANY control or COMPANY own employees use it.

9

COMPANY Scaffold and Work at Height Co-ordinator shall also monitor that scaffolds etc. erected by COMPANY/sub/work package contractors are safe and inspected as required by Regulations and are only erected by trained, competent and certified persons.

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10

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SCAFFOLDS, WORKING PLATFORMS AND PERSONAL FALL PROTECTION ERECTED/USED BY SUB OR WORK PACKAGE CONTRACTORS' PERSONNEL All sub/work package contractors' personnel retain the responsibility for ensuring that any such equipment provided is safe for proper use and inspected as required by the Regulations.

Each sub or work package contractor has a responsibility to inspect equipment provided to it by another contractor before they use it. MANDATORY ITEMS RELATIVE TO WORK AND ACCESS/EGRESS TO HEIGHT

12

Staircases shall be the default primary means of access/egress to scaffolding/working platforms where practicable, and shall only be excluded by Risk Assessment.

13

Where ladders are to be used as a means of access/egress following considerations in above, they shall be incorporated into a ladder tower/ladder landing platform.

14

Where the above is not practicable ladder access openings shall be protected with a gravity gate, (running the top guard rail into the ladder access point as an alternative is not permissible.)

QCS 2014

Section 11: Health and Safety Part 2.3.12: Control of Working at Heights

Page 6

Where ladders are incorporated within a scaffold/working platform the access shall be protected by a ladder flap or suitable guard rails and toe boards, to protect the opening.

16

When considering the use of ladders including step ladders, they shall not be used for Work at Height unless Risk Assessment has demonstrated the other systems such as Podium or Tower Scaffolds are not practicable or are for very short duration only. A Ladder Permit must be issued for their use.

17

All working platform edges including edge protection to roofs, floor slabs and loading bays shall incorporate material fall protection whether in use or not

18

Material Transport Loading/unloading plans shall be produced by the material receiving company and applied and shall form part of the traffic management plan, and shall include fall prevention during these operations

19

To compliment the above, a pre unload check shall be carried out prior to releasing the ropes/chains/straps.

20

All Loading Bays shall be located away from building pedestrian access points where practicable and in all cases incorporate triple guard rails to sides and a proprietary front loading gate which protects users at all times.

21

Requirements for passive collective fall arrest where there is a risk of persons falling and edge protection cannot be provided, a fall mitigation system such as nets, air/beanbags shall be supplied and used. Where this is not practicable fall restraint shall be considered before fall arrest.

22

Where safety harnesses and lanyards are used by employees they shall be inspected before use and thoroughly examined at least every 3 months or as recommended by the manufacturer if a lesser period. Safety belts are prohibited.

23

Scaffolds must not be used until a scaffold handover certificate has been issued by the person erecting the scaffold and an entry has been made in the appropriate register.

24

Scaff-tag or similar notices are to be displayed on ALL scaffolding - in particular tower scaffolds.

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QCS 2014

Section 11: Health and Safety Part 2.3.12: Control of Working at Heights

Page 7

2.3.12.4 Reference Documents FORMS 1

Checklist for Scaffold Design Requirements (SHE-FRM-12-01)

2

Ladder/Step Ladder Use Authorisation (SHE-FRM-12-02)

FURTHER REFERENCE DOCUMENTS Qatar Regulatory Document (Construction) RD1.3

2

COMPANY Register Handover Certificates, Inspection Records and Training Records.

3

Contractors Check List for Initial Safety, Health and Environmental Meeting (SHE-PRO-007)

4

Standards and Guidance Risk Assessment Guides

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2.3.12.5 Author

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POSITION IN COMPANY

NAME

CONTACT DETAILS

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SECTION

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SHE Manager

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2.3.12.6 Approvals

Approved by:

NAME

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

QCS 2014

Section 11: Health and Safety Part 2.3.12: Control of Working at Heights

Page 8

All scaffolds and working platforms shall be properly constructed to provide a safe working place and be suitable for the type and nature of the work being carried out. There shall be provided suitable and sufficient safe access to and egress from every working place. Scaffolds shall only be erected or altered by competent, trained and experienced workmen. Materials used shall be of suitable quality, in good condition and free from patent defect. Scaffolds shall conform to current British or International Standards.

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Before the erection of any scaffold the following question shall be addressed: What is the scaffold for? 1 Where is it to be erected? 2 What materials are to be used? 3 Can safe access be provided for:4 Erection? I) Use? II) Dismantling? III) How many working platforms are needed? 5 What loading will be imposed? 6 Are the ground conditions or supporting structure suitable? 7 How and where can the scaffold be tied in? 8 What bracing will be used? 9 Will the scaffold be sheeted? 10 Is there a need to provide protection for the public? 11

… … …

… … … … … … … … … …

QCS 2014

Section 11: Health and Safety Part 2.3.12: Control of Working at Heights

Page 9

EXCLUDING INTERNAL SCAFFOLD LADDERS

Contract Name ……………………………………........ Date

Contract Number…………………..

……………………

Area check – description of work to be carried out Height to be accessed …………………………………………………………………………………….. Location

………………………………………………………………………………………………

………………………………………………………………………………………………………………..

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……………………………………………………………………………………………………………….. Yes

No

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Section A Can a mobile tower/MEWP be used?

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Can podium steps be used?

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Can fixed erected scaffold be used? If NO is answered to all questions in section A, is a step ladder the only means of access for the work activity?

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Section B – (If steps are the only option, the following must be answered

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Is the work of a light nature? Is the work of a short duration? Repetitious short use does not constitute short duration works

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Will the tools be of a light nature and hand held? If No is answered to any questions in section B, futher consideration must be given to providing a suitable working platform before completing sections C and D

Wood

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Type of steps to be used (tick as appropriate) Aluminium

Fibreglass

Number of treads required e.g. 6,10,12 Section C Has the operative read and understood the risk assessment and method statement?

Yes

No

Section D – Authorisation Employee

Signature …………………………………….. Print Name …………………………….

Supervisor

Signature …………………………………….. Print Name …………………………….

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ..................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ............................ 1

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2.3.13 ........................................................................................................................... FIRE PREVENTION AND CONTROL ON SITE ............................................ 1

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2.3.13.1  Responsibilities .............................................................................................. 5 

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2.3.13.2  Definitions ...................................................................................................... 5  2.3.13.3  Actions Required to Implement This Procedure ............................................ 6 

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2.3.13.4  Reference Documents ................................................................................... 7 

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2.3.13.5  Author........................................................................................................... 15 

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2.3.13.6  Approvals ..................................................................................................... 15 

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 2

Process Map Tender Team

Projects Engineer (CDM)

Design

Project Manager

SHE Dept

Appoint Fire Safety Co-ordinator

Ensure adequate resources for fire control/protection

1.2, 3.4

Ensure fire risk has been considered by designers 1.6, 3.2

Consider fire risks during development

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1.5, 3.2

Carry out a specific Fire Risk Assessment and Site Emergency 3.4

.

1.4

3.4

Provide advice on certificates, training, etc. If necessary, liaise with Anon 1.3, 3,4

Ensure specific Fire Risk Assessment is produced for office and storage units and monitor

Monitor controls are in place

3.1

3.4

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SHE Management Plan to detail relevant appointments and emergency details

Ensure information on fire risk is provided at project induction 3.4

Ensure adequate monitoring arrangements are in place and carry out emergence drills as required by the SHE Plan 3

Key

Activity Guidance

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 3

PURPOSE The purpose of this procedure is to ensure adequate controls are in place from fire and the adequate provision of emergency procedures.

SCOPE

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This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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Introduction

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This Section provides guidance on Fire prevention and control on site which is a legal requirement under the Regulatory document Section 1.7.

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It is strongly advised that reference is made to BS 5839 BS 5839-1:2013- Fire detection and fire alarm systems for buildings Code of practice for design, installation, commissioning and maintenance of systems in non-domestic premises.

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Fire extinguishers, emergency lighting, fire alarms and fire signs must comply with current local civil defense Standards and / or British Standards.

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Every year there are a number of large fires on construction sites and in buildings undergoing alteration and refurbishment. All have serious consequences: Injury and fatality to people, environment and property damages. Some irreplaceable buildings burn down.

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The risk of fire is greater during the construction, refurbishment or demolition of buildings than at any other time, and the loss of equipment, working time and resultant financial implications can be severe.

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Such fires have been started by the careless use of blowlamps, faulty electrical wiring etc.

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The practical steps which can be taken to prevent fire are a cost-effective investment that may bring great benefits. The majority of fires can be prevented by taking simple precautions and by adopting safe working practices. Every fire, no matter how large the end result, starts from a small beginning. But certain fundamentals are common to every fire, and knowledge of these will help to prevent or to control a fire. Everyone who has been trained will know the different types of fire that can occur and the right extinguisher to use in each case. Using the wrong extinguisher can make a fire situation deteriorate rapidly. If you are not trained, do not attempt to use them. Sources of fuels, such as bonfires, LPG cylinders, dangerous substances, and flammable materials, shall be identified as well as sources of ignition, such as smoking, cooking and heating appliances and operations involving hot works (e.g. welding and cutting) Controls shall take into account site security with respect to trespassers and acts of vandalism. Materials storage and all waste produced present a fire hazard and needs to be taken into account in the risk management process.

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 4

Fire alarms, emergency lighting, fire-fighting equipment, signage, fire safety procedures, emergency plans and staff training should keep in step with the progress of construction works so that all areas are adequately covered throughout all stages of development. The simplest fire procedure is as easy as A B C = •

Raise the alarm



Call the fire brigade (Civil Defense)



Immediate evacuation

REMEMBER!

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Fire legislation is designed to reduce the risk of a fire starting and ensures that, if it does there are adequate means of escape and measures to control the fire.

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The majority of fires on site can be prevented by taking simple precautions and by adopting safe working practices.

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 5

2.3.13.1 Responsibilities

SHE DIRECTOR Authorises this procedure. PROJECT / SITE MANAGER Ensures that works are carried out in accordance with this procedure.

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SHE MANAGER / ADVISER

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Provides advice and support in the application of this procedure and monitors others’ effectiveness to manage the activities.

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ESTIMATING / TENDER TEAM

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Ensure necessary resources are available for fire precautions.

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DESIGNERS

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Designers and specifies shall consider their proposals in terms of the potential for reducing construction phase fire risks at source. The ability to do this will vary according to the circumstances.

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PROJECT ENGINEER (CDM)

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The Engineer shall ensure that the relevant information provided by clients or designers is included in the tender stage information pack.

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They shall also monitor design proposals and if they note designs that appear to ignore significant fire matters, or introduce significant fire hazards for the construction phase, then they shall be referred back to the designer for resolution.

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INCIDENT CONTROLLERS, FIRE MARSHALS, ETC. Ensure duties are carried out in accordance with those detailed.

2.3.13.2 Definitions CDM Construction (Design and Management) and the definitions therein. INTRODUCTION AND SUMMARY OF CONTRIBUTION TO FIRE SAFETY FROM KEY PARTIES As with all health and safety issues, fire safety during construction work will best be achieved through adoption of the principles set out in the CDM i.e. design and planning to avoid or reduce the risks followed by thorough planning, organisation and control of the execution of the works.

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 6

The material contained in this document shall be used in the preparation of site fire plans that shall be included in the SHE Management Plan.

2.3.13.3 Actions Required to Implement This Procedure TENDER STAGE The person responsible for preparing the tender shall ensure that all necessary resources for fire precautions has been included and where necessary seek the advice of the SHE Department. DESIGN PHASE

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Where COMPANY is the designer, the design leader shall ensure that fire risks are considered in the process of developing the design. In practice designers shall consider the elimination or mitigation of construction phase fire risks as part of the design risk assessment.

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Where COMPANY is the Engineer the in house co-ordinator shall ensure that fire risks have been considered by designers in their design.

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PRE CONSTRUCTION PHASE

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All sub and work package contractors shall be required as a condition of contract, to comply with the requirements of the Qatar Regulatory Document (Construction) and as such this requirement has been incorporated in the COMPANY standard rules for sub and work package contractors.

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The location and fire precautions required for temporary site accommodation e.g. offices, canteens, cargo containers and caravans etc as well as parts of the existing buildings used for these purposes demand special consideration and the Project/Site Manager shall seek the advice of the SHE Department during the planning of such facilities.

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CONSTRUCTION PHASE

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The Project/Site Manager shall appoint a Incident Controller for the site whose name shall be recorded in the SHE Management Plan. In addition, and where appropriate, a sufficient number of fire marshals shall also be appointed.

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The Project/Site Manager in association with the SHE Adviser for the site shall undertake a Fire Risk Assessment and prepare a site specific emergency plan which shall be integrated into the SHE Management Plan. Safety induction of all personnel onto the project/site shall include fire related risks and arrangements. The Project/Site Manager shall in consultation with the SHE Manager/Adviser, prepare, undertake and record a specific Fire Risk Assessment for all Site Offices/Temporary Accommodation units. Contact the SHE Department for advice. The SHE adviser appointed for the site shall provide any necessary fire training requested and undertake fire audits, as circumstances dictate. The Project Manager shall arrange and carry out emergency evacuation drill as required by the SHE Management Plan. The Project/Site Manager must ensure that arrangements are in place to monitor the effectiveness of this procedure including the maintenance of any fire fighting equipment etc.

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 7

2.3.13.4 Managing fire risks On every construction site, there will always be the risk of fire. By the very nature of the operations carried out (cutting, burning, grinding, welding, etc.), the use of flammable substances and the amount of wood and other combustible materials used or stored on site, the potential for fire is always present and must be properly guarded against. As with all potential workplace problems, the situation can be effectively managed by: taking steps to prevent a fire starting in the first place preparing for, and effectively reacting to, a fire situation if it occurs. Contractors must make a suitable and sufficient assessment of the risks to health and safety of their employees whilst they are at work, and of the risks to any person not in their employ but who may be affected by their actions. The purpose of these risk assessments is to:

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establish the risks to health and safety arising from those hazards

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identify any hazards that may be inherent within any work process

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establish the control measures necessary to reduce the risks to an acceptable level. In circumstances where fire is an on-site hazard, a 'fire risk assessment' must be carried out.

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In many cases, fire risk assessments may be quite straightforward and completed relatively quickly. As outlined above, the principles of fire risk assessment are the same as for the risk assessment of any other construction work activity or process.

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In more complicated situations, carrying out a fire risk assessment may need more consideration and may need to be reviewed as the construction project progresses or new situations arise. It almost goes without saying that anyone carrying out a fire risk assessment on site needs to have both knowledge and competence in the subject. TEMPORARY BUILDINGS

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The design for Fire prevention and control need to include temporary structures and works such as office accommodation, canteens and other temporary accommodation and their maintenance.

BONFIRES

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2.3.13.5 Personal responsibilities

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Where bonfires are allowed, no fire should be left unattended at any time.

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A bonfire should only be lit after conducting a risk assessment: Special attention is to be given to drifting smoke which could be a nuisance and represent danger to road. They should be situated well away from any buildings, boundaries, roadways, fuel stores or other combustible materials or structures. Consideration must be given to wind direction and strength.

Never light a bonfire by using a flammable liquid. There is a danger of the person lighting the fire being burnt by the 'flash' as the flammable liquid ignites and also a chance of secondary fires starting as heavier-than-air vapours spread. SMOKING RESTRICTIONS

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 8

Where it is decided that smoking can be allowed in 'non-enclosed' areas, these areas must exclude any 'fire-risk' areas such as storage areas for combustible materials, flammable liquids and gas storage areas. The official NO SMOKING notice must be clearly displayed in any area where smoking is not allowed, including all entrances to all enclosed working places. Areas where smoking is allowed should be equipped with adequate fire-fighting equipment. Non-combustible containers should be provided to aid safe disposal of discarded smoking materials. As work progresses and the site develops it will be necessary to monitor the changes in the 'fire risk areas' and review the areas where smoking is allowed accordingly.

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Site rules should ensure that smoking is prohibited for an appropriate period at the end of each working day, for example the last hour. This will allow any developing fire to be discovered and dealt with before the site closes at the end of the day.

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TRESPASSERS

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Children and other trespassers may start fires on site. Sites should, as far as possible, be secured against intruders. In every case, combustible materials should be cleared on a regular basis (daily) and not left lying around. Storage areas for flammable liquids and gases should be secured during non-working hours. Everyone should know the correct action to take if they discover a trespasser on site during working

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hours.

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HOT WORK

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Cutting, burning and welding operations, together with the use of blowlamps and other LPG-fuelled tools, are the cause of many fires on building and construction sites. It is essential that anyone engaged in hot works is aware of the fire risk, and is trained and competent to use the equipment that will produce the heat.

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Precautions must be taken where heat from a work process could be transmitted to other combustible materials, for example where hot works are carried out on steelwork or pipes adjacent to or passing through flammable materials such as stud-work walls or timber floors.

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Where this kind of operation is anticipated, it is essential that all combustible materials (and liquids) are protected before any work is allowed to start. Special care should be taken when working with cutting or welding equipment at raised levels. Any equipment or combustible items situated below cutting or welding operations where there is a danger of sparks or fragments of hot metal dropping, should, if possible, be removed or covered with fire-resisting material.

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When working with blowlamps, welding, flame-cutting or grinding equipment, thorough checks should always be made to ensure that nothing is left smouldering after the work is finished. As an added precaution, always check into cavities, around eaves, behind studding and into other voids after any hot work has been completed. In many cases such work must be carried out in compliance with a Hot Work Permit. This will stipulate the safety conditions under which the work must be carried out and will usually require: that a suitable and serviceable fire extinguisher is available at the place of the work that hot work ceases at least one hour before the end of the working day that a check for the presence of fire or potential fire is carried out before the end of the working day.

HEATING APPLIANCES The risk of fire arises from the use of heating appliances if they are sited and installed incorrectly, inadequately maintained or are not suitable for the intended use or location. Fuel supplies for gas-fired appliances, especially propane or butane, should be kept secured outside the building and piped in through fixed pipework. Any flexible pipework should be kept as short as possible,

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 9

and used only for the final connection to the cylinder. Any room in which a gas fire is used must be fitted with a permanently open vent or louvre to enable the fire to operate properly without producing excess carbon dioxide. (A window that could be closed in cold weather, for example, is not acceptable.) Gas fires, plus the associate pipework and connections and so on must be regularly serviced. The use of oil heaters is not recommended due to the inherent risk of fire if they are knocked over or otherwise misused. Combustible material should be kept well away from heaters and stoves. The practice of drying wet clothing in front of fires should be prohibited. Care must be taken to see that newspapers, clothing or other combustible materials are not allowed to build up around such heaters. Care must be taken also to ensure heaters are not used near liquid fuel cylinders. Heat applied to the surface of such cylinders will cause the contents to pressurise and could trigger an explosion.

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All heaters and stoves, including cookers and kettles, must be turned off at the end of the working day. Portable electrical apparatus should be switched off, unplugged and disconnected from the mains supply.

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STORAGE OF MATERIALS

Many of the materials used in the construction process are combustible.

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Whilst it is appreciated that there is a need for enough material to be available to do the job, only an amount equivalent to one day's work supply should be stored in the work area. Where it is possible to use a material which is less flammable, but will do the same job, then that type of material should be specified by the designer.

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Wherever possible, the stockpiling of flammable materials should be avoided, as quantity increases the scale of any fire.

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DISPOSAL OF WASTE

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Where possible, all combustible materials should be stored outside the building under construction in a locked compound or storage container with adequate separation between differing types of product. Such items as LPG and flammable adhesives should be isolated into a separate locked compound.

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Most construction sites generate large quantities of rubbish and waste material which present a potential fire risk.

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Good housekeeping is essential. Rubbish and waste should be cleared from site on a regular basis, if the risk of fire is to be controlled. Although not all rubbish and waste can be taken to a centralised point for disposal, places should be organised so that skips and other waste disposal containers can be safely positioned not less than 3 metres way from any building or structure.

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Skips and other waste disposal containers should not be placed adjacent to means of escape from buildings or the site, but must be so positioned as to be readily available to vehicles contracted to collect skips or to clear the accumulations of rubbish and waste material.

PROTECTION OF FINISHED SURFACES Once a building is nearing completion, it is common practice to use temporary coverings to protect finished surfaces during the remaining fitting-out phase. These coverings often take the form of plastic sheeting, fibreboard, or similar materials, some of which may be flammable. They can therefore add to the fire loading of the building, and consequently increase the risk of fire. Ideally, fire retardant materials will be used. Care should be taken in such situations to ensure that, where possible, materials with flame-retardant surfaces are used, that fire precautions are upgraded as appropriate, and that features requiring such protection are installed as late as possible into the project.

2.3.13.6 Protection of employees FIRE RISK ASSESSMENTS

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 10

The Regulatory Document, in particular Section 1.7 sets out the law regarding Fire prevention and control and stipulates specific duties for conduct of fire risk assessments. The Regulatory Document requires that a ‘responsible person’ must carry out, and keep up to date, a risk assessment and implement appropriate measures to minimise the risk to life and property from fire. The responsible person will usually be the main contractor in control of the site or in teh case of a property the property owner. Sources of fuel and ignition shall be identified and general fire precautions including, means of escape, warning and fighting fire shall be established based on fire risk assessment. In occupied buildings such as offices, works must not interfere with existing escape routes from the building, or any fire separation, alarms, dry risers, or sprinkler systems. There are five steps in carrying out a fire risk assessment: Identify hazards: consider how a fire could start and what could burn;

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People at risk: employees, contractors, visitors and anyone who is vulnerable, e.g. person with physical disabilities; pregnant woman etc

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Evaluation and action: consider the hazards and people identified in the above and act to remove and reduce risk to protect people and premises;

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Record, plan and train: keep a record of the risks and action taken. Make a clear plan for fire safety and ensure that people understand what they need to do in the event of a fire; and

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Review: your assessment regularly and check it takes account of any changes on site. MEANS OF ESCAPE

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Key aspects to providing safe means of escape on construction sites include:

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Routes: your risk assessment should determine the escape routes required, which must be kept available and unobstructed;

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Alternatives: well-separated alternative ways to ground level should be provided where possible;

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Protection: routes can be protected by installing permanent fire separation and fire doors as soon as possible;

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Assembly: make sure escape routes give access to a safe place where people can assemble and be accounted for. On a small site the pavement outside may be adequate; and

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Signs: will be needed if people are not familiar with the escape routes. Lighting should be provided for enclosed escape routes and emergency lighting may be required.

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MEANS OF GIVING WARNING Set up a system to alert people on site. This may be temporary or permanent mains operated fire alarm (tested regularly), a klaxon, an air horn or a whistle, depending on the size and complexity of the site. The warning needs to be distinctive, audible above other noise and recognisable by everyone. MEANS OF FIGHTING FIRE Fire extinguishers should be located at identified fire points around the site. The extinguishers should be appropriate to the nature of the potential fire: wood, paper and cloth – water extinguisher; flammable liquids – dry powder or foam extinguisher; electrical – carbon dioxide (C02) extinguisher. Nominated people should be trained in how to use extinguishers RESPONSE TO A FIRE ALARM

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 11

In the event of a fire occurring, it is essential that the alarm is raised as quickly as possible so that employees and others, such as visitors, can quickly and safely reach a place of safety. This can be achieved by considering the steps outlined in Module HI that cover: emergency procedures calling the fire and rescue service means of escape. However, if a fire starts inside a building which is under construction, demolition or refurbishment, particularly in a basement, the location of the fire exits may be unknown to many of the people on the site. Therefore, publicised and clearly signposted escape routes must be established. As part of the site emergency planning, dedicated escape routes should be decided on during the planning phases of the project, and arrangements made for them to be clearly signed and adequately lit.

.

Escape routes and their signage may have to be reviewed and reorganised as construction work progresses.

rw

.l. l

As part of establishing a satisfactory means of escape, it will be necessary to install an emergency lighting system in circumstances where failure of primary lighting would create a hazardous situation.

2.3.13.7 Fire Alarm system and compliance

ta

A good fire alarm system should be installed within the site compliant to the current standards, and provides the level of protection demanded by current legislation.

qa

Correct documentation to be in place: An up-to-date risk assessment

as

A log book that records the date and time of weekly tests, and a record of any faults detected, false alarms and the service history, by whom.

er

se

A design certificate (such as a BS 5839-1 G1 Design certificate or equivalent) with Specification, Fire Plan or cause and effect, a set of drawings that clearly states the category or level of protection, plus any variations that have been agreed with interested parties such as Civil Defence, the Insurers or Building Control.

ov

An Installation certificate (such as a BS 5839-1 G2 Installation certificate or equivalent) including a set of ‘as fitted’ drawings. A commissioning certificate (such as a BS 5839-1 G3 Commissioning certificate or equivalent) including equipment manuals with user instructions.

ito

An acceptance certificate that confirms the date of handover

et

An inspection and servicing certificate (such as a BS 5839-1 G6 Inspection & Servicing certificate or equivalent) that record all tests and checks made at each service visit since original installation – handover.

m

Modification certificates as applicable (such as a BS 5839-1 G7 Modification certificate or equivalent) identifying any work undertaken on the system since the date of handover. The responsible person should ensure that certification is in place covering these subjects as identified in BS 5839-1. If there is inadequate certification available, it is recommended that a Verification Certificate (such as a BS 5839-1 G5) is obtained from a competent maintainer In the case where installations don\t have the certificates, it is recommended that the system is assessed by a competent service provider who can issue the necessary certificates detailed above. Anyone who will undertake the works will need to be competent and those carrying out works on a fire alarm system shall hold either a BAFE SP203 or LPS1014 certificate approved from Kahramaa. The certificates should include details of their capability to Design, Install, Commission and/or Maintain a fire alarm system. It is also important to ensure that any service provider is competent to advise of any potential sources of false alarms and their corrective action. EMERGENCY LIGHTING The provision of emergency lighting should always be considered when assessing the fire safety requirements for

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 12

a construction site. This is particularly important where being able to carry out work safely is dependent on artificial lighting because there is no natural light, for example in basements. If the lighting circuits should fail, any standby emergency lighting system must switch on automatically and clearly illuminate the following: exits and directional signs corridors and associated exits circulation areas changes in levels any projections and protrusions, such as temporary partitioning, trestles, scaffolding, items of plant and machinery

.

internal and external staircases, including ladders, particularly if these are essential to evacuate the site.

rw

.l. l

Emergency exit routes from the premises may have to be provided or maintained through the construction area for use by the occupiers of the premises. This is relevant where the building in which construction is taking place is partially occupied by others. It may be necessary to amend the location and extent of the emergency lighting system as works progress.

ta

Emergency lighting, whether powered by battery or standby generator or a combination, should be tested on a regular basis by a competent person in accordance with BS 5266 Part I.

qa

Records of tests of the emergency lighting equipment should be kept and must be available for inspection when required.

as

2.3.13.8 Fire-fighting equipment

se

As work progresses, the requirement and suitability of fire-fighting equipment must be reviewed, and amended as necessary.

ov

er

All mechanically-propelled site plant should carry its own fire extinguisher of the correct type. On large or costly items of equipment or plant, the installation of automatic fire detection and extinguishing systems should be considered if there is a risk of fire. MAINTENANCE OF FIRE-FIGHTING EQUIPMENT

et

ito

In addition to the monthly inspections of fire-fighting equipment it is particularly important to check extinguishers which, within a year, are sent to more than one site. When a site is being set up, on receipt of the fire extinguishers, the Site Manager must inspect them for the date that the next check is due.

m

2.3.13.9 Staff training

The Contractor must ensure that employees are provided with adequate safety training that includes suitable and sufficient instruction and training on the appropriate precautions and actions to be taken by employees in order to safeguard themselves and other relevant persons on the premises. It needs to take account of the fire risk assessment and the emergency procedures, and be easily understandable and repeated periodically. The training should cover: discovering a fire how to raise the alarm what to do on hearing the alarm procedure for alerting visitors and all staff calling the fire service evacuation procedures, assembly points and fire drills location and use of fire-fighting equipment location of escape routes

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

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how to open escape doors importance of fire doors how to stop equipment and isolate power not using lifts use and risks of highly flammable and explosive substances good housekeeping smoking policy and smoking areas. FIRST AID

Site security

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2.3.13.10

.

Trained first aiders will know how to deal with anyone who has been burnt in a fire on site. However, it may not be a trained first aider who is first on the scene.

rw

Effective site security is a way of preventing malicious fires caused by trespassers.

Irrespective of the site boundary fence, buildings and storage areas for flammable liquids, liquefied petroleum gas cylinders and other combustible materials should be individually fenced or otherwise suitably protected.

qa

ta

Illumination of the site, the provision of security guards or guard dogs or the installation of CCTV is additional deterrents to unauthorised access.

Fire safety and the Construction (Design and Management) CDM Regulations

se

2.3.13.11

as

At the end of each working day a fire check should be undertaken, particularly in areas where hot work has been carried out. Where 24-hour security is provided, fire checks should be undertaken throughout the night, during holiday periods and at weekends.

ov

er

CDM imposes duties with regard to the safe operation of construction sites on Contractors and Sub-Contractors. These duties focus on minimising the risk of fires and ensuring that, if a fire should occur, it can be correctly dealt with. Fire should be one of the hazards covered in a fire safety plan that will form a part of the construction phase health and safety plan. These Regulations require that the Contractor appoints a competent person to be responsible for continually assessing the fire risk and updating the Fire Safety Plan.

ito

Designers, who will be guided by the fire prevention and control elements of the QCS, should attempt to 'designout' fire risks where possible.

et

Additionally, CDM requires that:

m

suitable and sufficient steps are taken to prevent, so far as is reasonably practicable, the risk of injury from fire or explosions. measures to be taken to detect and fight fires in relation to work are carried out on construction sites.

2.3.13.12

Guarding against fire

DESIGN PHASE Effective fire prevention planning begins at the design stage. The architect or designer must consider the measures which will eliminate or diminish the potential for fire. It is essential that, where appropriate, an experienced and qualified person is appointed to consider the fire aspects of the design phase; not only to ensure that fire risk and potential for damage are properly assessed and kept to a minimum during construction, but also to see that the finished building will comply with all statutory requirements in respect of fire precautions. FIRE SAFETY PLAN On a site of sufficient size or complexity, or if required by the Contractor they may need to appoint a competent

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 14

person (for example, a site fire-safety adviser). This person should be responsible for formulating and regularly updating the site fire safety plan as construction work proceeds. A site fire safety plan should include details of: the organisation of fire safety procedures the names and positions of persons, and their responsibilities for the various aspects of fire safety, for example calling the fire and rescue service general site fire precautions fire detection and warning alarms installed on site arrangements for maintaining fire escape routes and changing them as necessary as work progresses arrangements for notifying staff of the emergency escape routes and any changes to them

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the location, construction and maintenance of site accommodation

.

the procedures for a Hot Work Permit system, if such is in use

rw

fire evacuation plans and procedures for calling the fire and rescue service fire and rescue service access

ta

fire drills and training, and also procedures for maintaining a written record of all checks.

qa

The person responsible for site fire safety should:

ensure that the site fire safety plan is clearly understood and complied with by all those on the site

as

ensure that a system using Hot Work Permits is established, as necessary, and monitor its effectiveness carry out regular checks of fire-fighting equipment and facilities installed on site

se

test all alarms and detection devices weekly

carry out weekly inspections of emergency escape routes

er

ensure that fire and rescue service access is always maintained

ov

liaise with site security staff, if they are employed arrange for the necessary inspections, tests and fire inspections to be carried out

ito

regularly monitor and check the arrangements and procedures for calling the fire and rescue service carry out the duties required for the safe evacuation of the site in the event of an emergency situation

et

ensure that all staff and visitors report to the assembly points.

m

The site fire adviser or other competent person may, in consultation with the Contractor, need to arrange for the appointment of fire marshals to assist in the implementation of the site fire safety plan, particularly any site evacuation. On large sites it is usual for a fire marshal to be appointed from each company of subcontractors to account for that company's staff in the event of a site evacuation. Where fire marshals' duties are more extensive, they must be allowed sufficient time to carry out their duties and to undertake any training that may be necessary. Notices detailing the action to be taken in case of a fire should be displayed on all notice boards and adjacent to fire alarm call points.

2.3.13.13

SAMPLE PROCEDURE FOR CONTRACTORS

2.3.13.14

Reference Documents

FORMS Fire Prevention Checklist (SHE-FRM-13-01)

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Page 15

REFERENCE DOCUMENTS Qatar Regulatory Document (Construction) RD1.7 SHE Management Plan Safety, Health and Environmental Risk Management and Written Safe Systems of Work (SHE-PRO-001) QCS 2007 Fire Prevention Standards and Guidance for Buildings under Construction.

Author POSITION IN COMPANY

CONTACT DETAILS

rw

NAME

ta

SECTION

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.

2.3.13.15

Approvals

ito

ov

NAME

er

2.3.13.16

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as

qa

SHE Manager

m

et

Approved by:

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Para No. 1.0

Page 16

Tick Box for yes

Question Design Phase Has a Co-ordinator been appointed for the Design Phase? Does the Co-ordinator understood the full scope of his responsibilities?

2.0

Construction Phase Has a Site Fire Safety Co-ordinator been appointed by the COMPANY? Has the Fire Safety Co-ordinator : formulated a fire safety plan? ensured that staff are familiar with the plan and understood it?

.l. l

.

monitored compliance are fire safety plan, especially with regard to hot?

rw

work permits?

established a regime of checks and inspections office protection

ta

equipment and escape routes?

established effective liaison with security contractors or staff?

qa

written records of checks, inspections, maintenance work, fire patrols and fire drills?

as

carried out a fire drill and analysed the results?

3.0

se

checked the arrangements and procedures for calling the fire brigade? Large Projects

er

On the large projects, has the Fire Safety Co-ordinator:

ov

appointed fire marshals and/or deputies, trained them and delegated responsibilities to them?

ito

provided site plans for the emergency services detailing the escape routes, fire protection equipment and facilities for the fire brigade?

et

Fire Safety Plan

Does the fire safety plan detail:

m

4.0



the organisation and responsibility for fire safety?



the site precautions?



the means for raising the alarm in case of fire?



the procedure for calling the fire brigade?



the means of escape in case of fire?



the hot work permit scheme?



the site accommodation, its use, location, construction and maintenance?



the points of access and sources of water for the fire brigade?



the control of waster materials?



the security measures to minimise the risk of arson?



the staff training programme?

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Para No. 5.0

Page 17 Tick Box for yes

Question Emergency Procedures Is the means of warning of fire known to all staff? It is checked routinely and can be heard in all areas above background noise? Are fire instruction notices prominently displayed? Are the fire brigade access routes clear at all times? Have specified personnel been briefed to unlock barriers when the alarm sounds? Have signs been installed indicating fire escape routes and the positions of fire protection equipment? Fire Protection

.l. l

Have measures been taken to ensure the early installation and operation of:

.

6.0

rw

escape stairs (including compartment walls)? lighting conductors?

ta

automatic fire alarms automatic sprinkler systems

qa

hose reels?

are fire dampers and fire stopping provided at the earliest opportunity? •

are adequate water suppliers available for fire fighting purposes?



are all hydrants clear of obstruction?

Temporary Covering Materials

se

as

is steel work protected as soon as possible?

er

7.0



ov

Are temporary protective materials required to protect surfaces and fittings? Have these been selected so that the fire load is still acceptable?

Portable Fire Extinguishers

et

8.0

ito

Where flexible covering materials are used do they comply with relevant Standards? Are adequate numbers of suitable extinguishers provided?

m

Are sufficient personnel trained in their use? Are extinguishers located in conspicuous positions near exits? Are carbon dioxide extinguishers in place adjacent to electrical equipment? Does all mechanically-propelled site plant carry suitable extinguishers? Have procedures been implemented for the regular inspection and maintenance of extinguishers? 9.0

Site Security Against Arson Are adequate areas of the site, including all storage areas, protected by hoarding? Is security lighting installed? Has closed circuit television (CCTV) been installed? If CCTV is in position are the screens monitored and/or recorded? Is the site checked for hazards at the end of each work period, particularly where hot work has been in progress?

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Para No. 10.0

Page 18 Tick Box for yes

Question Temporary Buildings Is the fire break between the temporary building and the structure undergoing work more than 10 meters? If the fire break is less than 6 meters Is the temporary building constructed with materials which will not significantly contribute to the growth of a fire? Is the building fitted with an automatic fire detection system?

is access for the Civil Defence (Fire Department) readily available?



is the building fitted with an automatic fire detection system?

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.

If the temporary building is within the building under reconstruction or refurbishment: • is escape for personnel sufficiently easy?

ta

rw

If the floor of the building is raised above ground level is the space beneath enclosed with non-combustible material? Are heaters enclosed with guards and securely fixed on the walls? If separate buildings contain heaters for drying clothes, are the heaters

as

qa

thermostatically controlled? (with enclosed elements) are the drying racks fixed firmly at a safe distance? Are all heaters and cookers properly installed and is adequate ventilation provided?

11.0

ov

er

se

Are automatic fire and intruder alarms installed and is temporary buildings used for storage of flammable liquids and gases? Do temporary buildings contain the minimum of furniture and fittings made from synthetic materials? In all areas of fire hazard does a no smoking policy prevail and there adequate “No Smoking” signs in place? Site Storage of Flammable Liquids and LPG

m

et

ito

Are containers of flammable liquids and LPG stored in purpose designed compounds? If flammable liquids are not stored in compounds, is the quantity less than 50 litres (or half a days’ supply, whichever is less) and is it kept in a fire resistant cupboard or bin? Is the storage area at least 10 meters from temporary and permanent buildings If not, are the recommended precautions taken? Are cylinders of oxygen and chlorine and containers of similar agents kept separately from flammable liquids and LPG? Are the stores properly signed? Has the store a paved or compacted base, and is clear if weeds and rubbish? Are all electrical fittings of intrinsically safe design? Is automatic gas detection equipment installed? Are suitable fire extinguishers provided at the entrances? 12.0

Site Storage of Flammable Liquids and LPG Do electrical installations conform to British or International Standards? Is all electrical work undertaken by competent electricians? Are all circuits, other than those controlling security devises and security lights,

QCS 2014

Section 11: Health and Safety Part 2.3.13: Fire Prevention and Control on Site

Para No.

Page 19 Tick Box for yes

Question turned off when work ceases? Are all gas suppliers installed by a competent gas fitter? Are all gas suppliers in fixed piping or armoured flexible tubing? Where gas cylinders are used are they located outside building, secured and protected from interference? Are flexible links for LPG supplies only connected by a competent person?

13.0

Hot Work Is a permit to work system in operation? Does that system include an adequate maintained register?

ta

rw

.l. l

.

Is the area involved cleared of combustible materials before work commences, and are the opposite sides of walls or partitions also inspected? Is a careful watch maintained while hot work is in progress, with suitable extinguishers of appropriate type at hand? Is wooden flooring and other combustible material which is not movable covered before commences? Is the work area screened when welding or grinding is undertaken?

qa

Are gas cylinders secured vertically, and are they fitted with flashback arresters?

Waste Materials

se

14.0

as

Are tar boilers supervised by experienced operatives, and only taken onto roofs in exceptional circumstances? Is the work area thoroughly examined and hour after work is finished?

Are provisions made for the safe storage and removal of waste materials?

ov

er

Are checks carried out routinely to ensure that waste materials are not accumulating on the site? Are metal bins, with metal lids provided for oily rags?

ito

Is collected waste, awaiting disposal, kept away from temporary buildings stores and equipment? Is all dry vegetation removed regularly from around the site?

Plant

m

15.0

et

Is there an absolute prohibition on burning rubbish on site?

Is all plant with internal combustion engines positioned in well-ventilated, noncombustible enclosure with the exhaust pipes clear of combustible materials? Are compressors housed away from other plant? Do notices and staff training make it clear that fuel tanks must not be refilled whilst engines are running? Is plant equipment protected from accidental impact? Are air intakes positioned so that air is cool and free from flammable gases and vapours? Are sand-trays provided to absorb drips of fuel and lubricant?

QCS 2014

Section 11: Health and Safety Part 2.3.14: Asbestos

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ..................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ............................. 1

2.3.14 ASBESTOS ....................................................................................................... 1

2.3.14.1  Responsibilities .............................................................................................. 4 

.

2.3.14.2  Definitions ...................................................................................................... 4 

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2.3.14.3  Types of Asbestos Surveys ........................................................................... 5 

rw

2.3.14.4  Procedure ...................................................................................................... 5  2.3.14.5  Project Delivery .............................................................................................. 6 

ta

2.3.14.6  Monitoring & Performance ............................................................................. 8 

qa

2.3.14.7  Feedback & Action ......................................................................................... 8  2.3.14.8  Records .......................................................................................................... 8 

as

2.3.14.9  Appendices .................................................................................................... 9  Reference Documents .............................................................................. 14 

2.3.14.11 

Author ....................................................................................................... 14 

2.3.14.12 

Approvals .................................................................................................. 14 

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et

ito

ov

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se

2.3.14.10 

QCS 2014

Section 11: Health and Safety Part 2.3.14: Asbestos

Page 2

PROCESS MAP Client

Project Manager

Competent Person/Contractor

Estimator

Supervisor

SHE Advisor

Ensure that the system is

Provide PreConstruction information including Asbestos S

1.2

Review PreConstruction Information

Review PreConstruction Information

Review PreConstruction Information

4.1

4.1

4.1

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.

4.2

Ensure Risk Assessment findings/controls are incorporated into the Plan of work if identified 5.5

Ensure that the Induction references asbestos material is on site

Issue Asbestos Survey, Risk Assessments/ Method Statement /Emergency Plan to supervisor 5.5

as

5.1, 6.1

se

Provide details to relevant personnel 1.4

ov

er

5.13

Provide support and training if

rw

Authorises and implements method statement/risk assessment

Produce and record a suitable and sufficient asbestos risk assessment 5.5

ta

4.2

Inform team of Asbestos Risks

qa

Ensure that Asbestos Survey has been completed and the report is available

Monitor activities to ensure compliance

m

et

ito

5.1, 6.1

Provide Health Surveillance as required 5.12

Monitor activities to ensure compliance

1.5, 5.8

Monitor and review performance

5.1, 6.1

Notify competent person of any change needed to controls

Conduct a subcontract review and record results

Attend a subcontract review

7

7

Ensure that the Induction references any changes in asbestos material on site

Ensures that all relevant records are maintained and/or archived 8

Key

Activity Guidance

QCS 2014

Section 11: Health and Safety Part 2.3.14: Asbestos

Page 3

PURPOSE 1

The purpose of this procedure is to define how Asbestos related activities shall be carried out safely.

SCOPE

et

ito

ov

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se

as

qa

ta

rw

.l. l

.

This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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1

QCS 2014

Section 11: Health and Safety Part 2.3.14: Asbestos

Page 4

2.3.14.1 Responsibilities SHE DIRECTOR 1

Authorises this procedure. PROJECT/SITE MANAGER

2

Ensures the procedure is established and that the identification and removal of asbestos containing materials (ACMs), is carried out in accordance with this procedure and relevant information is communicated to interested parties.

.l. l

Ensures that the information provided by the client or his representative is considered when pricing the works and informs the relevant persons of details with regards to asbestos and asbestos containing materials.

rw

3

.

ESTIMATOR

Either supervises the work activities or the sub/work package contractor undertaking those work activities and ensures preparation of the necessary control documents required by this procedure.

as

qa

4

ta

SUPERVISOR

SHE MANAGER/ADVISER

se

Provides advice and support in the application of this procedure and monitors effectiveness to control the activities.

er

5

Person’s undertaking the work activities and required to carry out the task in accordance with this procedure.

et

ito

6

ov

OPERATIVE/CONTRACTOR EMPLOYEE

m

2.3.14.2 Definitions

PROJECT MANAGER

1

For the purpose of this procedure, Project/Site Manager may also mean Depot Manager or Office Manager. SUPERVISOR

2

Ensures duties are carried out in accordance with this procedure. CONTRACTORS

3

Means work package contractors and their sub-work package contractors. (Includes work equipment supplies.)

QCS 2014

Section 11: Health and Safety Part 2.3.14: Asbestos

Page 5

2.3.14.3 Types of Asbestos Surveys TYPE 1 – PRESUMPTIVE SURVEY The purpose of the survey is to locate, as far as reasonably practicable, the presence and extent of any suspect ACM’s in the building and assess their condition. This survey essentially defers the need to sample and analyse for asbestos (or the absence thereof) until a later time (e.g. prior to demolition or major refurbishment). The duty holder bears potential additional costs of management for some non asbestos-containing materials. All areas should be accessed and inspected as far as reasonably practicable (e.g. above false ceilings and inside risers, service ducts, lift shafts etc), or must be presumed to contain asbestos. Any material which can reasonably be expected to contain asbestos must be presumed to contain asbestos, and where it appears highly likely to contain asbestos, there should be a strong presumption that it does. All materials which are presumed to contain asbestos must be assessed.

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.

1

The purpose and procedures used in this survey are the same as for Type 1, except that representative samples are collected and analysed for the presence of asbestos. Samples from each type of suspect ACM found are collected and analysed to confirm or refute the surveyor’s judgment. If the material sampled is found to contain asbestos, other similar homogeneous materials used in the same way in the building can be strongly presumed to contain asbestos. Less homogeneous materials will require a greater number of samples. The number should be sufficient for the surveyor to make an assessment of whether asbestos is or is not present. Sampling may take place simultaneously with the survey, or as in the case of some larger surveys, can be carried out as a separate exercise, after the Type 1 survey is complete.

This type of survey is used to locate and describe, as far as reasonably practicable, all ACM’s in the building and may involve destructive inspection, as necessary, to gain access to all area’s, including those that may be difficult to reach. A full sampling programme is undertaken to identify possible ACM’s and estimates of the volume and surface area of ACM’s made. The survey is designed to be used as a basis for tendering the removal of ACM’s from the building prior to demolition or major refurbishment so the survey does not assess the condition of the asbestos, other than to note areas of damage or where additional asbestos debris may be expected to be present.

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et

ito

ov

3

er

TYPE 3 – FULL ACCESS

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as

qa

ta

2

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TYPE 2 – SAMPLING SURVEY

2.3.14.4 Procedure TENDER 1

It is the responsibility of the client and their nominated representatives to provide detailed information including an Asbestos Survey. Pre-Construction Information should be examined by the Project Manager, Estimator and SHE Adviser to determine the presence of asbestos containing materials (refer to Asbestos Control Procedures Pre-Construction Stage Flow Chart at Appendix 1). PROJECT START-UP

2

The Estimator should inform the site team of the Asbestos Risk including previous asbestos removal during handover meeting. If an Asbestos Survey has not been provided, the Project Manager must request from the client information regarding the presence of asbestos. If the

QCS 2014

Section 11: Health and Safety Part 2.3.14: Asbestos

Page 6

client confirms asbestos is or may be present the Project Manager must request a survey be carried out – the type of survey should be determined by the nature of the work to be undertaken but where practical a Type 3 survey should be requested. Any identified asbestos must be removed by an approved and licensed contractor prior to commencement of works (refer to Asbestos Control Procedures Pre-Start Flow Chart at Appendix 1).

2.3.14.5 Project Delivery ON SITE ACTIVITIES The Project Manager should ensure that relevant control measures from the asbestos risk assessment have been implemented. In addition, all relevant information shall be communicated to personnel during the site induction process (refer to Asbestos Control Procedures On Site Flow Chart at Appendix 1).

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STOP – ISOLATE – PREVENT – INFORM

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ASBESTOS SURVEY

The results of all types of survey should be recorded and the information provided to anyone who may work on, disturb, be exposed to or supervise work on these materials.

ta

2

.

1

A list of approved surveys shall be monitored and held by the Procurement/SHE Department

as

3

qa

COMPANY APPROVED ASBESTOS SURVEYORS

Work with the most dangerous asbestos-containing materials (which give off high fibre levels when disturbed), require a competent contractor to undertake the removal works. Further guidance is available from the SHE Manager/Advisor.

ov

er

4

se

ASBESTOS REMOVAL CONTRACTORS

ASBESTOS RISK ASSESSMENT

(a)

If any work which will, or could, disturb asbestos is planned, has the risk assessment been done by a competent person? Does it relate specifically to the particular job and site?

m

(b)

ito

A suitable risk assessment should be made before carrying out any work which may expose employees to asbestos.

et

5

(c)

Does it cover other risks (like falls from height or electricity?

ASBESTOS REMOVAL 6

Selection of an approved competent contractor should be made from the company approved supplier/subcontractor database. Database administrators monitor the approval status of these specialists.

7

Although COMPANY appoints a specialist contractor for the removal of Asbestos, the Project/Site Manager should ensure that they work in accordance with the requirements of the Qatar Regulatory Document (Construction) and do not put others at risk from their operations.

8

The appropriate checklists should be used to assess the suitability of the method of removal and to monitor the on-site activities. The checklist should be used in conjunction with the method statement/risk assessment review form.

QCS 2014

Section 11: Health and Safety Part 2.3.14: Asbestos

Page 7

ASBESTOS WASTE 9

All forms of asbestos (including overalls used for removal & enclosure materials) requires double bagging and specialist waste removal procedures. ROLE OF VIEWING PANELS AND CCTV A sufficient number of viewing panels should be installed in enclosures. The purpose of such panels is to allow supervisors, managers to monitor work, thereby minimising the need to enter enclosures. Viewing panels should be located to ensure that all areas inside the enclosure are visible, as far as reasonably practicable.

11

Where such panels are not reasonably practicable or where they do not allow good visibility of the active work area, a CCTV system should be installed such that ongoing work can be seen.

12

Entry will be required on appropriate occasions in order to check compliance with the plan of work and relevant health and safety procedures. CCTV and/or viewing panels do not replace the need for enclosure entry but they may help to reduce the frequency of entry.

ta

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All air testing, sampling of asbestos and clearance certification must be carried out by someone who is accredited by an appropriate body.

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SAMPLING, AIR TESTS AND CLEARANCE CERTIFICATION

SITE MANAGEMENT

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In any circumstance where there is an emergency including an accidental uncontrolled release of asbestos fibres or uncovering of previously unidentified ACM, it is essential to limit exposure and the subsequent risks to health by implementing the Site and SHE Advisors emergency procedures (refer to Asbestos Control Procedures Site Emergency Flow Chart at Appendix 1).

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All asbestos removal contractors must have prepared procedures which can be put into effect should an incident, accident or emergency occur which could put persons at risk because of the presence of asbestos e.g. employee collapsing or suffering serious accident within the active stripping enclosure or an uncontrolled release of asbestos fibres.

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ASBESTOS REMOVAL CONTRACTORS

These procedures should include sufficient information to enable the emergency services (paramedics, Civil Defence (Fire Department) to properly protect themselves against the risks of asbestos when attending an on-site emergency. Spare PPE and RPE should be available for the use of emergency personnel who may have to attend to persons removed from an enclosure without full decontamination procedures being carried out.

MEDICAL AND HEALTH SURVEILLANCE 17

In circumstances where cases of inadvertent exposure to asbestos may have occurred, the following steps should be considered: (a)

Ascertain as far as possible the type of asbestos, the likely exposure levels involved and the duration of exposure.

(b)

Where employees may have been significantly exposed (for instance exposure may have exceeded the relevant action level), obtain advice from the appointed occupational health service provider, particularly regarding the medical assessment and counseling of exposed employees.

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Page 8

(c)

Consider offering those involved – employers, employees or members of the public, the opportunity to discuss the situation with a medical or occupational health advisor, particularly where they are otherwise unlikely to have access to an occupational health service.

(d)

Complete and archive an Inadvertent Exposure Record for each person who may have been exposed to airborne asbestos dust in the course of work for COMPANY.

INFORMATION, INSTRUCTION AND TRAINING Personnel who are, or may be, exposed to asbestos should attend asbestos awareness training given at regular intervals.

19

The safety induction format for the project shall include the discovery of asbestos whilst working within the premises and working at height.

20

All workers should attend a safety awareness tool box talk.

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2.3.14.6 Monitoring & Performance

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THE PROJECT MANAGER SHALL:

Review the Management System/Asbestos Management Plan every 6 Months and record details.

2

Review Risk Assessments and Method Statements (SHE-PRO-001) at regular intervals or, if there is a significant change to either the task to be carried out or substances to be used or produced.

3

Inspect known ACM for deterioration at least every 12 months or as indicated in the Asbestos Management Plan and record results.

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2.3.14.7 Feedback & Action

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Project/Site Manager should conduct a sub-contract review of all contractors and record their findings on the Procurement Database

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2.3.14.8 Records

An effective Management System/ Asbestos Management Plan should be in place to protect staff, operatives and the public. Details should include: (a)

Label ACMs clearly with a suitable asbestos warning sign and make personnel aware of where it is located;

(b)

Make a note of where ACMs are on a site plan or other records and keep this information up-to-date;

(c)

Maintain records demonstrating that both training and information in relation to asbestos has been delivered to personnel;

(d)

Inadvertent Exposure and Health Records shall be kept and archived for a period no less than 40 years.

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2.3.14.9 Appendices

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APPENDIX 1 – ASBESTOS CONTROL PROCEDURES 1 - 5

PRE-CONSTRUCTION (TENDER) STAGE

Examine documents to see whether Asbestos is mentioned

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CONTROL PROCEDURE 1

Request assistance from SHE Advisor

Looking For

Asbestos Survey

Does the survey cover the work area and is it a Type 3 Survey

Request that client TYPE 3 survey be carried out

Proceed to next stage (Pre-Start)

Refer to SHE Advisor

PRE-START Internal Tender Handover Meeting

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Control Procedure 2

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Is TYPE 3 Survey in place?

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Estimator to inform site team of Asbestos Risk including previous asbestos removal during handover meeting

Training Required

Have you attended Asbestos Training

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SHE Advisor to organise Asbestos Training

Actions for SITE MANAGER

Arrange Asbestos removal by a competent Contractor

Proceed to next stage

Request assistance from She Advisor

Team review of Asbestos Survey

Ensure all Asbestos associated Surveys and documentation (including Risk Assessments and Asbestos Management Controls are retained.

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ON SITE

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Control Procedure 3

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Inform all persons on site of risk of Asbestos Risk

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Is Asbestos present on site?

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Site Manager to inform all operatives of controlled Asbestos areas during site induction process

Asbestos Management

If Asbestos materials are suspected, which have not been previously identified?

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Asbestos Removal

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Contractor to Monitor Asbestos Removal Subcontractors

Ensure relevant control measures from risk assessment been implemented?

STOP WORK ISOLATE AREA PREVENT EXPOSURE

Notify Line Managers Contractor

INFORM SHE ADVISOR Refer to site emergency procedure

Notify Sampling Contractor

SITE EMERGENCY PROCEDURES

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Control Procedure 4

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Potential Asbestos Disturbance

Site Manager to notify SHE Advisor

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Notify Line Managers

STOP, ISOLATE, PREVENT FURTHER

SHE Advisor to notify MD & SHE Manager

SHE Advisor & Site Team commence incident investigations

Confirmation of Asbestos Containing Materials NO

Proceed with Works

Appoint competent contractor to carry out clean up/removal

Notify Sampling Contractor

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SHE ADVISORS EMERGENCY PROCEDURES

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Control Procedure 5

Discuss emergency procedures (stop work, isolate, limit, prevent)

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SHE Advisor receives phone call/notification

Notify MD & SHE Manager

Decide if incident investigation should be carried out, then attend site

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Assist in planning for professional clean up/removal

Complete RIDDOR Dangerous Occurrence notification F100 within 10 days

Undertake Investigation

Contact fellow SHE Advisor for advice

Is exposure considered a Dangerous Occurrence in accordance with RIDDOR

Note: Decision to be undertaken in consultation with MD & SHE Manager

Record notification decision outcome within incident investigation report and close out investigations with regional and site management

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Section 11: Health and Safety Part 2.3.14: Asbestos

2.3.14.10

Reference Documents

Page 14

FORMS Asbestos Removal Method Statement Checklist (SHE-FRM-14-01)

2

Asbestos Removal On-Site Activity Checklist (SHE-FRM-14-02)

3

Inadvertent Exposure Record (SHE-FRM-14-03)

4

Method Statement Tracking and Content (SHE-FRM-1-04)

5

Permit to Work (SHE-FRM-11-02)

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2.3.14.11

Author POSITION IN COMPANY

NAME

CONTACT DETAILS

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SECTION

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Qatar Regulatory Document (Construction) RD1.2.8

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FURTHER REFERENCE DOCUMENTS

Approvals

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SHE Manager

Approved by:

NAME

POSITION IN COMPANY

SHEQ Director

SIGNATURE & DATE

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Page 15

REMOVAL METHOD – CHECK LIST

ACL 1

ASBESTOS

Introduction Although we appoint a specialist contractor for the removal of Asbestos we still have a duty to ensure that they work in accordance with current legislation and do not put others at risk from their operations. This checklist must be used in conjunction with your method statement review form. Training and Capability

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Operatives undertaking this nature of work should have been trained annually on working methods, types of equipment used, types of works carried out and PPE & RPE use. Note young persons must not undertake asbestos removal works.

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Control Arrangements

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Checked

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Item Name and address of asbestos removal contractor Asbestos competency evidence Name and address of the site to which the method statement relates Names of the supervisor/foreman and appointed safety adviser and arrangements for monitoring the work Type of work e.g. removal of roof sheets, insulation boarding or lagging Type and quantity of asbestos and the results of any analysis Probable duration of works The controls to be applied to reduce exposure other than by PPE e.g. controlled wetting method Details of expected exposures Details of the steps to be taken to control the release of asbestos to the environment e.g. enclosure arrangements, negative pressure equipment, reassurance monitoring, clearance certificate on completion etc. Location of decontamination unit Arrangements for 240v power supply and clean water supply Details of the equipment, including PPE, to be used for the protection and decontamination of those carrying out the work Procedures for the removal of waste from the work area and the site, and disposal of contaminated water Procedures for dealing with emergencies

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No. 1 2 3 4

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Asbestos removal method statements should normally include the following so far as is relevant to the specific works:

11 12 13 14 15 Note

The above list is not exhaustive for every asbestos removal task but should be used as an aid. Consult with your regional SHE advisor for further guidance.

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ON-SITE ACTIVITY – CHECK LIST

ACL 2

ASBESTOS

Introduction Although we appoint a specialist contractor for the removal of Asbestos we still have a duty to ensure that they work in accordance with current legislation and do not put others at risk from their operations. Site Management Requirements

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Site Managers and their appointed supervisors must understand company procedures on Asbestos management. Read through procedures and discuss with your regional SHE advisor. Control Arrangements

4

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Checked

Suitable plan/method statement has been supplied, outlines the method of work and any health and safety issues raised by the risk assessment Facilities provided by the asbestos removal contractor are suitable and do not obstruct any access, etc This applies particularly to the enclosure, the hygiene facility and air ducting. Before work commences, that the enclosure within which the contractor is to work, will not permit any escape of asbestos fibre into the atmosphere. This can be achieved by witnessing the smoke test being carried out. Insist that the enclosure includes a viewing panel. A maintenance/inspection schedule is in place for the enclosure and any air extraction equipment.

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Asbestos removal works must be monitored throughout their duration and this check list is intended to assist in this process.

That asbestos does not escape into the atmosphere during the stripping operation. Air monitoring around the enclosure during stripping works will indicate efficiency.

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The adequacy of the personal decontamination procedure, so that asbestos is not released from persons moving through the site. That the area being stripped is clean, both visually and with the supporting air sampling results. That the removal of the enclosure does not give rise to the release of asbestos fibre. Air monitoring around the enclosure before stripping work commences and during enclosure removal. That the storage of removed asbestos on site does not give rise to asbestos fibre release and that all asbestos is effectively removed from site double bagged and in suitable skips. Air clearance certification received for work area concerned prior to re occupation by Anon and associated contractors.

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Note The above list is not exhaustive for every asbestos removal task but should be used as an aid. Consult with your regional SHE advisor for further guidance.

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Section 11: Health and Safety Part 2.3.14: Asbestos

Inadvertent Exposure Record

Page 17

Region:

ASBESTOS

Department: The person named below may have been exposed to airborne asbestos dust in the course of work for COMPANY. The circumstances are detailed for record purposes. Worker Number: Name: Home Address:

DOB:

Job Title

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Project where incident occurred:

Finish:

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Date of Exposure; Start:

Finish:

Activity at time of exposure:

□ □ □ □

YES/NO

Type of asbestos: Crocidolite (Blue) Amosite (Brown) Chrysotile (White) Other:

□ □ □

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Respiratory Protective Equipment in use?

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Time of Exposure; Start:

Indicate nature of product: Cement AIB Lagging Sprayed

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Employer:

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Other:

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Air testing results attached? Sampling date:

YES/NO Time:

Name of person completing this form: Signature:

Title:

Region:

Department

Date: This record should form part of the investigation into the inadvertent exposure; all records must be kept for a minimum of 40 years.

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Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ........................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ................................... 1



ENVIRONMENTAL PROTECTION ........................................................................ 1

2.3.15.1 Responsibilities ...................................................................................................... 4

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2.3.15.2 Definitions .............................................................................................................. 5 2.3.15.4 Guidance to This Procedure .................................................................................. 9 2.3.15.5

Reference Documents ..................................................................................... 12

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2.3.15.13 Author ................................................................................................................ 25

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2.3.15.14 Approvals ........................................................................................................... 25

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2.3.15.14 Approvals……………………………………………………………………………26

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Process Map Input

Design

Procurement

Contact SHE for input

Receive contract documents Communicate any design decision that impacts in waste and environment

Risk Assessment and ECCoP Procedures

Project Management

SHE

Dept: Complete Risk Assessment and produce specific ECCoP and SWMP opportunity/early decision

SWMP documents or client documents

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Assist Audit, check and correct

Tender ECCoP SWMP

ECCoP Guidance

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SHE-FRM8 05 01

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SWMP

Develop and complete on site – record Waste through TRAKER

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SWMP Archive documents O & Ms

SWMP

SHE-FRM-1-03 Method Statement or Task Risk Assessment

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Works Order Request

Assist

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Monthly Data Collection Form (SHE-FRM-8 05-01)

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Construction

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Draft ECCoP and Risk Assessment

Output

With Project team/Estimati ng assist with Risk Assessment / ECCoP and SWMP

.

Pre-Construction

Contract Documents

Estimating

SHE-FRM-1-02

Assist

O & Ms,

Issue to client

Documents for archive SWMP Consent Records Etc. Issue to Client

Key

Activity Guidance

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Page 3

PURPOSE The purpose of this procedure is to provide a framework by which environmental impacts and aspects will be managed. COMPANY Policies and in compliance with the requirements of the Environmental Management System Standard BS EN ISO 14001.

4

The Environmental Protection Law No. 30 of 2002 translates environmental policy objectives into a benchmark standard of environmental operation and this Environmental Management System may be subject to third party, independent certification by external Environmental Auditors.

5

The Environmental Protection Law No. 30 of 2002 provides a structure in which legislative requirements, best practice and pollution prevention obligations can be addressed in a logical, orderly manner. The framework can be extended to incorporate Client and/or regulatory nonstandard requirements. The law also provides a vehicle for corporate commitments to be translated into everyday activities.

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SCOPE

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1. This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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Note: Environment Ministry is the competent authority in relation to matter relating to environmental protection and any spillages of hazardous material/substances must reported accordingly.

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2.3.15.1 Responsibilities 2.3.15.1.1 SHE Director 1

Authorises this procedure. PROJECT/SITE MANAGER/SUPERVISORS Ensure this procedure is established and works are carried out in accordance with this procedure.

3

Environmental or SHE Advisers should be contacted to carry out the Environmental Survey and Risk Assessment and assist site management in the implementation of the Environmental Protection Law No. 30 of 2002. Successful operation of the system is dependant on Project Management's commitment to make it work.

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2.3.15.1.2 ENVIRONMENTAL MANAGER/ADVISOR/SHE ADVISER

Provide advice and support in the application and monitoring of this procedure. In conjunction with Project Management, carry out Environmental Survey and Risk Assessment form and produce project specific framework.

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2.3.15.1.3 PROCUREMENT/ESTIMATING

Determine the relevant issues identified by this procedure and provide for adequate resources at the tender stage.

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Consider environmental issues in the preparation of designs and provide input to the construction process to facilitate environmental best practice.

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2.3.15.1.5 ENVIRONMENTAL CO-ORDINATOR In most cases the Site Safety Co-ordinator shall assume the role as Site Environmental Coordinator.

2

Where more than one Site Environmental Co-ordinator is appointed their areas of responsibility shall be clearly defined and agreed with them.

3

The role of the Site Environmental Co-ordinator is to assist the site/location manager to comply with their environmental responsibilities.

4

The main duties of the Site Environmental Co-ordinator are as follows:

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(a)

To assist management in identifying environmental requirements set out in the contract documentation.

(b)

Accompany Environmental Advisers during visits to site.

(c)

Assist management in the implementation of the Environmental Protection Law No. 30 of 2002.

(d)

Co-ordinate and attend Environmental forum meetings.

(e)

Conduct regular environmental inspections to check compliance with the Environmental Protection Law No. 30 of 2002.

(f)

Liaise with management to facilitate environmental improvement where deficiencies have been highlighted.

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(g)

Respond to observations/comments from personnel with environmental concerns.

(h)

To maintain a liaison role with COMPANY Environmental Adviser and the appropriate local agencies (e.g. Labor & Environment Ministries)

(i)

Assist the Site Safety Co-coordinator in the timing of environmental awareness talks.

(j)

To assist in site induction preparations and/or presentations.

(k)

Ensure adequate emergency procedures are developed for the site/location

2.3.15.1.6 DUTIES OF WASTE CO-ORDINATOR In association with the Purchasing Team, monitor sub or work package contractors’ replies relating to waste.

2

Notify sub or work package contractors of site requirements relating to waste including separation.

3

Monitor waste handling and containment on site or at the permanent location ensuring that the requirements of the Environmental Protection Law No. 30 of 2002 are being fulfilled.

4

Check that the waste is disposed of at an appropriately authorized facility obtaining relevant copies of documentation and as necessary follow loads to disposal facilities to support this requirement.

5

Report any inadequacies in carrier performance immediately to the site or permanent location manager and the Purchasing Team.

6

Report any failure of sub or work package contractors to handle waste correctly to the site or permanent location manager.

7

Liaise with the SHE Team if there are any doubts on classification of waste such as hazardous waste.

8

Where COMPANY vehicles carry waste, determine that the waste to be carried is acceptable to the authorized waste manager/disposer for whom it is destined.

9

Maintain records for archiving for a period of three years.

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2.3.15.2 Definitions

2.3.15.2.1 RISK ASSESSMENT 1

2.3.7.1.2 2

The process of hazard, aspect and impact identification, assessment of the risk and identification of the controls required to manage the risk to an acceptable level to ensure the health and safety of those affected by the activity and the protection of the environment from harm. HAZARD/ASPECT/IMPACT Is something with the potential to cause harm (this can include substances or machines, methods of work, harm/damage to the environment including the potential of causing a statutory nuisance and other aspects of work organization).

2.3.15.2.3 METHOD STATEMENT 1

A statement describing the proposed working methods that address the output from a risk assessment process. A Method Statement provides instruction and guidance for those individuals carrying out the activities.

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Section 11: Health and Safety Part 2.3.15: Environmental Protection

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ENVIRONMENTAL PROTECTION LAW NO. 30 OF 2002

The Environmental Protection Law No. 30 of 2002 forms a key part of COMPANY’s Environmental Management System, particularly on larger projects, and provides an effective environmental management tool for a project, office or other fixed location.

2.3.15.3 Action Required To Implement This Procedure 2.3.15.3.1 INITIAL CONTRACT OR SUB-CONTRACT ENQUIRY On receipt of the tender enquiry, the contract documents shall be reviewed by the Estimating Team to ascertain the following (where required assistance should be sought from the Environmental Adviser) : (a)

Pollution sources potential or impact identified

(b)

Possible areas of pollution/contamination, or potentially contaminated past and use, e.g. landfill, heavy industrial works.

(c)

Conditions of any Environmental Statement (contact the Environmental Adviser).

(d)

Waste types and quantities likely to be generated.

(e)

Other environmental issues such as special Client requirements.

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In view of the necessity to identify applicable legislation and prevent breaches, advice, where appropriate, shall be sought from the following sources:

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The environmental issues identified in 3.1 shall be communicated to the project team to allow environmental issues to be addressed by appropriate team members such as Designers, Estimators etc.

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(a) The Client (b) Enforcing Authorities (e.g. Labor & Environmental Ministries) (c) Environmental Adviser/Manager

The elements of the Environmental Protection Law No. 30 of 2002 (Appendix 1) shall be taken into account in the tender submission in addition to any other requirements identified through section 3.1.

2

Any tendering sub or work package contractors shall be made aware of any environmental constraints or issues potentially affecting their works and likely commercial effects.

3

It is a policy requirement that only sub or work package contractors who can demonstrate a commitment to environmental management shall be invited to tender for work. Estimators or procurement personnel shall therefore implement this requirement where the environmental performance of a sub or work package contractor is previously unknown.

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2.3.15.3.3 DESIGN 1

Initial and any subsequent design shall take into account the requirements of the Environmental Protection Law No. 30 of 2002 (see Appendix 1).

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2.3.15.3.4 CONTRACT AWARD/PRE-COMMENCEMENT The Project Manager shall contact the Environmental Adviser to initiate an Environmental Risk Assessment (Appendix 1) for applicable contracts and advise on establishing contact with the appropriate regulatory authorities (e.g. Labor & Environment Ministries). The Environmental Adviser shall carry out the baseline Risk Assessment with assistance from the Project Team.

2

On contract award the Project Manager shall review the Environmental Protection Law No. 30 of 2002 (Appendix 1) in conjunction with an Environmental Adviser and relevant parts implemented. Additional environmental requirements identified in section 3.4 shall be incorporated in and be managed through the SHE Management Plan specific to the contract.

3

The project Supply Chain Manager/Procurement Team shall make sub and work package contractors shall be made aware of their environmental obligations as detailed under the Environmental Protection Law No. 30 of 2002 and if applicable the SHE Management Plan.

4

For smaller projects that are instructed via a works order an Environmental Protection Law No. 30 of 2002 is not required. Environmental Management (Document, efficient etc) must be considered as part of the Risk Assessment SHE-PRO-001.

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2.3.15.3.5 CONSTRUCTION PHASE

The Construction Manager/Project Manager/Site Manager shall ensure that the Environmental Protection Law No. 30 of 2002 has been implemented on site where applicable.

2

In the event of a works order being placed environmental impact is assessed via a ‘Job/Task Risk Assessment/Method Statement (SHE-FRM-1-02) or detailed ‘Method Statement’ (SHE-FRM-1-03) dependent on the scope of work.

3

The Project Team shall include Environmental issues in site inductions within Safety, Health and Environmental Information and Training for all Employees, Newly Assigned Employees, and Subcontractors, (SHE-PRO-006)

4

Environmental issues shall be covered in detail within Safety, Health and Environmental Risk Management and Written Safe Systems of Work SHE-PRO-001

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The Project Management Team shall ensure that all site supervisory staff regularly monitors environmental matters whilst executing their normal site duties.

6

The Project Management Team shall ensure environmental matters shall be listed and discussed as an agenda item.

7

Project Manager, with the SHE Adviser, shall review the Environmental Protection Law No. 30 of 2002 on a regular basis throughout the project, and in line with the SHE Management Plan, to take into account changes in the job.

8

The Project Team and Environmental Adviser shall, in pursuance of good relationships with enforcing authorities and where it is deemed practicable, contact the statutory authority (e.g. Labor & Environment Ministries), invite them to site to inspect works and keep them fully informed of the progress of the works. This should be managed through the SHE Management Plan.

9

The Project Team shall record and report any environmental incidents in accordance with SHEPRO-008 – The Report and Investigation of Accidents and Incidents procedure.

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2.3.15.3.6 OFFICES/FIXED LOCATIONS 1

The Office/ Facility Manager shall develop an Environmental Protection Law No. 30 of 2002 and waste plan for each office/fixed location (yard/depot/factory etc), in conjunction with the Environmental Adviser.

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2.3.15.3.7 HANDOVER 1

The Project Team shall ensure all temporary consents are closed out with the appropriate authority or handed over to the Client; the Client shall be informed of any statutory and/or on-going environmental restrictions, permits, and consents operating on the contract at handover.

2.3.15.3.8 SITE CLEARANCE 1

All waste materials under the control of COMPANY shall be removed from site in accordance with the COMPANY Environmental Standards and Guidance documents.

2

Following site clearance the client shall be invited to agree that the site is clear of any waste, polluting or contaminating materials. Agreement shall be recorded in writing.

2.3.15.2.9 NOTICES Any Environmental Notice pertaining to any environmental matter shall be notified using the COMPANY SHE Alert System, SHEPRO-008 – The Report and Investigation of Accidents and Incidents procedure.

2

Any such notice shall be fully complied with and copies served on sub contractors or others likely to be affected by the document contents.

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Should any summons be received in relation to environmental matters it shall be referred to the COMPANY SHE Director who shall forward it immediately to the COMPANY MD and Regional MD and will brief solicitors and handle the matter directly.

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PROSECUTIONS

Formal visits to site by a Workplace Inspector shall be accompanied at all times and the Project Manager made aware of their visit who in return will notify the Environmental Adviser or Environmental Manager using the First Alert Form SHE-FRM-8-01

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2.3.15.3.10 VISITS BY LABOR & ENVIRONMENT MINISTRIES, WORKPLACE INSPECTORS

(

).

Notes shall be made of any action taken, comments, testing and/or sample taken including locations at which samples have been taken during a formal visit.

3

Should any sample be taken off site the company should request a share of the sample and this shall be retained, if it is refused the fact shall be recorded. Details of the exact origin of the sample, time of sampling and the method used shall be requested.

4

Should a statement be requested the following should be adhered to:

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(a)

Immediately notify the COMPANY SHE Director and Line Manager.

(a)

Request the presence of a third party (Project Manager or equivalent) who shall take notes.

(b)

Request a copy of any statement you have made and make it clear that you wish a copy of the statement to be made available to your employer.

For routine visits by a Workplace Inspector, record in the Project Diary and notify the SHE Team.

2.3.15.3.11 MAINTENANCE PERIOD 1

Where maintenance operations impose a serious environmental risk any such operation shall only be carried out under the guidance of, and in compliance with a prepared environmental method statement and/or Client's occupier's environmental codes of practice.

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Maintenance staff/operatives shall be briefed that their operations shall not affect the environmental integrity of plant and control measures shall be put into place to ensure that all environmental risks are adequately controlled.

2.3.15.3.12 POST CONTRACT AND COMPLETION ENVIRONMENTAL 1

Wherever an environmental problem is raised by the client after occupation the COMPANY Environmental Manager shall be notified as soon as possible.

2.3.15.4 Guidance to This Procedure 1. The framework Environmental Protection Law No. 30 of 2002 (Appendix 1) is designed to

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be tailored to the environmental risks that are specific to the project/office, through the use of the Environmental Risk Assessment which precedes it. The Environmental Protection Law No. 30 of 2002 provides a robust framework detailing the company’s minimum environmental performance and community engagement standards, and can be amended to include any contract or Client specific requirements. 2. In the event of a works order being placed environmental impact is assessed via a

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‘Job/Task Risk Assessment/Method Statement (SHE-FRM-1-02) or detailed ‘Method Statement’ (SHE-FRM-1-03) dependent on the scope of work.

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APPENDIX 1 - ENVIRONMENTAL PROTECTION LAW NO. 30 OF 2002, ENVIRONMENTAL SURVEY AND RISK ASSESSMENT FORM (SHE-FRM-15-12) HOW TO DEAL WITH POTENTIAL THREATS TO THE ENVIRONMENT Site-specific environmental threats should be identified through the review of contract documentation and desk studies with the Project Team and incorporated in to the Environmental Survey and Risk Assessment Form. The control measures identified should be included within the Template of Environmental Protection Law No. 30 of 2002 and site specific controls (mitigation) included in order to control these threats.

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Task Specific Method statement (SHE-FRM-1-03) or Job/Task Risk Assessment /Method Statement (SHE-FRM-1-02) should also include specific environmental controls. As detailed below:

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IDENTIFICATION OF POTENTIAL THREATS TO THE ENVIRONMENT

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All activities which will require a risk assessment to be completed for the Health and Safety of the personnel undertaking the task must also include any environmental risks associated. Some commonly occurring potential threats to the environment can exist when:

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(a) there is a quantity of polluting material stored on site,

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(b) a site/material is located in an environmentally sensitive location such as near to a water source or surface water drain, next to a residential property/school (Examples of polluting materials: diesel, silty water, lubricant oils, paints, adhesives, battery acid, slurry, cement, treated timber, pesticide), (c) a site contains contaminated ground/materials,

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(d) noise/ vibration levels are predicted to be high,

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(e) an invasive species is present (Japanese Knotweed, Himalayan Balsam etc.), (f) waste is produced,

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(g) dust is generated,

Note: The above are commonly occurring however this does not cover all potential environmental risks, which could be present on any specific site.

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(h) plant/machinery is refueled

COMMUNICATING THE ENVIRONMENTAL RISKS 1

Once a specific risk assessment or method statement – (SHE-FRM-1-03) or Job/Task Risk Assessment/Method Statement (SHE-FRM-1-02) has been produced then all affected personnel must be informed of the relevant controls specified, most probably through a method statement briefing.

REVIEWING THE ENVIRONMENTAL RISKS 1

Once the specific risk assessment has been established it is imperative that it is periodically reviewed in light of changing circumstances on site, different materials and locations.

CHECK 1

All risk assessments should include any environmental risks associated with the activity. As an example, any activity which uses plant/ machinery will have diesel as a potential pollutant.

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Suitable control measures in the risk assessment should ensure that diesel from our site does not cause any pollution during either refueling or operations. 2

Action owners shall be assigned to all appropriate sections of the Environmental Protection Law No. 30 of 2002 and a regular review of progress shall be held at a separate environmental meeting or environmental issues can be discussed at regular site meetings.

ENVIRONMENTAL PROTECTION LAW NO. 30 OF 2002 (SHE-FRM-15-13) 1

The following items shall be addressed in order to ensure that the Environmental Protection Law No. 30 of 2002 is implemented effectively: (a) Assign responsibility to site management; (b) Assess needs for training or awareness; (c) Co-ordinate liaison with Ministry’s

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(d) Measure environmental performance of the project against that planned; (e) Amend Environmental Protection Law No. 30 of 2002 ; (f) Review environmental inspections/audits;

(g) Develop the profile of environmental performance on-site;

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(h) Ensure continuous improvement.

The above actions and review of progress may be conducted by the Project Management Team,

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Environmental Team, SHE Advisers, Engineers, Client.

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The Environmental Protection Law No. 30 of 2002 shall be revised on a regular basis, and in line with the SHE Management Plan (e.g. every 3 months), to take into account changes in the job; the revision programme will be dictated by the SHE Management Plan.

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Environmental Forum Structure

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2.3.15.5 Reference Documents 2.3.15.5.1 FORMS (a) Site Waste Management Plan Options (b) SWMP Word Version (SHE-FRM-15-01) (c) Complaints/Comments/Compliments Record (SHE-FRM-15-02) (d) Water Discharge Inspection Sheet (SHE-FRM-15-05) (e) Controlled Waste Transfer Note (SHE-FRM-15-06)

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(g) Communication Record (SHE-FRM-15-09)

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(f) Environmental Vibration Recording Sheet (SHE-FRM-15-07) (h) Environmental Check – Open culvert/Stream (SHE-FRM-15-10)

(i) Environmental Noise Survey Summary Sheet (SHE-FRM-15-11)

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(j) Method Statement – (SHE-FRM-1-03)

(l) First Alert (SHE-FRM-8-01)

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(k) Job/Task Risk Assessment/Method Statement (SHE-FRM-1-02)

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(m) Environmental Survey and Risk Assessment (SHE-FRM-15-12)

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2.3.15.5.2 REFERENCE DOCUMENTS

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(n) (SHE-FRM-15-13)

Safety, Health and Environmental Risk Management and Written Safe Systems of Work (SHEPRO-001)

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Safety, Health and Environmental Information and Training for all Employees, Newly Assigned Employees, Promoters and Sub-Contractor Personnel (SHE-PRO-006)

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Contractors Check List for Initial Safety, Health and Environmental Meeting (SHE-PRO-007)

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The Report and Investigation of Accidents and Incidents (SHE-PRO-008)

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2.3.15.6 Contractor Requirements 1. The Contractor will be required to appoint a suitably qualified Contractor’s Environmental Manager (CEM) who will ensure that all reasonably practicable means are adopted to fulfill the environmental requirements of the Employer. The Section D Technical Deliverables indicates the qualifications and experience required. The CEM will hold regular meetings, at least monthly, with the Engineer to discuss construction activities and compliance with the Construction Environmental Management Plan (CEMP).

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2. All CVs of contractor’s environmental management personnel will be subject to review and approval by the Engineer and, if appropriate, candidates will undertake a formal interview and be subject to an agreed probationary period. The Engineer has the right of rejection if environmental management candidates do not reach the required criteria during the probation period.

2.3.15.7 Legal Framework

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1. The Contractor working on the Work Order shall comply with relevant national and international legislation, local bylaws and codes of practice. In the absence of appropriate legislation, recognized best practice will be followed.

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2. The contractor shall ensure that all subcontractors and works under their control also comply with all relevant legislation and codes of practice. Best practice will be followed at all times. 3. The following national legislation and codes, but not limited to, will apply:

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QCS (Qatar Construction Specifications) latest edition; Labor Law 14 of the Year 2004; Qatar Traffic Law No 19 of the Year 2007; Environmental protection Law 30 of the Year 2002; Executive Bylaws of Environment Protection Law Issued under Ordinance Law No. (30) of 2002CDD (Department of Civil Defense) – Fire Safety Handbook; and Worker Rights Booklet 2009 (National Human Rights Committee).

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a. b. c. d. e.

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4. In the event that legislation is updated the latest version shall be followed. All relevant new legislation will be followed as appropriate. 5. The contractor shall comply with all Environment Impact Assessment Mitigation and Environmental Permit Conditions.

2.3.15.8 Programme Management Delivery System (PMDS) 2.3.15.9 Environmental Management and Responsibilities 2.3.15.9.1 General Requirements 1. The contractor shall be required to have a recognized environmental management system such as ISO 14001:2004 or be able to demonstrate that they are actively working towards implementing such a system. Prior to the commencement of the project the contractor shall produce a CEMP that will be reviewed by the Engineer. The CEMP will be submitted for approval within 30 days of the award of contract. The CEMP must be approved by the Engineer prior to the start of construction. The Contractor shall review

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and update the CEMP as appropriate but no less than quarterly. A record of the review and any recommendations shall be produced and retained on file by the Contractor. 2.3.15.9.2 Environmental Policy 1. The Contractor shall have an environmental policy dated and signed by the most senior person in the company. The policy shall:

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(a) Be appropriate to the nature, scale and environmental impacts of the organizations activities, products and services. (b) Include a commitment to continual improvement in environmental performance (c) Include a commitment to comply with all applicable legislation and with other requirements to which the organization subscribes which relate to its environmental aspects (d) Provide a framework for setting and reviewing objectives and targets (e) Be documented, implemented and maintained (f) Communicated to all persons working for or on behalf of the organization (g) Be available to the public

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2.3.15.9.3 Environmental Aspects

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1. The Contractor is expected to use a qualitative approach to identify and evaluate potential environmental aspects along with any controls to prevent or mitigate environmental damage. A simple risk matrix should be used to assess and evaluate all environmental risks on the project. An example of a risk assessment is presented below.

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2. Environmental Risk Assessment

A. STAGE ONE: Identify your Environmental Aspects

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1. Your environmental aspects are how you interact with the environment e.g. your activities, products or services. These will be identified for normal, abnormal and emergency conditions. 2. Key to operating conditions:

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3. Normal ‐ those activities, products or services as they are carried out or used on a regular day to day basis and operating as intended.

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4. Abnormal ‐ those activities, products and services as they are carried out or used on an irregular or limited basis but as intended e.g. maintenance 5. Emergency‐ those activities, products or services as they are carried out or used in an unintentional manner B. STAGE TWO: Identify your Environmental Impacts 1. Your environmental impacts are how your activities, products or services cause a change to the environment. These impacts can be positive or negative.

2. Consider the environmental media that could be affected:        

Air quality; Water quality; Land (contamination); Waste (solid, liquid, hazardous); Resource use (energy, water, materials consumption); Nuisance (noise, odour, dust); Wildlife; and Carbon.

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C. STAGE THREE: Detail Existing Control Measures 1. There may be control measures in place that limit the risk. The controls may be documented in procedures, physical controls (e.g. spill kits, interceptors) or control through training. D. STAGE FOUR: Evaluate the Environmental Risk 1. Evaluate the significance of the environmental risk. Example criteria:    

Legal Breach; Risk of environmental damage or harm; Significant use of resources; and Third party interest (stakeholder interest, source of complaints / questions).

E. STAGE FIVE: Determine Environmental Risk Rating

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1. Determine whether the risk to environment is High or Low risk. An example of how to do this is provided in the Environmental Register, available on the PDMS.

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2. If the activity is identified as High risk ‐ It will require management action to improve level of control e.g. permit may be required, EIA, mitigation detailed in CEMP. It will require documentation of control within EMS e.g. development of procedure or training requirement

F. STAGE SIX: Implementation

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3. If the activity is identified Low risk ‐ It does not require further action at this stage.

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1. The risk assessment process should be reviewed during the activity and any changes or updates should be communicated to those involved in the project. 2. Worked Example

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3. Activity: Storage Oil stored in tank used for powering generator

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4. Environmental Aspect: Leak identified from fully bunded Oil storage tank 5. Environmental impacts:

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 Potential for contamination of land;  Potential contamination of local water bodies; and  Hazardous waste from clean-up activities. 6. Controls:  Ensure oil tank is fully bunded capable of holding 110% of tank capacity;  Ensure sight gauge and pipe work are contained within the bund;  Introduce delivery procedures, signage and training;  Carry out regular inspection of the bund and tank to check for leaks; and  Have a spill kit at the location. 7. Risk: (a) High Risk ‐ If the fuel escapes to water or land it would be in breach of regulations and would be costly to clean up.

2.3.15.9.4 Objectives, Targets and Improvement Programmes 1. The Contractor shall establish, implement and maintain documented environmental objectives and targets at relevant functions and levels within the organization. Objectives and targets shall be measurable and should be consistent with the environmental policy and the sustainable development objectives set out in the PMDS. When establishing and reviewing its objectives and targets the contractor shall take into account the legal and other requirements to which it subscribes and its significant environmental aspects. 2. The contractor shall establish, implement and maintain programmes for achieving its objectives and targets. Programmes shall include:

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a) Designated responsibility for achieving objectives and targets at relevant functions and levels of the organization; b) The means, resources and timeframes by which they are to be achieved 2.3.15.9.5 Roles and Responsibility

1. The contractor shall ensure that resources are available to develop, implement, maintain and improve the CEMP including: (a) (b) (c) (d) (e)

Human resources; Skills and training; Organizational infrastructure; Technology, plant and equipment; and Financial resources.

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2. The Contractor shall define, document and communicate the roles, responsibilities and authorizations in order to facilitate effective environmental management.

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1. The following provides guidance on roles and responsibilities at various function levels and shall be used as a basis for further development in conjunction with the PMDS and QCS 2010.

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2. Business Head/Director: Responsible for implementation of the Environment Policy and overall environmental performance.

3. Contractor Environmental Manager (CEM): Responsible for development and

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implementation of the CEMP. Duties shall include but not be restricted to:

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(a) Development and implementation of the CEMP to meet the requirements of the Work Order in general, and PMDS; (b) Monitoring and reporting on environmental performance; (c) Ensuring that all staff are appropriately trained and informed; (d) Setting, monitoring and reviewing environmental objectives and targets; (e) Maintaining adequate environmental records; (f) Liaising with the client and others as required; (g) Ensuring that relevant statutory legislation is monitored and the requirements followed; (h) Ensuring that accidents and incidents are appropriately reported; (i) Ensuring that environmental issues are considered by all staff and are applied to their work; Responding to unplanned and emergency situations as required; and (j) Reviewing performance against relevant objectives and targets.

4. Site Based Responsible Environmental Person (SBREP): Duties shall include but not be restricted to: (a) Ensuring that the CEMP is developed, implemented and maintained on site according to the LR&DP PMDS requirements; (b) Reporting on performance of the CEMP and make recommendations for improvement; (c) Undertaking daily/weekly checks as required ; (d) Undertaking monitoring and reporting on environmental performance as required; and (e) Delivering toolbox talks. All staff: Duties shall include but not be restricted to: (a) Being environmentally aware and implementing the CEMP as appropriate;

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(b) For undertaking their work in a manner that does not adversely impact on the environment; and (c) Reporting environmental accidents, incidents and near misses. 2.3.15.9.6 Competences, Training and Awareness 1. The Contractor shall identify the training needs associated with the project, CEMP and its environmental aspects and produce a training plan. The training plan shall be subject to approval by the Engineer. The contractor shall provide appropriate training or take other action to meet these needs and shall retain associated training records. 2. The Contractor shall establish and implement a procedure to ensure that all persons working for it or on its behalf are aware of: The importance of the Environmental Policy and compliance with it; The requirements of the PMDS and CEMP; The significant environmental aspects and the potential impacts of the work; The benefits of improved environmental performance; The importance of complying with relevant environmental law and environmental permit (f) conditions; (g) The importance of complying with specified procedures; and (h) The potential consequences of departure from specified procedures, work instructions and method statements. (i)

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(a) (b) (c) (d) (e)

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3. The Contractor shall ensure that all staff with specific responsibility for the environment is trained in accordance with the PMDS.

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2.3.15.9.7 Communication

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1. The Contractor shall establish, implement and maintain communication procedures to enable the effective implementation of the CEMP. Specifically the communication procedure will be for:

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(a) Internal communications between the various levels and functions within the organization; and (b) Receiving, documenting and responding to relevant communications from external stakeholders including (but not limited to) GEC, PMC, PWA, MMUP and MoE.

2. All communication procedures must be compliant with the PMDS. 2.3.15.9.8 Documentation

1. The Contractor shall develop, implement and maintain a document system to include, but not be restricted to: (a) (b) (c) (d) (e)

The Environmental Policy; Environmental improvement objectives and targets; Including competencies and training; Relevant EIA documentation; CEMP:

 Procedures  Method statements  Work instructions (f) Record Keeping:

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Daily inspections Weekly inspections Internal and external audit reports Environmental permits and consents.

3. The Contractor shall develop, implement and maintain a procedure to:

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(a) Approve documents for adequacy and accuracy before issue; (b) Review, update and reapprove documents; (c) Ensure that changes to documents and the current revision status of documents are identified; (d) Ensure that relevant and up to date documents are available at the point of use; (e) Ensure that documents are legible and identifiable; (f) Ensure that documents of external origin are identified and their distribution controlled; (g) Prevent the unintended use of obsolete documents retained for any purpose. 2.3.15.9.9 Environmental Control Plans

The controls to manage and mitigate environmental damage will be identified and put in place during the design and development phase of the project. Despite this there are activities that can result in environmental damage which can only be managed and prevented through appropriate construction methods, awareness and training and appropriate contingency measures. Where a project has been the subject of an Environmental Impact Assessment (EIA) study and report, many of these measures will be stipulated in that EIA Report and associated CEMPs.

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2. The Contractor shall establish, implement and maintain documented environmental control procedures to manage the activities associated with the identified significant environmental aspects. These procedures should be consistent with the PMDS and the Environmental Policy, objectives and targets. It should be noted that all significant environmental aspects should be controlled. Environmental Control Plans must include, but not be limited to:

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(a) Soil Erosion and Sedimentation; (b) Waste Management; (c) Air Quality; (d) Pollution Prevention; (e) Water and Energy Use; (f) Dewatering activities; (g) Construction Noise; (h) Light Pollution; (i) Archaeological and Cultural; (j) Stockpile management; (k) Dust and air-born particulate control; (l) Contaminated land; and (m) Surface and groundwater protection

2.3.15.9.10 Environmental Inspections, Monitoring and Reporting (a) Daily Site Inspections 1. The Contractor shall carry daily site inspections to monitor environmental performance in accordance with the PMDS (Site Environmental Inspection Form). The inspections should include, but not be limited to, checking that:

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All waste is appropriately stored and segregated; Waste skips are covered to prevent windblown litter; Drip trays are in place for all stored equipment and plant; All chemicals/fuels are stored with appropriate containment/bunds/cover; Construction noise is within permitted limits and does not create a nuisance; Dust does not create a nuisance; Spill kits are present; and Fencing is secure.

2. Where there are particular permit conditions that require routine checks or similar, these should be included as appropriate. Records of daily inspections shall be kept and maintained. (b) Weekly Inspections

1. The Contractor shall carry out weekly inspections to monitor environmental performance in

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accordance with the PMDS. The inspections should include, but not be limited to checking that:  Daily checklists have been completed;  Waste storage areas have been checked and there is no build-up of waste materials ;  Spill kits have been checked and contain all relevant materials;  The performance of all pollution control equipment has been checked and the equipment is working effectively;  Noise reduction equipment has been checked and is operating effectively; and  Septic tanks are not overfull/discharging.

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Records of weekly inspections shall be kept and maintained

(c) Monitoring and Reporting

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1. The contractor shall be required to establish, implement and maintain procedures to

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monitor, measure and report, on a monthly basis, statistics in accordance with the requirements of the PMDS (Monthly Environmental Statistics Report). Statistics will include, but will not be restricted, to:

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 General Environmental Statistics: o Environmental incidents, accidents and near misses; o Site inspections; o Environmental audits; o Environmental complaints; o Number of training sessions delivered including topic and numbers of attendees.  Waste Management o Total amount of waste produced by type:  General;  Hazardous;  Excavated Material;  Metals;  Liquid. o Total amount of waste disposed of by type to:  Landfill;  Recycling;  Recovery/reuse;  Ground.  Total amount of water consumed:

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o Ground water; o Mains, potable water.  Noise and Vibration: o Number of complaints; o Monitoring undertaken; o Mitigation measures applied.  Air quality, dust and odour: o Number of complaints; o Monitoring undertaken; o Mitigation measures applied.  Ecology, protected species and habitats: o Protected species or habitats identified on site; o Vegetation removed.

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 Archaeological or cultural artefacts: o Number of archaeological or cultural artefacts identified on site. 2.3.15.9.11 Auditing

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1. The Contractor shall conduct internal audits of the CEMP at regular planned intervals to ensure that it is:

Audits shall be conducted in line with the requirements of ISO 19011 2002 ‘Guidance for quality and/or environmental systems auditing’. Audit Reports will be maintained by the contractor.

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(a) Properly implemented and maintained; (b) Conforms to the requirements of the PMDS.

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2.3.15.9.12 Nonconformity and Corrective and Preventative Action

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2. Non-conformities may be identified through: Internal contractor audits; Audits by GEC/PMC; Audits undertaken by external certification bodies; and General observations.

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(a) (b) (c) (d)

3. The Contractor’s procedures shall define the requirements for: (a) Identify and correct non-conformities; (b) Mitigating the environmental impacts of non-conformities; (c) Investing non-conformities including identifying root causes and implementing appropriate actions to avoid their reoccurrence; (d) Evaluating the need for actions to prevent non-conformities and implementing appropriate actions designed to avoid their reoccurrence; (e) Setting realistic timeframes for undertaking effective corrective and preventative actions; (f) Recording the results of corrective and preventative actions taken; and (g) Reviewing the effectiveness of corrective and preventative actions.

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3. All actions identified should be appropriate to the nature and magnitude of the problem and the environmental impacts encountered

2.3.15.10 Emergency Response Plan 2.3.15.10.1 Introduction 1. The Contractor shall establish, implement and maintain procedures to identify and manage potential environmental emergency situations and potential accidents. The contractor shall respond to actual emergency situations and prevent and mitigate adverse environmental impacts. 2. The Contractor should periodically test, review and update emergency preparedness and response procedures

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2.3.15.10.2 Key Requirements

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1. During construction accidents, incidents and emergencies that have an environmental impact may occur. In the event of an emergency, the first response is to locate the source and stop continuation of the situation, followed by the containment, control and mitigation of the situation.

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A copy of the Material Safety Data Sheets and an inventory for all the chemicals and their types and quantity used on the project site shall also be kept at each site office and in every vehicle used on the project site.

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(a) Site Offices; (b) Remote offices on site; and (c) Every vehicle on site.

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2. For each construction site the Emergency Response Procedure will be displayed at:

All Contractor personnel and sub-contractors shall be instructed and rehearsed, as appropriate, in the requirements of the emergency response procedure. Following control of an incident or emergency, an investigation will be conducted and corrective actions identified and addressed. The Site HSE Manager shall verify the close out of environmental related actions. The CEM shall be responsible for notifying the Engineer of any emergency.

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4. The main objectives of the Emergency Preparedness Response Plan are to: (a) To ensure that all means are available to contain the consequences of an accidental spill, fire or release of oil/fuel. (b) To ensure that employees are suitably trained to respond to fire and spill. (c) To ensure that proper reporting takes place. (d) To ensure that proper investigation is undertaken.

2.3.15.10.3 Incident Classification and Notification Requirements 1. What is an Environmental Incident (a) Near miss  An accident or incident that was narrowly avoided; and  An unplanned event that did not result in environmental damage or harm, but had the potential to do so. (b) Non-Compliance with legislation or permit  A breach of conditions set out in the environmental permit e.g. noise limits, waste water effluent, air quality, hazardous waste disposal; and  Breach of Qatar Environmental Protection Law. (c) Typical environmental incidents:

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Spillage of hazardous substance e.g. oil, detergent, paint, fuel; Loss of containment – fuel, oil, liquid waste; Fire; Explosion; Release to atmosphere e.g. gas, dust, pollutants; Excessive noise, vibration, light, dust or odour; Land contamination; Pollution from de-watering processes/unauthorised discharge; Incorrect disposal or storage of waste; Contamination of water course, drains, marine environment; Disturbance of or unplanned/unpermitted damage to or destruction of protected species, habitat or artefact; Legal breach/noncompliance with permit conditions; and Other environmental incidents.

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2. Incident Classification Major

Minor

The material is highly toxic or hazardous

The material has a low toxicity

The incident occurred in sensitive area e.g. close to residential areas, water course, marine environment

Incident can easily be controlled e.g. spill contained with spill kit and materials disposed of correctly  A site worker can usually clean up  Small spill of oil or diesel fuel  A spill of less than 200 litres (or 1 drum) The incident occurred in a area low sensitivity e.g. industrial area, hard standing

Large number and different type of sensitive receptors affected

Small number and type of sensitive receptors affected

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The quantity of material released to environment was very large (even if not dangerous)

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3. Reporting Requirements

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(b) Minor Environmental Incidents – Report to the Engineer within one week of the incident and complete Report Form

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(c) Non-compliance with legislation, environmental permit or procedure - Report to the Engineer within one week of the incident and complete Report Form (d) Near Miss – Include detail in Monthly Environmental Report 4. Spill Contingency Plan (a) The main causes of contamination can occur through:  Spillage of hazardous material including fuel oils, waste materials or chemicals;  Spillage of wastewater sewage and other liquid effluents; and  Spillage of contaminated wash down water with oils, chemicals etc from vehicles, equipment and machinery. (b) Prior to commencing activities on site, the Contractor shall develop, implement and maintain a Spill Contingency Management Plan. The Plan should include but not be restricted to the mitigation measures below. Activity

Mitigation Measures

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Response

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The Contractor shall carry out regular inspections/ audits of hazardous materials usage, handling and storage areas and regular/thorough maintenance of vehicles and hydraulic systems and inspections of sanitary facilities and disposal. In the event of a spill, immediate action shall be taken to contain or clean up the spill using sand or a suitable absorbent material. All contractors handling hazardous materials will keep appropriate spill clean-up material adjacent to storage and maintenance areas. Minimise the amount of diesel, oil, paint, thinners and other chemicals stored on site that pose potential spillage environmental hazards and use materials that minimize environmental impact such as lead free paints, asbestos free materials etc. Storage areas will be located away from drains/trenches/wastewater collection devices in an impervious bund area (volume of the storage bund >110% of the largest storage tank contained within the bund). Collection systems will be provided/bunded if necessary under machinery or equipment that may leak hydrocarbons/hazardous substances. All spillages of hazardous materials shall be reported immediately in accordance with the requirements of the PMDS. The area shall be inspected by the Contractor’s Project Manager and the Engineer and this shall form part of the incident report. Contaminated soil, rags and other clean up material shall be kept in appropriate containers before being disposed of in accordance with DoE guidelines to an approved site. The Contractor shall be responsible for training all staff in the Procedures for handling spills and shall provide all staff with appropriate personal protective equipment. The Contractor shall provide all staff with appropriate personal protective equipment. Avoid impacting adjacent sites by ensuring all contractors activities, equipment and waste storage is confined to the allocated site boundary.

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5. Contamination Discovery

et it

o

(a) The contractor must report any suspected contamination discovery, even if the Contractor did not cause it, to the Engineer.

m

(b) During construction, indications of possible contamination include, but are not limited to, the following:  Barrels and containers;  Stained or discoloured earth in contrast with adjoining soil;  Industrial waste debris;  Non-earthy odours which emanate when the earth is disturbed;  Oily residue intermixed with earth;  Sheen on groundwater;  Underground storage tanks;  Fuel/diesel tanks; and  Proximity to petrol stations.

2.3.15.11

Completion and Site Clearance 1.

On completion of construction works the Contractor shall ensure that all waste and polluting material is removed from the site and is disposed of using appropriately authorized contractors and ensure that the site is restored in compliance with the terms of the contract. Following site clearance the Engineer will undertake a final inspection of the site. Any environmental issues identified during the final inspection will be raised with the contractor. Mitigation measures and timeframes for completion shall be agreed between the contractor and the Engineer in line with agreed procedures prior to final sign off.

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection 2.3.15.12 Glossary of Terms

2. 3.

4. 5. 6. 7.

12.

as

m

14.

et it

o

13.

se

11.

er

10.

ov

9.

qa

ta

rw .l. l

8.

Audit – regular check of an organisational or project’s compliance with procedures, standards, legislation or other stipulated requirements Auditor – person with the training competence to conduct an audit. Continual improvement – recurring process of enhancing the environmental management system (EMS) to achieve improvements in overall environmental performance consistent with the environmental policy. Corrective action – action taken to eliminate the cause of a detected nonconformity. Environment – surroundings in which the organisation operates including air, land, water, natural resources, flora, fauna, humans and the interrelation. Environmental aspect – element of the organisations (or project’s) activities or products that interact with the environment. Environmental impact – and change to the environment, whether adverse or beneficial resulting wholly or partly from the organisations environmental aspects. Environmental Management Plan (EMP) - The EMP is the lead environmental management document that defines the procedures for achieving the objectives set out in the Environmental Policy and the identified environmental performance targets for the project. An EMP can also provide the framework for which commitments made in an Environmental Impact Assessment report or the requirements of planning or other development conditions can be realised. A Construction Environmental Management Plan (CEMP) outlines a contractors approach to environmental management, with respect to project commitments, throughout the construction phase and with the primary aim of reducing any adverse impacts from construction on sensitive receivers. Environmental Policy and identified environmental performance targets for the project. Environmental Management System (EMS) – management system used to develop and implement an organisations environmental policy and manage its environmental aspects. Environmental objective – overall environmental goal, consistent with the environmental policy. Environmental performance – measurable results of an organisations management of its environmental aspects. Environment policy – overall intention and directions of an organisation or project, related to its environmental performance as formally expressed by top management. It provides a framework for action and for the setting of its environmental objectives and targets. Environmental target – a detailed performance requirement applicable to the organisation or parts thereof that arises from the environmental objectives and that needs to be set and met to meet those objectives. Glare – uncomfortable brightness of a light source viewed against a dark background. Interested party – person or group concerned with or affected by the environmental performance of the organisation. Internal audit – systematic, independent and documented process for obtaining audit evidence and evaluating it objectively to determine the extent to which the environmental management system audit criteria set by the organisation are fulfilled. MSDS – Material Safety Data Sheets: instructions for the safe use and potential hazards associated with particular products or materials. Light Trespass – the spilling of light beyond the boundary or the property of the area being lit. Nonconformity – non-fulfilment of a requirement. Preventative action – action to eliminate the course of a potential nonconformity. Prevention of pollution – use of processes, practices, techniques, materials, products, services or energy to avoid or control the creation, emission or discharge of any type of pollutant or waste, in order to reduce adverse environmental impacts.

.

1.

Page 24

15. 16. 17.

18. 19. 20. 21. 22.

23. Procedure – specified way to carry out an activity or process, procedures can be

documented or not.

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 25

2.3.15.13 Author SECTION

POSITION IN COMPANY

NAME

CONTACT DETAILS

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.

SHE Manager

2.3.15.14 Approvals POSITION IN COMPANY

SIGNATURE & DATE

qa

ta

NAME

SHEQ Director

m

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o

ov

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se

as

Approved by:

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 26

Responsibility Name of client Name of contractor Name of person who drafted the plan Notes, amendments Construction Project Location (address, postcode if appropriate)

.

Estimated project cost

rw .l. l

Notes, amendments Materials Resource Efficiency

ta

Describe here any methods adopted during the conception, design and specification phase to reduce the amount of waste arising. Resource saving (quantify if possible)

se

as

qa

Method

er

Waste Management

ov

Declaration

m

Signatures

et it

o

The client and COMPANY will take all reasonable steps to ensure that – a) all waste from the site is dealt with in appropriately. b) materials will be handled efficiently and waste managed appropriately.

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 27

STAGE 1 –Design/Tender/Planning Period Yes

No

N/A

Comment

Has the client and key suppliers been consulted in production of the SWMP Have alternative options been considered which produce less waste on site? Identify waste management areas on site plan - is there sufficient space for segregation of waste types (3 or more skips)?

rw .l. l

.

Is sufficient space allocated for material storage to avoid damages? Have you consulted Supply Chain to identify waste minimisation options?

qa

ta

Has a programme been produced for estimated waste costs for the Project for monitoring against during the works?

se

er

Has a careful evaluation of materials been made to avoid over-ordering?

as

Can unused materials be returned to Supplier or used on another job?

ov

Has full consideration been given to use of secondary or recycled materials?

et it

o

Is unwanted packaging to be returned to the Supplier after use?

m

Have materials been ordered to fit – e.g. plasterboard sized to avoid offcuts etc? Have opportunities for re-use of wastes on-site been considered? Have opportunities for re-use of wastes off-site been considered?

Action owner

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 28

STAGE 2 –Construction

m

et it

o

ov

er

N/A

Comment

rw .l. l ta qa as

se

Has responsibility for waste minimisation been identified? NB it is recommended to identify an individual to Champion and drive waste min onsite. Has use of Tool Box Talk been planned into the project programme. Are sufficient skips available for segregating wastes? Are all skips clearly labelled? Are you measuring your waste costs against the programmed budget from your Planner? Have any materials or products been identified by design, your supply chain or Project team, for re-use? Can you monitor any cost savings from any re-use of materials during the Project? Does your supply chain (waste removal) recycle waste from site, can they give monthly figures for materials, which have been recycled & landfilled? Can your supply chain offer a reduced rate for providing a segregated system? Can any materials be re-sued on other construction sites locally? Have you identified any best practice that we can learn from?

No

.

Yes

Action owner

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 29

SITE MANAGEMENT PLAN Waste type

Quantity (m3 or tonnes) Reuse onsite

Reuse offsite

Recycling on-site

Recycling off-site

Other form of recovery on-site

Other form of recovery off-site

Estimates

rw .l. l

.

Inert

qa

ta

Non Hazardous

se

as

Hazardous

ov

er

Total (m3 or tonnes) Actual

m

et it

o

Inert

Non Hazardous

Hazardous

Totals (m3 or tonnes) Difference between estimates and actual

Sent to landfill

Other disposal

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 30

SITE MANAGEMENT PLAN WASTE RECORDS Waste type

Identity of the person removing the waste

Site the waste is being taken to and whether licensed or exempt

Waste carrier and registration number*

Confirmation of delivery*

qa

ta

rw .l. l

.

Date removed

as

Post-Construction

se

[Within three months of the construction work being completed]

er

Confirmation

et it

o

ov

This plan has been monitored on a regular basis to ensure that work is progressing according to the plan and has been updated to record details of the actual waste management actions and waste transfers that have taken place. Signature

m

Issue Explanation of any deviation from the planned arrangements Waste forecasts – exceeded Waste forecasts – not met Cost savings achieved

Details

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QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 31

Complaints/Comments /Compliments

Name & Phone Number

Date Actioned

se

Name:

er

Number:

ov

Name:

Name:

m

et

Number:

ito

Number:

Name:

Action Taken

as

Date

qa

ta

COMPLAINTS/COMMENTS/COMPLIMENTS RECORD

Number: Name: Number: Name: Number:

THIS RECORD SHOULD BE KEPT CAREFULLY ON SITE AND MADE AVAILABLE TO THE CCS MONITOR FOR INSPECTION AS REQUESTED

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QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 32

Complaints/Comments /Compliments

as

Name:

se

Number:

er

Name:

ov

Number:

et

Number:

ito

Name:

Name:

qa

Name & Phone Number

m

Date

ta

COMPLAINTS/COMMENTS/COMPLIMENTS RECORD

Number: Name: Number: Name: Number: Name: Number: Name: Number:

Action Taken

Date Actioned

. rw .l. l

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

WATER DISCHARGE INSPECTION SHEET

qa

Comments and Remedial Action

et

ito

ov

er

se

as

Person Monitoring

m

Date

ta

Contract :

Page 33

pH Reading

Priority

1.1.1.1.1.1.1 High/Med/Low

Action By

Date Completed

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 34

DUTY OF CARE CONTROLLED WASTE TRANSFER NOTE SINGLE TRIP DESCRIPTION

A

MULTIPLE TRIP

1. Describe the waste being transferred: ……………………………………………………………………………………………………..…………………… (Description)…..……………………………………………………..………… 2. Has the waste been treated to reduce its hazard or volume? etc. 3. How is it contained? Loose

Sacks

Drums

Skip

E.g. minimised, segregated, sorted

Other Describe: ………………………………………..……….

4. Quantity (number of drums, skip weight etc.): ……………………………………...…………………………. 5. Season ticket YES NO HOLDER Transfer

1. Name and address of company and contract:

B

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.

…………………………………………………………………………………………………………..……………… ………………………………………………………………………………………………………………..………… 2. Current location of waste:

ta

………………………………………………………………………………………………………..…………………

qa

3. Which of the following are you?: (Tick one or more boxes)

Registered Waste Carrier* Licence No.: ……………………………….

Waste producer

*Licence and exemption details and copies of documentation must be obtained by HOLDER prior to transfer

collecting or

as

………………………………………………………………………………………………………………………..… 2. Which of the following are you?: (Tick one or more boxes)

ov

disposing

………………………………………………………………………………………………………………..…………

se

Person

1. Name and address of the company:

er

TRANSFER

D

ito

Registered waste carrier* No.: ………………...………………

*Licence and/or exemption details and copies of documents must be furnished to HOLDER prior to transfer 1. Transfer location address:

et

DISPOSAL

Holder of waste management licence* Licence No.: …………………

m

C

Producer of waste Waste disposal Authority Waste exporter

…………………………………………………………………………………………………………..……………… 2. Date of transfer: …………………………………………………………..……………………………………………………………… 3. Time(s) of transfer (for multiple consignments, give period for which note is valid): …………………………………………………………………………………………………………………..……… 4. Name and address of broker arranging the waste transfer (if applicable):

……………………………………………………………………………………………………………………..…… *Licence and/or exemption details and copies of documents must be furnished to HOLDER prior to transfer COMPLETION

E

Person collecting or disposing of waste (Part C or D):

Waste Holder (as in Part B):

Signed: Signed: Name: Name: Representing:

Representing: * For Hazardous Waste please use Hazardous Waste Consignment note. Speak to Environmental Adviser for guidance. Distribution: White copy – Workplace recipient Pink copy – Distribute as required Blue copy – Retain in book (file copy)

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 35

ENVIRONMENTAL VIBRATION RECORDING SHEET Contract:

Date:

Weather/Environmental Conditions:

Vibration Monitor used:

Serial/Certificate No: Calibration:

Comments on Building/Structure (if relevant)

Results Summary:

rw .l. l

Works/Operation:

ito

ov

er

se

as

qa

ta

Monitoring Location:

.

Monitor Mode:

m

et

Site Sketch:

Person Undertaking Monitoring : Date : Position :

Print-out attached? Comments/Recommendations:

Yes/No

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 36

COMMUNICATION RECORD Site Set-Up Pack

Revision No.:

Date:

Community Relations

Reference No.:

Page

rd

*Example investigation by Enforcing Authority, Workplace Inspector, solicitor etc.

Address:

Name:

Position:

rw .l. l

Date/Time:

.

Representative (Person making comment/complaint)

as

qa

ta

Detail Comment/Complaint

se

Comment/complaint received by:

ov

er

Date:

m

et

ito

Action Taken

Follow Up

Project Manager:

Date:

Party*

Page 37

et

ito

ov

er

se

as

qa

ta

rw .l. l

.

Section 11: Health and Safety Part 2.3.15: Environmental Protection

m

QCS 2014

. rw .l. l

Section 11: Health and Safety Part 2.3.15: Environmental Protection

qa

ENVIRONMENTAL NOISE SURVEY SUMMARY SHEET

Monitoring Location :

Weather/Environment :

as

Contract :

Page 38

ta

QCS 2014

er

Survey Location (Freefield/Façade) :

se

Date:

ov

Start Time :

ito

Finish Time :

Calibration Certificate no.:

Serial Number: Type 1 or 2: Time Response (Slow/Fast) :

Start :

YES/NO

L90 (dB)

LAeq (dB) (

Finish :

Results Sheet Attached: mins)

YES/NO

Comments/Events

SPL MAX

m

Activity/Operation

et

Location Map Attached:

Sound Level Meter:

(dB)

SURVEYOR Sign: SURVEYOR Print:

Date :

Distribution:………………………………………..

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Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 39

ta

QCS 2014

qa

ENVIRONMENTAL NOISE SURVEY SUMMARY SHEET

Monitoring Location :

Weather/Environment :

as

Contract :

Survey Location (Freefield/Façade) :

ov

er

Start Time :

se

Date:

Finish Time :

et

Calibration Certificate no.:

Serial Number: Type 1 or 2: Time Response (Slow/Fast) :

Start :

YES/NO

SURVEYOR Sign: SURVEYOR Print:

L90 (dB)

LAeq (dB) (

Finish :

Results Sheet Attached: mins)

m

Activity/Operation

ito

Location Map Attached:

Sound Level Meter:

YES/NO

Comments/Events

SPL MAX

(dB)

Date :

Distribution:………………………………………..

. rw .l. l

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

ta

Environmental Survey and Risk Assessment Form

qa

Surveyor(s) Methodology

Page 40

Survey Date

ov

er

se

as

1. Desk study: Review drawings, understand nature of project, the construction processes, their aspects and their potential effects. Note existing features, eg. current occupation, geography especially drainage, infrastructure and surrounding built environment. Check for existence of designated sites, heritage features, eg. ancient monuments. 2. Site visit: Identify potential receptors of environmental harm or damage and assess the significance of construction effects on them. Effects are significant if they have the potential to cause  particularly in regard to pollution of Controlled waters  harm or damage resulting in costs to remedy  complaint from any stakeholder including the general public

m

Desk Study Notes

et

ito

3. Assess the environmental risk rating. 4. Identify the measures required to minimise construction effects and where baseline and construction stage surveys should be carried out.

. rw .l. l

ta

P – Personnel engaged in construction processes 0 – Others on or off the site, e.g. other contractors, visitors, neighbours, passersby, road traffic E – Environmental receptors e.g. land, air, water, flora and fauna, geological and historical features

qa

Effects Risk

Page 41

F – Frequency C – Consequence R – Risk resulting from construction effects. NA = not Targets Effects

applicable Environmental Aspect of Construction Works

Yes No NA

ito

Nuisance – noise, vibration, visual, dust and odour

ov

Significant waste streams and potential for minimisation. Opportunities for greater sustainability

m

et

Existing and potential levels. Sensitive receptors. Potential sources, e.g. piling. Workplace issues. New earthworks, dirt roads, sewage provision, litter.

Water and Effluents Existing drainage and effects of construction. Site water disposal and pollution prevention. COSHH controls.

Materials and Fuels, Oils and COSHH Storage Significant planned materials with potential for pollution and/or substitution.

P O E Potential Effects

er

Waste

as

Potential Targets

Section 11: Health and Safety Part 2.3.15: Environmental Protection

se

QCS 2014

Mitigation / Control Measures /Consent requirements F

C R

Risk of Residual Effects

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QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

ta

Ecology, Archaeology & Built Environment

qa

Designated sites, existing flora and fauna, noxious weeds. Listed sites and structures, archaeology.

as

Plant & Equipment

se

Traffic movements, setting, site access, pedestrians, parking

Resources and Energy Use

Former land use, existing condition, site investigations.

ito

Community Relations, etc

ov

Contaminated Land

er

Scope for reductions and efficiencies

Training

m

et

Proximity to housing, schools, hospitals, parks, delicate installations etc. Site security, community involvement. Site specific training requirements likely

Other Aspects

Page 42

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QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Examples of Aspects v Effects Rating (R)

Page 43

ta

Risk Level 2-3 Varied wastes generated, both hazardous and non-hazardous.

0-1 Minimal quantities of waste likely to be generated.

Noise, Vibration, Visual, Dust and Odour

Noise: Higher than background levels expected but no receptors nearby. Vibration: Expected but at levels below that unacceptable to neighbours or sensitive structures. Visual: Site remote, well screened from site or in existing building or facility. Dust and Odour: No emissions expected and/or no receptors nearby. No change in existing water regime likely. No effluents arising.

Noise: High/disturbing levels, receptors in vicinity. Complaints may arise. Vibration: High day time levels of vibration, receptors nearby. Complaints may arise. Minor damage may occur. Visual: Site noticeable in landscape or setting, temporarily affecting amenity value. Dust and Odour: Minor emissions, receptors nearby.

Noise: High/disturbing levels, receptors in vicinity. Expect complaints especially at night. Vibration: High levels of vibration, receptors in vicinity. Expect complaints and/or damage especially at night. Visual: Site in area of high visual quality and affecting normal enjoyment for some time. Dust and Odour: High levels of emissions, receptors nearby. Expect complaints.

Water regime affected by works, discharge off site may require consent. Minor effluents arising from site compound.

Material inputs negligible, e.g. mainly site clearance, landscaping. Minimal volumes of fuels and COSHH materials stored. None in vicinity or no disturbance expected.

Considerable material inputs required, with some environmental impact in resource use. Some fuels and COSHH materials stored on site. Local designated area or minor disturbance likely to designated site or protected species.

Works in main river or disturbance of receptors likely, e.g. downstream fishery. Large site with significant effluent discharge. Large material inputs with corresponding impacts in resource use and/or transport. Large site with significant volumes of fuels and COSHH materials stored. Major disturbance expected to designated site or protected species.

No road works expected but access may cause some minor delays. No large plant

Road works will not close access. Local traffic may be delayed by site traffic. Some items of larger plant.

m

et

ito

ov

er

se

as

qa

Aspects Waste

Water and Effluents

Materials, Fuels, Oils and COSHH Storage Ecology, Archaeology & Built Environment Plant & Equipment

4-9 Significant wastes with large disposal costs, e.g. wastes from large asbestos strip.

Road works close access. Existing access unsuitable for site plant /vehicles. Considerable amount of larger plant, e.g. for major earthworks

. Few material and plant resources necessary and minor site establishment.

Contaminated Land

No contamination proven or is unlikely.

Community Relations, etc

No sensitive receptors nearby. No additional security required.

Some additional training required.

ov

er

se

as

Night time work, receptors in vicinity. Full time security required.

No services in vicinity needing consideration.

Day time works, receptors in vicinity. Normal out-of-hours security measures required. Some services present, requiring diversion/protection.

ito

Major construction site with large establishment for extended period

Contamination proven, potential pathways and receptors nearby. Spread of contamination likely.

et m

Some significant resource use and medium sized site establishment

Possibility of contamination exists, potential pathways and receptors nearby.

No training beyond normal site inductions.

Training

Page 44

qa

Resources and Energy Use

Other

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Section 11: Health and Safety Part 2.3.15: Environmental Protection

ta

QCS 2014

Important and valuable service assets affected by works requiring significant design/temp and diversion works. Extensive environmental training required.

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Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 45

ta

Risk resulting from construction effects = Consequence times Frequency

ov

er

se

as

qa

HAZARDOUS LEVEL ACTION No further preventative action. Consideration shall be given to more cost-effective solutions or Insignificant Impact improvements that impose no additional cost burden. Monitoring required ensuring that controls in place are properly maintained. Work shall not be started or continued until the Impact level has been reduced to an acceptable Impact level. While the control measures selected shall be cost-effective, legally there is an absolute Significant Impact duty to reduce the Impact, this means that if it is not possible to reduce the Impact even with unlimited resources, then the work shall not be started or shall remain prohibited.

et

Aspects Significance

m



SIGNIFICANT

ito

Do not starts work if The HAZARDOUS IMPACT IS?

Severity Likelihood Certain 5 Very Likely 4 Likely 3 Unlikely 2 Very Unlikely 1

Very High 10

High 8

Moderate 6

Low 4

Minor 2

None 1

50

40

30

20

10

5

40

32

24

16

8

4

30

24

18

12

6

3

20

16

12

8

4

2

10

8

6

4

2

1

Significant Impact

Insignificant Impact

QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 46

FRAMEWORK ENVIRONMENTAL PROTECTION LAW NO. 30 OF 2002 ENVIRONMENTAL PROTECTION LAW NO. 30 OF 2002 – INDEX REGISTER OF CONSENTS AND AUTHORISATIONS SITE WASTE MANAGEMENT PLANNING (WM)

4947

5048

NUISANCE – NOISE, VIBRATION, VISUAL, DUST & ODOUR (NU) WATER & EFFLUENTS (WAT)

5250 5351

ECOLOGY, ARCHAEOLOGY & BUILT ENVIRONMENT (ECO)

5552

rw .l. l

5653

RESOURCES & ENERGY USE (RES) 5754 5855

ta

CONTAMINATED LAND (CL)

.

MATERIAL AND FUELS, OILS and COSHH STORAGE (MFS) PLANT & EQUIPMENT (PLA)

5149

5956

qa

COMMUNITY RELATIONS, COMMUNICATION AND REPORTING (COM) Completed - No Further Action Required

as

Completed - But Ongoing Work Needed

se

Not Completed - Action Required

er

Not Applicable at Present

ov

Contract/Office: Initial Meeting Attendance:

et it

o

Date:

Revision:

m

Abbreviations:

The Environmental Protection Law No. 30 of 2002 shall be revised on a regular basis, and in line with the SHE Management Plan (e.g. every 3 months), to take into account changes in the job; the revision programme will be dictated by the SHE Management Plan.

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QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

qa

ACTIONS REQUIRED FOR COMPLIANCE

et

ito

ov

er

se

as

ISSUEING AUTHORITY Contact details

m

CONSENT TYPE / NUMBER

ta

REGISTER OF CONSENTS AND AUTHORISATIONS

GUIDANCE FOR COMPLIANCE

Page 47

ACTION OWNER

EVIDENCE REQUIRED / SHE FORMS

TARGET DATE

CLOSE DATE

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Section 11: Health and Safety Part 2.3.15: Environmental Protection

qa

ta

SITE WASTE MANAGEMENTPLANNING (WM)

Page 48

ACTION

MANDATORY

WM1

Waste Planning Identify and quantify waste streams likely throughout project including waste disposed of via subcontractors Complete Site Waste Management Plan for project

SHE-FRM-15-01 (Checklists) SHE-FRM-15-02 (Word)

MANDATORY

WM2

Trained competent Waste Coordinator for the project

Training Records

MANDATORY

WM3

Select and appoint waste management contractors ensuring ‘Duty of Care’ checks are carried out prior to disposal

Audit Records SWMP

MANDATORY

WM4

Waste Minimisation Carry out waste minimisation workshop.

Waste Minimisation

MANDATORY

WM5

GUIDANCE

ACTION OWNER

EVIDENCE REQUIRED / SHE FORMS

MANDATORY

m

et

ito

ov

er

se

as

REF

WM6

Waste Storage 

Assess requirement for Waste Management



Ensure waste can not leach or cause dust nuisance



Establish waste management compound/area to allow segregation where required. Provide clear signage



ALWAYS Keep hazardous waste separate to general waste



Ensure waste is segregated as per SWMP

Waste Disposal 

Ensure the appropriate waste transfers notes are completed.



Record waste movements off-site in SWMP

Environmental Advisors Records

Visual Inspection

Consignment Notes Waste Carriers Details

TARGET DATE

CLOSE DATE Frequency

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Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 49

ta

NUISANCE – NOISE, VIBRATION, VISUAL, DUST & ODOUR (NU) ACTION

WHERE REQUIRED

NU1

Conduct baseline environmental noise/vibration survey prior to works commencing, if noise/vibration identified as an issue at risk assessment stage

WHERE REQUIRED

NU2

Conduct ongoing environmental noise/vibration surveys during course of works as required.

WHERE REQUIRED

NU3

Establish traffic plan to minimise nuisance from deliveries & site traffic. Ensure safety of pedestrians. Provide adequate parking for site personnel & visitors and avoid parking nuisance to local community

Traffic Plan

WHERE REQUIRED

NU4

Locate site cabins to shield neighbours from site activities. Where possible locate generators / pumps away from site boundaries.

Visual Inspection Site set up plan

WHERE REQUIRED

NU5

Identify and implement procedures and methods to minimise noise/vibration nuisance and include in method statements (MSs). Adopt Best Practicable Means (BPM) in accordance with BS5228

WHERE REQUIRED

NU6

Communicate noise/vibration & other nuisance issues & control methods to staff, operatives & visitors

Training /induction records

WHERE REQUIRED

NU7

During periods of dry weather, use methods to damp down sites and access roads to inhibit dust generation (e.g. road sweepers)

Continual monitoring Site inspections

WHERE REQUIRED

NU8

Site Inspections

WHERE REQUIRED

NU9

Install wheel-washing facilities, fit dust covers to scaffolds and use other mitigation measures to reduce dust nuisance Assess lighting requirements and position to avoid glare and nuisance to neighbours

GUIDANCE

SHE-PRO-015

er

se

as

qa

REF

ACTION OWNER

EVIDENCE REQUIRED / SHE FORMS Survey / Monitoring Results SHE-FRM-15-07 SHE-FRM-15-11

m

et

ito

ov

Survey / Monitoring Results SHE-FRM-15-07 SHE-FRM-15-11

SHE-PRO-001 BS5228

SHE-FRM-1-03

Site inspections

TARGET DATE

CLOSE DATE

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QCS 2014

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WATER & EFFLUENTS(WAT) ACTION

MANDATORY

WAT1

Ensure Environmental Impact Assessments (EIAs) and method statements address issues associated with any consents within register, including pollution prevention measures

MANDATORY

WAT2

Monitor discharges

WHERE REQUIRED

WAT3

Identify areas of potential run-off and take appropriate protection measures (install French drains etc)

Design & Visual Inspection

WHERE REQUIRED

WAT4

Conduct dewatering / over pumping discharges to foul sewer in compliance with consent conditions

Operational records Site inspections

WHERE REQUIRED

WAT5

Design and construct settlement lagoons appropriately

Design documents Site inspection

WHERE REQUIRED

WAT6

Maintain and inspect settlement lagoons regularly to ensure effectiveness.

Operational records Site inspections

WHERE REQUIRED

WAT6

Provide wash out facility for concrete wagons with adequate pollution prevention measures in place. Record in MS.

SHE-FRM-1-03

WHERE REQUIRED

WAT7

Know site drainage systems, flow directions and outlets. Colour code drainage gullies to minimise risk of pollution. Blue for surface water drainage and red for foul drains.

Drawings Site inspections

WHERE REQUIRED

WAT8

Monitor and report water consumption for site activities and office space

Meter Readings

WHERE REQUIRED

WAT9

Set project specific targets for water resource use

Project specific Targets and Objectives in SHE

GUIDANCE

SHE-PRO-001

ACTION OWNER

EVIDENCE REQUIRED / SHE FORMS

TARGET DATE

CLOSE DATE

Ongoing

End of project

Ongoing

End of project

Ongoing

End of project

Ongoing

End of project

SHE-FRM-1-03

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REF

Monitoring Records

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Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 51 plan

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QCS 2014

ACTION

MFS1

Oils / Fuels and other liquid materials to be stored with secondary containment:

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 Either within a bund, on a catchment pallet or within a proprietary double-skinned tank  Bunds and trays to have no less than 110% of capacity of largest container and no less than 25% of total container volume when several stored  Do not allow rain water to escape from bunds and trays  All hoses, nozzles to be locked inside bund or double skinned tank when not in use  Check tanks, pipework, bunds and pollution prevention equipment regularly. Ensure no build-up of rainwater Locate oil /fuel storage areas away from surface waters and site drainage

GUIDANCE

ACTION OWNER

EVIDENCE REQUIRED / SHE FORMS

TARGET DATE

CLOSE DATE

Site inspections

Ongoing

End of project

Site inspection

Ongoing

End of project

SHE-FRM-1-01 SHE-FRM-1-03

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MANDATORY

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MATERIAL AND FUELS, OILS and COSHH STORAGE (MFS)

MANDATORY

MFS2

MANDATORY

MFS3

Locate oil /fuel storage areas on hard standing or on sacrificial layer of sand underlain with impermeable membrane

Site inspection

Ongoing

End of project

MANDATORY

MFS4

Locate appropriate spill response equipment close to storage facilities and operating plant. Check regularly and maintain

Site inspection

Ongoing

End of project

MANDATORY

MFS5

Establish site specific spill response plan and train staff in spill response

Plan & Training Records

WHERE REQUIRED

MFS6

Store and handle dusty materials (aggregates) in ways to minimise nuisance

Site inspection

Ongoing

End of project

MANDATORY

MFS7

Maintain high standard of site housekeeping. Store materials to avoid damage, wastage and potential pollution

Site inspection

Ongoing

End of project

. Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 52

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ECOLOGY, ARCHAEOLOGY & BUILT ENVIRONMENT (ECO)

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ACTION

Mandatory

ECO1

Undertake Ecological assessment of site to determine actions to improve ecology of project and any mitigation measures required

WHERE REQUIRED

ECO2

Ensure preventative / mitigation measures are detailed in RAs and MSs and are implemented

SHE-FRM-1-03

WHERE REQUIRED

ECO3

Avoid disturbing natural habitats (including trees/vegetation) whenever possible and especially during nesting seasons

SHE-FRM-1-03

WHERE REQUIRED

ECO4

Manage invasive plant species (Japanese Knotweed, Himalayan Balsam etc) appropriately, contacting Env. Advisor in first instance (Baseline Environmental Risk Assessment should identify these)

SHE-FRM-1-03

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GUIDANCE

ACTION OWNER

EVIDENCE REQUIRED / SHE FORMS

TARGET DATE

CLOSE DATE

Ongoing

End of project

Eco survey recommendations incorporated in to project Site inspections Site inspections Site inspections

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QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

MANDATORY

PLA1

WHERE REQUIRED

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ACTION

EVIDENCE REQUIRED SHE FORMS

TARGET DATE

CLOSE DATE

Ensure plant is adequately maintained, fit for purpose and in a safe condition

Supervisor Checklist Site inspections

Ongoing

End of project

PLA2

Where appropriate, establish dedicated plant storage area(s) away from surface waters and drains

Site inspections Site Layout plan

WHERE REQUIRED

PLA3

Where appropriate use drip trays under temporary static plant (pumps, generators etc.)

Site inspections

Ongoing

End of project

WHERE REQUIRED

PLA4

Where appropriate, specify and use plant with low emissions and particulate filters

Plant Records

WHERE REQUIRED

PLA5

Ensure all authorised plant. Conduct regular monitoring

Monitoring records

Ongoing

End of project

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PLANT & EQUIPMENT (PLA)

Page 53

GUIDANCE

ACTION OWNER

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Section 11: Health and Safety Part 2.3.15: Environmental Protection

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RESOURCES & ENERGY USE (RES) REF

ACTION

MANDATORY

RES1

Ensure no-cost energy efficiency practices are adopted on site (switching off lights and heaters, closing windows etc)

WHERE REQUIRED

RES2

ECO Cabin low cost energy efficiency measures adopted (i.e. motion sensors in toilets, timers on office equipment)

WHERE REQUIRED

RES3

Ensure plant / equipment is not left running unnecessarily

WHERE REQUIRED

RES4

Record energy consumption on site (mains and diesel plant)

MANDATORY

RES5

WHERE REQUIRED

RES6

Consider Environmental Impact and waste hierarchy of material specification.

Material specifications and supplier orders

MANDATORY

RES7

Ensure materials are stored to avoid damage, vandalism or theft

Site inspections Supervisor checklist

WHERE REQUIRED

RES8

Consider off-site manufacturing – can this be used to produce quality, safety and environmental improvements?

SHE-FRM-1-03

Procurement ECO Cabin Specification

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GUIDANCE

Page 54

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Ensure compliance with COMPANY Sustainable Timber Policy

ACTION OWNER

EVIDENCE REQUIRED / SHE FORMS

TARGET DATE

CLOSE DATE

Site inspections

Ongoing

End of project

Site inspections

Ongoing

End of project

Records of consumption (bills)

Ongoing

End of project

Ongoing

End of project

Ongoing

End of project

Site inspections

COMPANY Policy

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QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

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CONTAMINATED LAND (CL)

Page 55

ACTION

MANDATORY

CL1

Ensue Site Investigation includes risks to human health and the environment from contaminated land, water and ground gas

Completed SI Checklist New Form

WHERE REQUIRED

CL2

Formulate plans to deal with contaminated land

SHE-FRM-1-03

WHERE REQUIRED

CL3

Establish preventative measures to avoid pollution of water courses or ‘clean’ land.

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Where practicable conduct remedial treatment of contaminated soils in-situ or on-site. Regard off-site disposal as least preferred option

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WHERE REQUIRED

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REF

GUIDANCE

ACTION OWNER

EVIDENCE REQUIRED / SHE FORMS

SHE-FRM-1-01 SHE-FRM-1-03

Site inspections SHE-FRM-1-03

TARGET DATE

CLOSE DATE

Ongoing

End of project

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QCS 2014

Section 11: Health and Safety Part 2.3.15: Environmental Protection

Page 56

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COMMUNITY RELATIONS, COMMUNICATION AND REPORTING (COM) ACTION

MANDATORY

COM1

Forward any communication from Enforcing Authority.

MANDATORY

COM2

Provide details of surface water and foul drainage discharge consents and, if appropriate, permission to work in/adjacent to rivers to SHE Team for records

MANDATORY

COM3

Report significant spills of polluting materials (oil, chemicals) as RIDDOR procedure

WHERE REQUIRED

COM4

MANDATORY

COM5

Record all comments/compliments/complaints/external environmental enquires using a logbook or form, ensure complaints are investigated and closed out where appropriate

MANDATORY

COM6

MANDATORY

MANDATORY

GUIDANCE

TARGET DATE

CLOSE DATE

As occur

As occur

SHE-FRM-15-14 Complaints Log / RIDDOR Procedure SHE-FRM-8-02/02 SHE-FRM-8-01

Ongoing

End of project

Notify SHE Department if any invasive or protected flora / fauna are encountered. Stop work if archaeological remains found

E-mails to SHE Department

As occur

As occur

COM7

Record and Report delivery staff and delivery mileage in Site Register (starting point and destination)

Site Register / Staff Mileage claims

Ongoing

End of project

COM8

Disseminate best practice and learning points across the business via SHE Department

Case-Studies Produced

As occur

As occur

as

REF

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EVIDENCE REQUIRED / SHE FORMS Communication SHE-FRM-15-09 Database of consents

SHE-PRO-008

First Alert SHE-FRM-801 AIR SHE-FRM-8-2/02

Develop Community doc strategy

Newsletters / Minutes of meetings

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Establish community engagement strategy, e.g. advise of activities through newsletters, public meetings / open days

ACTION OWNER

QCS 2014

Section 11: Health and Safety Part 2.3.16: Learning Event Reporting

Page 1

2

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ..................................................... 1

2.3

SAFETY, HEALTH AND ENVIRONMENT PROCEDURES ............................. 1

2.3.16 LEARNING EVENT REPORTING ..................................................................... 1

Responsibilities ............................................................................................ 4 

2.3.16.2 

Definitions ..................................................................................................... 4 

2.3.16.3 

Actions required to implement this procedure.............................................. 5 

2.3.16.4 

Reference Documents.................................................................................. 5 

2.3.16.5 

Author ........................................................................................................... 6 

2.3.16.6 

Approvals...................................................................................................... 6 

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2.3.16.1 

QCS 2014

Section 11: Health and Safety Part 2.3.16: Learning Event Reporting

Page 2

PROCESS MAP Project/Site Manager

COMPANY Employees

Subcontractor Employees

SHE Team

Include information regarding the reporting of Learning in the Site I d ti 1.3, 3.2 Ensure Learning Event cards are available on site

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3.2

Ensure details are recorded

3.3

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For high potential events complete a First Alert form and distribute as appropriate

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*Complete the learning Event Form and identify the potential severity 3.3

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Where possible and safe to do so, take action to put right the unsafe situation/condition

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Where observed, record and report any Learning Event to the Line Manager/ Company Manager using the learning Event cards 3.2

.

3.1

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3.3

For high potential events complete a First Alert form and distribute as appropriate

Feedback details of outcome to the original person submitting the report

3.3

Review all Learning Event reports at the Project SHE meeting 3.3

*Or nominated person

Key

Activity Guidance

Circulate significant learning to all of Company to prevent reoccurrence in other areas

QCS 2014

Section 11: Health and Safety Part 2.3.16: Learning Event Reporting

Page 3

PURPOSE 1

To ensure that all learning events (near misses) are recorded and the lessons communicated. A learning event is an event or condition that occurs that has the potential of causing damage or injury to people, property or the environment (not to include actual accidents). SCOPE

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This procedure covers all COMPANY Projects and locations under the control of COMPANY. A COMPANY is defined as the organization with responsibility for management of safety at a construction site.

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QCS 2014

Section 11: Health and Safety Part 2.3.16: Learning Event Reporting

Page 4

2.3.16.1 Responsibilities SHE DIRECTOR 1

Authorises this procedure. CONTRACTS DIRECTOR/MANAGER

2

Provides support in the application of this procedure PROJECT/SITE/OFFICE MANAGER Ensures that any reporting and investigation of Learning Events is carried out in accordance with this procedure (and any associated client procedures).

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3

To actively report Learning Events to the appropriate person.

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4

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SHE MANAGER/ADVISER

Provides advice and support in the application of this procedure.

as

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EMPLOYEE / CONTRACTOR EMPLOYEE

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2.3.16.2 Definitions

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A learning event is an event or condition that occurs that has the potential of causing damage or injury to people, property or the environment (not to include actual accidents).

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LEARNING EVENT (NEAR MISS)

QCS 2014

Section 11: Health and Safety Part 2.3.16: Learning Event Reporting

Page 5

2.3.16.3 Actions required to implement this procedure LEARNING EVENT CARDS (HOTLINE) 1

Learning Event Cards and poster displaying the COMPANY hotline number will be made available onsite and will be included in the site induction. Consideration should be given to placing Learning Event returns boxes onsite. COMPLETING LEARNING CARDS All employees and contractors employees on site will be encouraged to report all learning events observed onsite, either verbally to the appropriate person or by completing a learning event card or through the COMPANY Hotline number ……………, which is displayed on posters around site. Where possible and safe to do so, take immediate action to rectify any unsafe situation or condition.

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REPORTING AND INVESTIGATION OF A LEARNING EVENT

Complete the Learning Event Form to assess potential outcome and severity, investigate immediate and root causes, consider lessons learned and take actions to prevent recurrence.

4

Inform the SHE Team of the event.

5

If potential severity has been identified on the learning event form as high or above the Project / Site Manager / SHE Adviser / Manager will complete First Alert report and circulate as appropriate.

6

The Project/Site Manager or nominated person should communicate the learning throughout the project and give feedback on the actions to the person who reported the learning event.

7

Ensure that Learning Events are reviewed on a regular basis at the appropriate project/site meetings.

8

Details of all learning events should be passed to the appropriate person for entering on to the COMPANY record system.

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2.3.16.4 Reference Documents FORMS 1

Learning Event (SHE-FRM-16-01)

2

Learning Event Card (SHE-FRM-16-02)

REFERENCE DOCUMENTS 3

Qatar Regulatory Document (Construction) RD1.6

QCS 2014

Section 11: Health and Safety Part 2.3.16: Learning Event Reporting

Page 6

2.3.16.5 Author SECTION

POSITION IN COMPANY

NAME

CONTACT DETAILS

SHE Manager

POSITION IN COMPANY

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SHEQ Director

SIGNATURE & DATE

ta

NAME

Approved by:

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2.3.16.6 Approvals

QCS 2014

Section 11: Health and Safety Part 2.3.16: Learning Event Reporting

Date

Page 7

Print name Contact No. Location On Site

Time Project Classification Health

Safety

COMPANY

Environment

COMPANY Sub-Contractor

Other Sub-Contractor

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Details of the Learning Event (include all relevant information) :

Potential Severity (please tick)

as

Potential Outcome (please tick) Personal Injury

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Property Damage

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Equipment Damage

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Environmental Issue

Slight Moderate First Alert to be issued if ‘High’ or above High Very High

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Other (please detail in comments box)

Negligible

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Lessons Learned (consider immediate and root causes) (please tick) Work environment Defective workplace

Design/layout

Housekeeping

Lack of room

Lighting

Noise/distraction

Weather

Access/egress

Management System of work

Supervision

Training

Communication

Management of change Plant/equipment Construction/design

Installation

QCS 2014

Section 11: Health and Safety Part 2.3.16: Learning Event Reporting

Page 8

Safety device

Operation/use

Mechanical Failure

Maintenance

Human Factors Failure to follow rules

Instructions misunderstood

Error of judgement

Lack of experience

Unsafe attitude

Undue haste

Horseplay

Lapse of concentration

Fatigue

Working without authorisation

Design

Wrong type used

Maintenance

Not provided/unavailable

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Not Used Other

Under investigation

qa

Third Party

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Other (please state)

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Responsible

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Actions Required

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FOLLOW UP

Signed:

Date:

Completed

QCS 2014

Section 11: Health and Safety Part 2.3.16: Learning Event Reporting

Page 9

LEARNING EVENT CARD Date:

Time:

Location on site:

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Brief details of observation:

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Action taken:

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Optional Information:

Reported by:

Company:

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 1

SAFETY AND ACCIDENT PREVENTION MANAGEMENT / ADMINISTRATION SYSTEM (SAMAS) ....................................................................................................................................

2.4

RISK ASSESSMENT GUIDES AND METHOD STATEMENT .................................................

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INTRODUCTION What is risk assessment? Legal requirements for risk assessment and written method of Work Risk assessment in practice Hazard and risk Risk assessment Process Identify the Hazards Work out who might be harmed and how evaluates the risks and decides on precautions Record your findings and implement them Review your risk assessment and update if necessary Suitable and sufficient risk assessment Recording the assessment Qualitative and quantitative risk assessments Qualitative assessments Quantitative assessments Consultation in development of risk assessment Young persons and children Language issues Safety Culture and other Behavioral Safety issues Other issues Health Surveillance Example of work activities requiring risk assessment Safe method of work (Method statement) Review of the method statement Communication of risk assessment and method statement Training programmes Appendix

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2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.6.1 2.4.6.2 2.4.6.3 2.4.6.4 2.4.6.5 2.4.7 2.4.8 2.4.8.1 2.4.8.2 2.4.8.3 2.4.9 2.4.10 2.4.11 2.4.12 2.4.13 2.4.14 2.4.15 2.4.16 2.4.17 2.4.18 2.4.19 2.4.20

.

2.

2 2 3 3 3 6 6 6 6 7 7 7 8 8 8 9 11 11 12 12 13 13 13 14 14 14 15 16

QCS 2014 2.4.1

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 2

INTRODUCTION Risk assessment is a fundamental principle in the management of health and safety. It is an important step in protecting workers and business, as well as complying with the law. It helps you focus on the risks that matter in or in connection to your work activity or construction work.

2

Section 1.1.7 of the Regulatory Document places legal duty on Contractors and the self-employed to assess the risks to the health and safety of their employees and others that arise out of or in connection with their work activities. They are also legal duty to develop written methods of work commonly referred to as method statement.

3

A risk assessment can be interpreted as a structured examination of a work activity so as to identify what could cause harm to people (employees or others) and how appropriate control measures can be put in place to eliminate or control risks.

4

For any risk assessment is to be effective, it is essential that the person who carries it out is familiar with all aspects of the task being assessed, specialist advice is sought where necessary and those to deliver the work activities are consulted in development of the risk assessment.

5

For any risk assessment to be effective, it is essential that the risks and controls are communicated to those affected.

6

The legal requirement on contractors to carry out risk assessments and written method of work support the requirements for a Contractor to provide for their employees A safe place of work

(b)

Safe access and egress to and from that place of work

(c)

Safe method of work

(d)

Safe plant and equipment

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(a)

Risk assessment and written method of work should identify the requirements for the contractor to provide for his employees information about how to undertake the work activity safety and without risk to their health

(b)

implementation of instructions for undertaking the work activity safety and without risk to their health

(c)

necessary training to employees so that they have the understanding and skills to undertake the work activity without risk to their health and safety

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(a)

(d) 2.4.2

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1

implementation of supervision of the work activity

What is risk assessment

1

A risk assessment is a careful examination of what, in your work, could cause harm to people, so that you can weigh up whether you have taken enough precautions or should do more to prevent harm. Workers and others have a right to be protected from harm caused by a failure to take reasonable control measures.

2

A risk assessment should usually involve identifying the hazards present in any working activity and identifying the associated risks, evaluating them, identifying those affected and putting in place suitable and sufficient mitigation. The exercise should take into account any existing precautions and their effectiveness.

3

Accidents and ill health can ruin lives and affect business too if output is lost, machinery is damaged, insurance costs increase or you have to go to court. Contractors are legally required to

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 3

assess the risks for or in connection to their work so that a plan to control the risks are put in place and implemented 2.4.3

Legal requirements for risk assessment and written method of work Section 1.1.7 of the Regulatory Document requires all contractors (employers and self-employed people) to assess the risks to workers and any others who may be affected by their work activity or construction work. The risk assessment will enable them to identify the measures they need to have in place and implement in order to comply with section 1.1.7.

2

There are requirements to undertake suitable and sufficient risk assessment, to record the assessment and to monitor & review its implementation. Development of risk assessment shall involve consultation with expert knowledge as required and it findings shall be communicated to those affected.

3

Any risk assessment shall give consideration to young persons and take into account risk barriers such as safety culture, behavioral safety and language issues as applicable to the place of work.

4

There are requirements for risk assessments to be supported by effective and written method statement identifying and implementation of training needs, instruction and supervision.

5

The contractor should work with other contractors, subcontractors to identify the hazards and assess the risks related to their work, including the risks they may create for others. Risk assessment in practice

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2.4.4

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1

The principle of risk assessment to eliminate and control risk to safety and health is not new. In fact, many Contractors will have been carrying out risk assessments to their day to day business as part of business planning and success. However section 1.1.7 imposes specific legal requirements on the Contractor to undertake risk assessment for health and safety.

2

If the task to be assessed is substantial, difficult or complex then, it will not be practical or effective to carry out a single risk assessment to cover the whole of the work. The job will need to be broken down into separate elements or work activities, each of which will have to be assessed separately.

3

Many Contractors, who have recognized potential problems in course of their business as they occur, will have taken the necessary action to avoid an incident (including near misses and accidents). Conducting risk assessment, proper recording and ongoing review of the risk assessments is an essential process in preventing incidents.

4

Factors that need to be considered during the risk assessment process is the complexity of the activity, the number of persons involved or affected, the plant or equipment being used, and the types and nature of the materials involved. The environment where the work will be carried out is also a factor which should be taken into account.

5

In many instances, straightforward measures can readily control risks, for example ensuring spillages are cleaned up promptly so people do not slip, or cupboard drawers are kept closed to ensure people do not trip. For most, that means simple, cheap and effective measures to ensure your most valuable asset – your workforce is protected.

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2.4.5

Hazard and risk

1

A hazard is something with the potential to cause harm and this can include articles, workplace, substances, plant or machines, tools, methods of work, the working environment and other aspects of work organization and includes the potential to harm/damage the environment and/or causing a statutory nuisance.

2

A risk is the likelihood of potential harm from that hazard being realized. The extent of the risk will depend on:

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 4

(a)

the likelihood of that harm occurring

(b)

the potential severity of that harm, i.e. of any resultant injury or adverse health effect; and

(c)

the population which might be affected by the hazard, i.e. the number of people who might be exposed

(d)

The frequency and time of exposure Risk = consequence x probability and is classed as either Acceptable or Unacceptable, depending on the results of the quantifying matrix

A risk is the chance, high or low, that somebody could be harmed by these and other hazards, together with an indication of how serious the harm could be. i.e. is the likelihood of potential harm from that hazard being realized. The extent of the risk will depend on: the likelihood of that harm occurring

(f)

the potential severity of that harm, i.e. of any resultant injury or adverse health effect; and

(g)

the population which might be affected by the hazard, i.e. the number of people who might be exposed

(h)

The frequency and time of exposure

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(e)

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Risk = consequence x probability and is classed as either Acceptable or Unacceptable, depending on the results of the quantifying matrix It is very important to distinguish between hazard and risk; the two terms are often confused.

5

Construction works are inherently hazardous and the risk associated with it will be reduced as controls are implemented. The level of risk remaining when controls have been adopted is known as the residual risk. There should only be high residual risk where there is poor health and safety management and inadequate control measures.

6

“‘Reasonably practicable’ is a narrower term than ‘physically possible’ … a computation must be made by the owner in which the quantum of risk is placed on one scale and the sacrifice involved in the measures necessary for averting the risk (whether in money, time or trouble) is placed in the other, and that, if it be shown that there is a gross disproportion between them – the risk being insignificant in relation to the sacrifice – the defendants discharge the onus on them.

7

Who is responsible for managing risk?

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All employers (and self-employed) are required to take reasonably practicable steps to assess the risk to both employees and others who could be affected by the undertakings of their business. Others who could be affected include: (a) Visitors to the workplace (b)

Consumers of products or services

(c)

Service providers working on the premises

(d)

Work colleagues and fellow persons working in the vicinity

(e)

Neighbours or residents in the surrounding area

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 5

Minor injury, damage or environment impact

Major injury, damage or environment impact

.

Fatality building loss, catastrophic environment impact

3

4

A

A

U

A

A

U

U

A

U

U

U

A

U

U

U

1

A small probability

2

A high probability

3

A

qa

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Almost no probability

4

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Almost Certain

ta

Risk Factor

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No injury, damage or environment impact

2

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Risk Assessment Methodology

Acceptable

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Risk Level

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Consequence X Probability = Risk

Acceptable

Unacceptable

Unacceptable 1–4

Action No further preventative action. Consideration shall be given to more cost-effective solutions or improvements that impose no Additional cost burden. Monitoring required to ensure that Controls in place are properly maintained. Work shall not be started or continued until the risk level has Been reduced to an acceptable risk level. While the control measures selected shall be cost-effective, legally there is an absolute duty to reduce the risk, this means that if it is not possible to reduce the risk even with unlimited resources, then the work shall not be started or shall remain prohibited.

4

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Page 6

Risk assessment Process A risk assessment is a five-stage process: (a)

Identification of all the hazards and associated risks

(b)

Work out who might be harmed and how

(c)

Evaluate the risks and decide on precautions

(d)

Record your findings and implement them

(e)

Review your assessment and update if necessary

2.4.6.1

Step 1: Identify the Hazards

Identification is simply working out how people could be harmed. Some techniques for risk identification are: brainstorming, refer to sources of information such as relevant legislation, code of practice and guidance, supplier manuals and manufacturers’ instructions, data sheets, safety alerts, lessons learnt, use information supplied by designers (pre-construction information), the residual risk supplied by designers, seeking advice from experts and competent sources and guidance from trade associations, etc.

2

Identification of hazards can also be undertaken by walking around the place of work and consult with employees or their representative about concerns in relation to the place or work or the work activity.

3

Checking the accident and ill-health records often helps to identify the less obvious hazards.

4

A valuable source for such information is obtainable from the UK governing body for Health and safety; known as the Health and Safety Executive (HSE). The HSE publishes practical guidance on where hazards occur and how to control them. Visit the HSE website (www.hse.gov.uk). 2.4.6.2

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Step 2: Work out who might be harmed and how

For each hazard you need to be clear about who might be harmed; it will help identify the best way of managing the risk. That doesn’t mean listing everyone by name, but rather identifying groups of people (e.g. ‘people working in the storeroom’ or ‘passers-by’). In each case, identify how they might be harmed, i.e. what type of injury or ill health might occur. For example, ‘shelf stackers may suffer back injury from repeated lifting of boxes’.

2

Remember that some workers have particular requirements, e.g. young persons or others with impaired mobility, expectant mothers etc.

3

Extra thought will be needed for some hazards to visitors, other contractors, members of the public etc if they could be hurt by your activities.

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2.4.6.3

Step 3 Evaluate the risks and decide on precautions

1

Having spotted the hazards, you then have to decide what to do about them. The law requires you to protect people from harm. You can work this out for yourself, but the easiest way is to compare what you are doing with good practice.

2

Think about what controls you have in place and how the work is organized. Then compare this with the good practice and see if there’s more you should be doing to bring yourself up to standard. In asking yourself this, consider: Can I get rid of the hazard altogether? If not, how can I control the risks so that harm is unlikely?

3

When controlling risks, apply these principles: try a less risky option (e.g. switch to using a less hazardous chemical); prevent access to the hazard (e.g. by guarding); organize work to reduce exposure to the hazard (e.g. put barriers between pedestrians and traffic); issue personal

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protective equipment (e.g. clothing, footwear, goggles etc); and provide welfare facilities (e.g. first aid and washing facilities for removal of contamination). 2.4.6.4

Step 4: Record your findings and implement them

1

Putting the results of your risk assessment into practice will make a difference when looking after people and your business. Writing down the results of your risk assessment, and sharing them with your staff, encourages you to do this. When writing down your results, keep it simple, for example ‘Tripping over rubbish: bins provided, staff instructed, weekly housekeeping checks’, or ‘Fume from welding: local exhaust ventilation used and regularly checked’.

2

You need to be able to show that: a proper check was made; you asked who might be affected; you dealt with all the significant hazards, taking into account the number of people who could be involved; the precautions are reasonable, and the remaining risk is low; and you involved your staff or their representatives in the process. 2.4.6.5

Step 5: Review your risk assessment and update if necessary

The risk assessment should be appropriate to the nature of the work and should identify the period of time for which it is likely to remain valid. This will enable the existing control measures to be reviewed and modified, and to put in place as necessary.

2

Construction sites do not stay the same. Thus hazards would be dynamic as the environment changes and works progresses and also with the bringing in of new equipment and substances etc. It makes sense, therefore, to review what you are doing on an ongoing basis. This means that any significant change to a place of work, process, or activity requires the risk assessment to be reevaluated or the introduction of any new process, activity or operation to be subject to a new risk assessment.

3

Look at your risk assessment again and the changes. Consult workers and lessons learnt from accidents or near misses.

4

Make sure your risk assessment stays up to date and set a review date proportionate to the complexity of the work activity or construction works. If there is any significant change to activities or a new sub/work package contractor starting work which could lead to new hazards then these shall be incorporated into the assessment. The need for review will depend upon the level of risk but in every case will be reviewed on sites at the same time as the Contract Management Plan or at permanent locations annually.

5

A risk assessment should always therefore be viewed as a ‘live’ document and must be reviewed following certain trigger events, or at least annually.

6

Risk Assessments should be reviewed when: (a)

2.4.7 1

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There has been an incident (accident or near miss)

(b)

Any significant change to processes, equipment or substances occurs

(c)

When there have been changes in the law

(d)

When enforcement action has taken place

(e)

When people identify an opportunity for improvement

Suitable and sufficient risk assessment An assessment required under The Management of Health and Safety at Work which: (a)

Correctly identifies a hazard

QCS 2014 (b)

Disregards negligible hazards and those associated with life in general

(c)

Determines the likelihood of injury, harm or loss 

Probability of exposure



Maximum probable loss



Number of persons at risk and/or the financial loss to the company

(d)

Identifies any specific legal duty or requirement relating to the hazard

(e)

Provides sufficient information to enable appropriate control measures to be taken

(f)

Enables control measures to be prioritized

Page 8

.

Suitable and sufficient risk assessment means the risk assessment should do the following: Should identify the risks arising from or in connection with work

(g)

The level of detail in a risk assessment should be proportionate to the level of risk the work activity entails

(h)

The level of risk arising from the work activity should determine the degree of sophistication of the risk assessment; for example risks which require specialist knowledge such as a particularly complex process or technique, or large and complex projects, hazardous sites will require the most developed and sophisticated risk assessments to address the level of risks.

(i)

Risk assessments must also consider all those who might be affected by the undertaking, whether they are workers or others such as members of the public.

(j)

Whenever specialist advisers are used, contractors shall ensure that the advisers have sufficient understanding of the particular work activity they are advising on, this will often require effective involvement of everyone concerned contractor, subcontractor, employees and specialist.

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Recording the assessment

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2.4.8

Risk assessment shall be recorded in writing. This means writing down the significant hazards identifying the associated risks coming, evaluate the risks by identifying those affected, the impacts and the controls put in place.

2.4.8.1

Qualitative and quantitative risk assessments

1

The risk of something going wrong is considered in terms of probability (likelihood) and the consequences (seriousness).

2.4.8.2

Qualitative assessments

1

The probability of a hazard actually causing harm or an accident is rated as being High, Medium or Low in accordance with the following:

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(a)

HIGH: it will happen regularly, or it could be a usual or a common occurrence

(b)

MEDIUM: it is less regular, but is still recognized as being likely to happen

(c)

LOW: it has not happened for a long time, is known to be infrequent and is not likely to happen

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The consequences of the event, should it happen, can then be categorised as follows: (a)

HIGH: the result could be a fatal accident or multiple injuries / major property damage / substantial pollution or environmental impact

(b)

MEDIUM: it would probably cause serious injuries, or persons would be off of work for over three days due to their injuries / substantial property damage / there may be some pollution

(c)

LOW: there would be minor injuries to persons or some slight damage to property

Probability and consequences can then be shown on a matrix as follows High Medium Low

Probability

Medium Consequences

High

Probability and consequences can then be assessed and the highest outcome of the two entered in the matrix as follows

Medium Low Low

High Medium Medium Medium Consequences

High High High High

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High Medium Low

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Low

A combined risk of HIGH should be totally unacceptable and the work should not be undertaken until the risk has been reduced MEDIUM: it would probably cause serious injuries, or persons would be off of work for over three days due to their injuries / substantial property damage / there may be some pollution.

(b)

When there is a combined risk of MEDIUM, action must be taken, and work stopped if necessary, to reduce the risk level.

(c)

If the combined risk is LOW, start the work as long as everything reasonably practicable has been done in order to reduce the risk, and that the assessment is reviewed at regular intervals

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Using this information, decisions can now be made on whether an activity is safe to continue, or whether control measures are necessary, either to completely change the way that the job is done or measures put in place so as to bring the risks down to an acceptable level. In the ideal situation, both probability and consequences should be LOW.

6

Probability and consequences can then be shown on a matrix as follows

2.4.8.3

Quantitative assessments

1

The principle is the same as for Qualitative assessments, but numerical scores rather than a grade are assigned to probability and consequences.

2

The probability or likelihood of the event is rated on a scale of 1 to 5 as follows: (a)

It is certain to happen.

(b)

It is very likely to happen, and would not be at all unusual

QCS 2014 (c)

Likely to happen, and would not be totally unexpected

(d)

Unlikely to happen, but not by any means impossible

(e)

Very unlikely to happen

Page 10

The consequences or the severity of the event, should it happen, are also then rated on a scale of 1 to 5 as follows: (a)

No injury. It would be a 'near miss'. Minor property damage.

(b)

Minor injury. Less than three days' work time lost. Property damage more than just minor likely to happen, and would not be totally unexpected.

(c)

Reportable injury to the HSE with over three days’ time lost, but not a major injury. Substantial property damage or something causing environmental damage.

(d)

Major injury, long term absence. Major damage, serious environmental impact.

(e)

Fatal accident or multiple major injuries. Public or others could be involved as well.

(f)

A matrix can then be constructed using these numbers, as follows

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Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

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All possible resulting numbers are calculated by multiplying all the probability figures by all the consequence figures. These are included in the matrix, as shown below. This means that once a risk assessment has been made on a particular activity, and the probability factor is multiplied by the consequence factor, the number produced indicates where the assessment places the risk associated with the activity on the matrix

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3 4 Consequences

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5 4 3 2 1

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Probability

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5 4 3 2 1 1

10 8 6 4 2 2

15 12 9 6 3 3 Consequences

20 16 12 8 4 4

25 20 15 10 5 5

Clearly, the higher the resulting number, the less acceptable the level of risk. The matrix shows where actions need to be taken to reduce either the probability or the consequences in order to reduce the risks to an acceptable level

Probability

5 4 3 2 1

5 4 3 2 1 1

10 8 6 4 2 2

15 12 9 6 3 3

20 16 12 8 4 4

25 20 15 10 5 5

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Consequences

Contractors themselves can use these numbers to set in-house criteria, if desired, along the following lines, and as indicated by the shaded areas in the above matrix: (a)

Risks with a rating above 16 are totally unacceptable and the work will not be undertaken until the risk has been reduced.

(b)

Where the risk rating is between 10 and 15, immediate action must be taken, including a stoppage of work if necessary, to reduce the risk level.

(c)

If the rating is between 5 and 9, the risk is acceptable provided that everything reasonably practicable has been done to reduce the risk.

(d)

With a rating of 4 or less then the risk is acceptable, provided that the assessment is reviewed at regular intervals and further reduced if possible.

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Note: - It is stressed that it is for individual companies or managers to decide where the boundaries between what is and what is not acceptable lie, and the numerical score at which certain actions should be taken

Consultation in development of risk assessment

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If either the qualitative or quantitative methods are used in conjunction with a simple form, then the Contractors will have a straightforward basic risk assessment procedure

Consulting employees or their representatives about matters to do with their health and safety and in developing risk assessment is a requirement under section 1.1.7 of the Regulatory document and is a good management practice as well.

2

Any risk assessment shall involve effective consultation with the workforce who will undertake the job.

3

Thus contractors need to involve employees concern or their representative in developing risk assessment.

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2.4.10 Young persons and children Contractors are required to specifically assess and review the risks to the health and safety of children and young person’s due to their lack of maturity, lack of experience and lack of knowledge of potential risks.

2

There is a requirement that young people should not carry out certain types of work, except in circumstances involving training and supervision where the young person is no longer a child.

3

A 'child' is anyone under the minimum school leaving age and a 'young person' is anyone over the minimum school leaving age but less than 18 years of age.

4

A young person under 16 years of age cannot be employed at all in a Qatar workplace; this is stated in Labor Law 14, Article 86.

5

Before a young person is employed, the Contractors must ensure that any risk assessments pertaining to the job take account of the following factors in relation to the young person:

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(a)

their inexperience

(b)

their immaturity and lack of awareness of risks

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

(c)

the tools and equipment that they may have to use as part of their training

(d)

the layout of the workplace and the environment in which they may have to work.

(e)

any hazardous substances with which they may come into contact

(f)

exposure to physical, chemical or biological hazards

(g)

the organization of work processes and activities

(h)

the extent of health and safety training that is to be provided

Page 12

Careful consideration must be given to the way in which information is conveyed to young person’s to ensure that it is fully and readily understood.

6

Where children are employed either for work experience or work in offices then the Contractors must, before commencing the employment of the child, provide that child's parents or guardians with details of any risk assessment which has been carried out. This information must contain details of any risk and a description of any preventative or protective measures, whether the risk arises from the Contractors own activity or the activities of others at the workplace.

7

Contractors are further required to consider the special nature of young person’s due to their lack of experience, knowledge of risks and the fact that they are not fully mature. To that end, young people must not be employed in any work.

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with which they cannot physically or psychologically cope

(b)

that exposes them to a range of hazardous substances, including any carcinogen, toxic substance or radiation

(c)

where they might not recognize the risk of accidents due to their inexperience or lack of training

(d)

where their health would be at risk from excessive cold, heat, noise or vibration

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The prohibition above does not apply when a young person is undergoing recognized training, or being properly supervised by a competent person, or when any risks identified in a risk assessment have been reduced to the lowest level that is reasonably practicable.

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2.4.11 Language issues

Site workers who have a poor or no understanding of either written or spoken Arabic must be taken into account when compiling risk assessments. Effective communication is an essential element of controlling risk; how such communication can be established must be a priority issue where there is the potential for language difficulties on site.

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2.4.12 Safety Culture and other Behavioral Safety issues 1

Site workers coming from abroad have different backgrounds and different perception of risks and safety culture. The contractor needs to consider this as an important factor in developing the risk assessment and implementing it.

2

The contractor must be proactive in monitoring behavioral safety issues and address them as part of the risk assessment.

3

The contractor must implement a positive health and safety culture which means the avoidance, prevention and reduction of risks at work must be accepted as part of the organization’s approach and attitude to all its activities. It should be recognized at all levels of the organization, from junior to senior management.

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2.4.13 Other issues 1

While it is a legal obligation for contractors to regularly review risks at the place of work, some other issues to consider would be persons with impaired mobility and new and or expectant mothers. The assessment will help to decide additional action that needs to be taken in such scenarios.

2

Any such risks identified must be included and managed as part of the general workplace risk assessment.

3

The contractor must implement a positive health and safety culture which means the avoidance, prevention and reduction of risks at work must be accepted as part of the organization’s approach and attitude to all its activities. It should be recognized at all levels of the organization, from junior to senior management. 2.4.14 Health Surveillance The contractor is required have in place health surveillance programmes where the findings of a risk assessment identify health risks to employees that can be eliminated or reduced by applying health surveillance techniques.

2

Health surveillance should be introduced where the risk assessment indicates that:

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there is an identifiable disease or adverse health condition related to the work concerned

(b)

there are valid detection techniques

(c)

there is a reasonable likelihood that the disease or condition may occur under the particular conditions of work

(d)

health surveillance has the potential to increase the protection of the health of the employees concerned.

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The contractor must implement a positive health and safety culture which means the avoidance, prevention and reduction of risks at work must be accepted as part of the organization’s approach and attitude to all its activities. It should be recognized at all levels of the organization, from junior to senior management.

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2.4.15 Example of work activities requiring risk assessment Example of work activity that need to be risk assessed are: (a)

the use of hazardous substances

(b)

noise in the place of work

(c)

manual handling activities

(d)

the presence of asbestos

(e)

work at height

(f)

Work with vibrating tools and equipment

See appendix A for more examples of work activities and guidance for undertaking risk assessment.

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2.4.16 Safe Method of Work (Method Statement) A written method of work is commonly referred to as a method statement which is developed for construction activities including temporary works. The method statement describes the logical sequence of how a work activity is to be carried out safely and without risk to health. It should identify the risks and the controls to be put in place, responsibilities like induction supervision training and other elements needed to complete the work e.g. man power, plant, equipment etc.

2

It is good practice at planning stage of construction to identify a list of work activity which will need development of method statement. This is sometimes referred to a schedule of method statement which gets updated in the construction phase of the project as and when required, according to the project complexity and the level of risks it entails.

3

The Contractor shall submit a Method Statement Schedule to the Engineer for approval no later than thirty (30) days from the start of the Contract. The Method Statement Schedule shall define all Method Statements to be prepared for the Works forming part of the Contract and the target dates for their submission to the Engineer for approval.

4

The Contractor shall submit Method Statement for his work activities to the Engineer for approval thirty (30) days prior to the commencement of the work activity covered by a Method Statement.

5

The method statement should be developed prior to undertake any such work activity identified as mentioned above and should be unique to each work activity means No work covered by a Method Statement shall begin until it has been approved by the Engineer.

6

The risk assessment will provide support to the development of the method statement.

7

Any development of method statement shall involve consultation with the workforce and shall identify the requirements for:

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information about how to undertake the work safety and without risk to health

(b)

implementation of instructions for undertaking the work safety and without risk to health

(c)

identify and conduct necessary training to employees before execution of the activity; so that they have the understanding and skills to undertake the work activity without risk to their health and safety

(d)

implementation of supervision of the work activity

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The method statement should be briefed and acknowledged by the supervisor and the worker respectively before undertaking of the work activity.

9

An example template for method statement is at appendix B.

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2.4.17 Review of the method statement 1

Any method statement needs to be reviewed after any incident in undertaking or related to the works, so that additional necessary mitigation can be embedded into the work procedure. 2.4.18 Communication of risk assessment and method statement

1

Any risk assessment and safe working method will be as good as the way they are communicated to those affected.

2

The contractor should make sure they are communicated to employees and their representatives so that they are aware of the health and safety risks for a work activity and the preventive and protective measures in place. Thus establishing effective means of communication should be devised by the contractor.

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Effective communication will ensure that employees are provided with sufficient information and they understand the risks and control measures can be implemented effectively.

The method statement should be developed prior to undertake any such work activity identified as mentioned above and should be unique to each work activity 2.4.19 Training programmes The contractor needs to have in place and implement necessary training to employees so that they have the understanding and skills to undertake the work activity without risk to their health and safety.

2

Risk assessment should identify opportunities for training of workers and ensure they are competent for the work activity.

3

Contractor should maintain training records.

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2.4.20 Appendix 2.4.20.1 Appendix A: Example of work activities requiring risk assessment

NUMBERED ASSESSMENTS Associated with this project (Tick boxes)



SITE ESTABLISHMENT

REF NO. 2



HOARDING/FENCING (TEMPORARY)

REF NO. 3



DEMOLITION GENERAL

REF NO. 4



DEMOLITION (ASBESTOS REMOVAL)

REF NO. 5



BUILDINGS ADJACENT TO WORKS

REF NO. 6



OVERHEAD SERVICES/OBSTRUCTIONS

REF NO. 7



UNDERGROUND SERVICES

REF NO. 8



PILING (DRIVEN/BORED/BENTONITE)

REF NO. 9



EXCAVATIONS (SHALLOW/DEEP/CONTAMINATED)

REF NO. 10



HAUL ROAD CROSSINGS ON CONSTRUCTION SITES

REF NO. 11



BULK EARTHWORKS

REF NO. 12



REDUCED LEVEL DIG AND IMPORTED FILL

REF NO. 13



CONTAMINATED GROUND (WORKING WITH)

REF NO 13B



POTENTIALLY CONTAMINATED GROUND/BUILDING FABRIC (ANTHRAX)

REF NO. 14



REF NO. 15



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REF NO. 1

ENVIRONMENTAL ISSUES WORKING ON PUBLIC ROADS



WORKING OVER OR ADJACENT TO WATER

REF NO. 17



WORKING OVER OR ADJACENT TO RAILWAYS

REF NO. 18



CONCRETE WORKS AND REINFORCEMENT

REF NO. 19



CONCRETING, CONCRETE REPAIR, CONCRETE FINISHING

REF NO. 20



PRE CAST CONCRETE STAIRS, WALLS AND FLOORS

REF NO. 21



SCAFFOLD (ALL TYPES)

REF NO. 22



STRUCTURES (WORKING AT HEIGHTS)

REF NO. 23



STEEL ERECTION (GENERAL)

REF NO. 16

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Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement



WELDING, BURNING, STEELWORK

REF NO. 25



ROOFWORK/WORK NEAR FLOOR ETC OPENINGS

REF NO. 26



INFILLING OF FLOOR OPENING(S)

REF NO. 27



ROOFWORK (FLAT)

REF NO. 28



ROOF STRUCTURE (PLATES/TRUSSES/TIMBER)

REF NO. 29



ROOF COVERINGS (FELT/BATTEN/TILE)

REF NO. 30



EXTERNAL CLADDING (INC GLAZING)

REF NO. 31



WATER STORAGE DEVICES

REF NO. 32



LIFTING OPERATIONS

REF NO. 33



MANUAL HANDLING

REF NO. 34



SITE PLANT MOVEMENT/CARE

REF NO. 35



TOOLS (ELECTRIC/PNEUMATIC/CARTRIDGE)

REF NO. 36



CONFINED SPACES

REF NO. 37



NIGHT WORK

REF NO. 38



REF NO. 39



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STORAGE OF HIGHLY FLAMMABLE MATERIALS (COVERS SOME USAGE REQUIREMENTS)



REF NO. 42



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REF NO. 41

INSTALLATION OF FIRE PROTECTION COATINGS (BOARD)

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REF NO. 40

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INSTALLATION OF FIRE PROTECTION COATINGS (SPRAY) LIFT INSTALLATION

REF NO. 43



ELECTRICAL/MECHANICAL SERVICES

REF NO. 44



PLUMBING WORKS

REF NO. 45



CARPENTRY/JOINERY

REF NO. 46



PLASTERING AND EXTERNAL RENDERING

REF NO. 47



CEILING FIXING

REF NO. 48



FLOOR AND WALL TILING

REF NO. 49



PAINTING AND PAPERING

QCS 2014 REF NO. 50

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement



USE OF SPECIALIST EQUIPMENT (e.g. NUCLEAR DENSOMETERS, THERMIC WELDERS AND LANCES, LASERS H.P. WATER JETTING

REF NO. 51

Page 18



USE OF CLASS 3B LASERS (PREDOMINANTLY IN CONFINED OR



ARC WELDING

REF NO. 53



RADIOGRAPHY

REF NO. 54



COMMISSIONING PLANT

REF NO. 55



BLOCK PAVING, FLAGGING KERBS AND EDGINGS

REF NO. 56



ROAD/PATH SURFACING

REF NO. 57



FENCING (PERMANENT)

REF NO. 58



LANDSCAPING

REF NO. 59



TREE SURGERY/CHAINSAW WORK

REF NO. 60



FIRE PREVENTION IN WORK AREAS

REF NO. 61



FIRE IN OFFICES

REF NO. 62



OFFICE ENVIRONMENT (PERMANENT/TEMPORARY)

REF NO. 63



YOUNG PERSON IN CLERICAL POSITION (SITE)

REF NO. 64



CABLE PULLING OPERATIONS

REF NO. 65



WORKING IN CHEMICAL/RADIOACTIVE DRAINS

REF NO. 66



BRICK/BLOCKWORK OPERATIONS

REF NO. 67



REF NO. 68



REF NO. 69



LEAD BURNING/PLUMBING WORK

REF NO. 70



MOBILE ELEVATED WORKING PLATFORMS (MEWP's)

REF NO. 71



UNLOADING OF VEHICLES

REF NO. 72



USE OF STEP LADDERS

REF NO. 73



TRAFFIC MANAGEMENT

REF NO. 74



BLANK GENERIC ASSESSMENT FORM

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REF NO. 52

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RESTRICTED AREAS)

CLEANING/BUILDER'S CLEAN LADDERS

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RISK ASSESSMENT GUIDE Assessment for: Significant risks:

Page 19

REF NO. 1

SITE ESTABLISHMENT Falls of persons, falling objects, Moving plant/equipment, Trapping of personnel/limbs, Overhead obstruction. DETAILS OF CONTROL MEASURES Layout drawings prior to delivery of cabins. Location of services (gas, water, electric, sewer and telephone).

Instruction

General safety instruction before activity commences e.g. Toolbox talks on general risks etc.

Training

General health and safety. Certificated crane/HIAB operator. Banks man training where appropriate.

Supervision

Competent person familiar with activity. Check no power lines/overhead services in vicinity of lift.

Access

Safe access for vehicles – suitable base. Safe access/egress to roof of temporary accommodation to fix or unfix lifting slings. Proper access to cabin doorways to be provided. Secure doors at first/second floor levels not provided with staircases.

Environment

Establish ground loading and set up before delivery. Check location of necessary services.

Equipment

Crane/HIAB and lifting slings – check Safe Working Load (SWL) and radii. Check statutory documents before lift. Adequate ladder for access to roof level.

Emergencies

Standard COMPANY procedures to be in place ie. Mobile/phones/radios, first aid etc.

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CONTROL ITEM Information

PPE

Other

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COSHH

Activity to be under the control of one competent person familiar with task/activity/types of hazards.

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Communications

Check that ground is not highly contaminated. If so conduct COSHH assessment. Hard hats, safety footwear, gloves and outdoor clothing. Harness at roof level if appropriate. Keep third parties/general public well away from lifting operation area. Obtain certificate for electrical integrity for inclusion in COMPANY register. Fire precautions.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 20

REF NO. 2 RISK ASSESSMENT GUIDE Assessment for: SITE FENCING/HOARDING Significant risks:

Manual handling, striking underground services, crushing/trapping by plant & equipment

CONTROL ITEM Information

Instruction/Training

DETAILS OF CONTROL MEASURES Emergency telephone numbers. Permits to dig contact all service companies and private service owners for service plans and tracings. Site boundary lines structuring and height of fence/hoarding details. Operatives to work to Safety method statements. Operatives to sign Safety method statements. Operatives to be advised on hitting buried services. Do Not assume depth. Use of detection equipment. Operatives to temporarily fence when working adjacent to public. To be fully conversant with services in work area. Must be qualified to working in public highways/footpaths. If using crane/HIAB banks man to be present.

Access

Traffic management for works in public highways/footpaths. Compliance with relevant guidance when working adjacent to overhead lines. Ground conditions. Exclusion zone prior to concrete curing.

Environment

Working adjacent to buildings. Overhead services. Traffic. Consider effects of tree/shrub removal. Consider washing out facilities for concrete delivery vehicles. Consider emergency action plan when near water courses.

Equipment

As applicable. Detection equipment. Temporary support for fence posts/gates/hoardings as applicable whilst concrete cures.

Emergencies

Liaise with emergency services and service providers. First aid kit, fire protection, evacuation, accident reporting and investigation. Major incident response plan. Emergency procedure to be detailed in contract safety plan. Ensure openings/gates in hoardings/fencing are suitable for emergency services.

Communications

PPE

Other

Warning signs. Hazard tape. Phone/radio. As applicable for products used. Possible ground contamination.

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Supervision

High visibility clothing, hardhats, protective footwear, ear protection, gloves, goggles. Detailed review of service drawings. Consider colour scheme for hoardings. Viewing panels for security in hoardings.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 21

REF NO. 3 RISK ASSESSMENT GUIDE Assessment for: Significant risks:

DEMOLITION GENERAL Falls from height, entrapment, health hazards. Injury from falling/flying objects to operatives and general public, sudden collapse of buildings/structures, fragile roofs, fires, flooding, explosion, electrocution, contamination. Inadequate access/egress.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Surveys, Safety Method Statements, structural assessments, scoping exercise for hazards, equipment’s and structures etc. Previous drawings and plans. Site history, past use, desk top study. Consultation at all levels. Description of work to be carried out and methods to be used i.e. piecemeal or controlled collapse. Specific responsibilities for plant and tools to be used. Restrict others from area. Operatives to sign Safety Method Statement. Induction: Lifting and manual handling; hazardous materials and hazardous areas; oxygen and fuel cutting equipment; abrasive wheels; confined spaces when applicable.

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Training

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Other

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COSHH PPE

Work to be placed under competent person qualified and experienced in demolition operations of work. Monitor certification of drivers. Monitor works. Essential to restrict access of personnel at place of work being carried out. Effect on adjacent areas. Prohibition of unauthorised persons. Traffic marking of danger zones. State of existing property. Adequate welfare facilities. Overhead and general services. Security of site during operations. General public, traffic, contaminated material, dust, noise etc. No rubbish burning. Effect on residents, monitoring requirements. Provision of all relevant certification. Type to be approved as suitable to carry out operations. Warning notices. Monitoring equipment. Consider transport safety. Use of harnesses and equipment checks. Standard first aid, fire protection, evacuations, accident and investigation reporting. Emergency procedures to be detailed in the contract safety plan. Other workers in the vicinity should be made aware of restricted access. Use of lookouts, warning signs, letter drops to public, advice to other sub-contractors. Handling of explosives, adhesives used for temporary support fixings, dust, biological hazards and various chemical hazards must be identified and actioned. Hard hats, boots, protective clothing, goggles, ear protection, face masks, harnesses. Discuss storage/operations/use of explosives with Qatar Police as appropriate. Carry out administration and monitoring on daily basis. Structural assessments must be carried out by a suitably competent person. Disposal of smoke sensor heads must be in accordance with manufacturer’s recommendations due to heads containing radioactive isotopes. Because hot/cold water systems may be contaminated, i.e. legionella, personnel involved in the dismantling/demolition of such systems should wear suitable respiratory protective equipment. Contact/discuss with your Safety SHE Dept prior to commencing work.

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Supervision

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

Page 22

REF NO. 4

Assessment for: Significant risks:

DEMOLITION (ASBESTOS REMOVAL) Asbestosis lung disease, mesothelioma, respiratory infections to operatives and public. Increased risk for smokers. Dust inhalation, ingestion and absorption. Contaminated clothing.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Analysis of type of asbestos and evaluate the required measures. Safety Method Statements. Provide specification for work. Survey the area.

Instruction

Consult the Safety and Environmental Department, strict control of personnel to trained persons. Medical surveillance. Operatives to sign Safety Method Statement. Normally a specialist operation. Personnel to be fully trained in the handling and removal of asbestos. Check all details.

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Training

Specialist training is required for all persons supervising the plant, equipment and labour associated with asbestos.

Access

Clean, tidy. Consider airlocks into work area decontamination unit. Designated and controlled access are to be used. Exclusion zones.

Environment

Zoning of areas to be established provision of ventilation etc. Consider sealed working area to control dust, damping down and effects of weather, i.e. wind and rain. Monitor atmosphere against the allowed levels of exposure. Clearance tests if applicable. Disposal as special waste.

Equipment

Consider suitable decontamination plant and materials to seal area, and dispose of asbestos. Good separate welfare facilities. Air monitoring equipment.

Emergencies

Clearance tests, first aid (seek medical advice). Fire protection, evacuation, accident reporting and investigation. Major incident response plan. Emergency procedures to be detailed in the contract safety plan.

Communications

Standard warning signs and labelling of material for disposal. Advise all persons who may be affected by work. Warning systems in event of emergencies.

Other

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Supervision

Suitable respirators, disposable overalls, gloves, goggles, masks. This is a highly specialised activity; seek advice from Safety and Environmental Department.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: BUILDINGS ADJACENT TO WORKS Significant risks:

Page 23

REF NO. 5

Collapse/settlement. Associated services. Effect upon occupiers from vibration and general inconvenience etc. Undermining

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Details of existing construction and condition of the adjacent structure should be used to produce a method statement. A detailed sequence, after consultation with a qualified engineer, should be arrived at where applicable. Design checks on excavations. Consider dewatering risks. Site induction, briefing in position of existing services, methods to be employed and special measures to limit noise, dust etc. Operatives to sign Safety Method Statement. Ensure all plant and equipment operators are certificated.

Instruction

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Training

Supervisors to mark all services and monitor building, and wherever possible verify details of foundations etc. Permits to dig to be issued and possible additional supervision of operations.

Access

Safe access and egress to be provided for operators and occupiers. Consideration to be given to restricted access zone.

Environment

Noise, dust and vibration to be kept to a level that does not interfere with client installation or operations and monitored if applicable.

Equipment

As required by specific operation, possible monitoring equipment required for noise, dust, movement and vibration.

Emergencies

Standard site first aid, reporting procedures. Emergency procedures for occupiers to be considered. Major incident response plan.

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Supervision

Communications

Warning signs and hazard markers.

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Other

Standard for activities being undertaken.

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PPE

Depends on exact activity undertaken.

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COSHH

Agreed dilapidation survey of structure prior to work commencing (if possible). Temporary works coordinator involvement.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: OVERHEAD SERVICE/OBSTRUCTIONS Significant risks:

Page 24

REF NO. 6

Electrocution, structural damage to services, injury from structural collapse or plant capsize. Disruption to client/public services. Explosion DETAILS OF CONTROL MEASURES Contact service provider and clients for plans, details and exclusion zones. Seek possibility of isolation of overhead electrics.

Instruction

All employees advised of location of all overhead services (with sketches and clearances) and nature of services (electricity, gas, steam, air etc.). Working Safety Method Statements are to consider installation dangers. Operatives to sign Safety Method Statements.

Training

All personnel in the work area are to be inducted and given Safety Awareness Talks on handling long object and plant movements in vicinity of overhead services.

Supervision

Regular inspection of barriers and notices. To be fully conversant with services in the work area.

Access

Consider exclusion zones, designated accesses and ground conditions.

Environment

Consider the effects of weather and ground conditions. In particular wind and rain e.g. heightened risks of arcing.

Equipment

Provide crash deck where possible. Barriers to be of suitable construction and design. Warning signs, hazard tapes and markers. Use of nonconductive material. Height restrictions in plant.

Emergencies

Liaise with Civil Defence (Fire Department) Standard site first aid, fire protection, evacuation, accident reporting and investigation. Emergency procedures to be detailed in contract safety plan.

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CONTROL ITEM Information

PPE Other

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COSHH

Emergency contacts to be posted as applicable. Warning signs and hazard markers.

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Communications

As appropriate to the operations. Hard hats and as appropriate to operations. Note that the highest risks often exist at the time of erection and removal of barriers and height restrictions.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: UNDERGROUND SERVICES Significant risks:

Page 25

REF NO. 7

Electrocution, explosion, asphyxiation, serious injuries, working in vicinity of underground services with mechanical equipment, disruption to public/client services.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Emergency telephone numbers. Permits to work. Contact service provider and private service owners for service plans, tracings, as available. Marking and hand excavation as appropriate. Working to Safety Method Statements. Operatives to sign Safety Method Statements. Operators to be advised on hitting buried services, (tracing services). Do not assume depth. Use of detection equipment, confined spaces.

Instruction

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Training

To be fully conversant with services in the work area. Consider exclusion zones. Review on hourly/daily basis to suit service in work area.

Environment

Working adjacent to buildings. Overhead services. Traffic. Consider the effects of water/flooding/weather on services and possible emissions/discharges from services.

Equipment

As applicable. Detection equipment. Possible shoring, Protection and Support systems.

Emergencies

Liaise with Civil Defence (Fire Department). Standard site first aid, fire protection, evacuation, accident reporting and investigation. Major Incident Response Plan. Emergency procedure to be detailed in contract safety plan.

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Supervision Access

Communications

Warning signs, hazard tape and markers.

Other

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High visibility clothing, hard hats, protective footwear, ear muffs, goggles, gloves etc.

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PPE

As applicable for possible emissions/discharges, ground contamination.

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COSHH

Detailed review of available plans for identification of buried services. Note also the following that may be in the area, Cable television, hydraulic, process fluids, pneumatics, Railway signalling, petroleum fuel oils, private communications, civil aviation, military authorities, also gas transmission pipe lines (refer to owners requirements). Plastic pipes – not detectable.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: PILING (DRIVEN/BORED/BENTONITE) Significant risks:

Page 26

REF NO. 8

Crushing/laceration and entrapment injuries, drowning, damage to plant and structures, plant and equipment instability, reversing and slewing machinery, noise and dust. Lifting reinforcing cages, piling gates, top men. Contact with contaminated ground.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Obtaining information relating to services, ground conditions, adjacent structures/foundations. Produce Safety Method Statement. Employees are to be briefed on the Safety Method Statement and correct use of equipment. Operatives to sign Safety Method Statement. Visitors are to be escorted. Personnel are to receive Safety Awareness Talks as appropriate. Operators, banks men and piling hands are to be suitably trained and certificated where appropriate.

Instruction

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Training

Supervisors to ensure that plant and equipment is operated and banked ONLY by persons who have been trained, certificated and authorised to do so. Ensure that weekly registers and maintenance requirements are performed.

Access

Keep work area clear and tidy. Consider exclusion zones. Stabilise or harden and maintain the piling mat/work area as appropriate for the work proposed.

Environment

Consider weather, adequate lighting, ground conditions, ground water, nearness of buildings, traffic, noise, fumes, dust and vibration. Consider disposal of arisings – in particular those contaminated.

Equipment

To be suitable for operations being carried out and test certificated (including sub- contractor’s). Regular inspection, maintenance, cleaning and reporting on condition. Check condition of plant and equipment upon arrival on site. Weighted or anchored covers to Bentonite filled holes and bored holes. Standard site first aid, fire protection, evacuation, accident reporting and investigation. Major incident response plan.

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Supervision

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Emergencies

Warning signs, hazard lights and markers, audible warning units. Consider the use of radio/transmitters.

COSHH

As applicable to materials used.

PPE

As appropriate together with high visibility clothing, ear defenders and head protection, boots in particular for driven piling.

Other

Refer to generic risk assessment lifting equipment and contaminated land. Avoid inhalation of Bentonite powder. Seek specialist advice as necessary.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: EXCAVATIONS

Page 27

REF NO. 9

(SHALLOW/DEEP/CONTAMINATED/BORROW PITS) Significant risks:

Water ingress/flooding. Collapse of adjacent structures. Injury from falling equipment and materials. Entrapment, Contact with overhead/underground service, personal injury to oneself or others. Failure to check and ensure safe use of equipment. Overturning of vehicles/plant etc. Collapse of excavation sides. DETAILS OF CONTROL MEASURES Check for services in area , evaluate ground conditions and investigate possible flooding. Obtain adequate propping material before commencement. Major excavations must be the subject of design check. Check for buildings, scaffolds and other operations around trench. Operatives to enter and leave excavation by safe access only. Monitor for possible gas. Prevent access to public (remember blind persons require firm barriers). Adequate lighting and signs. Check for contaminated ground. Prevent unauthorised access to excavation. Method statement for installation and removal of support system, also services support systems. Operatives to sign Safety Method Statement. Permit to dig system to be adopted in identified areas of service location i.e. urban areas, factory premises etc. Operatives to be trained in the use of support systems and gas monitors. Machine drivers to be conversant with support systems, also banks man and possible confined space training. Advice on any identified risk and control measures.

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CONTROL ITEM Information

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Instruction

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Training

Competent person must be in attendance at all times. Daily/shift checks on trench/support system. Weekly inspection and register kept up to date. Watch for deterioration of ground in wet conditions. Materials and plant not stored too close to edges of excavations. Edge protection.

Access

Safe access and egress in and around excavation to be provided. Use ladders, ramps, cut in steps. Well lit at night. Handrails to top of batters. Stop blocks for vehicles. Excavations area to be kept clear of unnecessary material or plant. Keep any water levels to acceptable levels (ensure adequate sumps). Rain could affect ground conditions. Monitor for gases and contaminated ground. Consider disposal of pumped water. Plant and equipment to be suitable for operation especially support system. Adequate supply of support materials. Pumping equipment to be available if water present. Standard first aiders. Rescue procedure in place. Possible major incident response plan to be put in action. Emergency procedures to be established in contract safety plan. Surrounding area for excavation to be adequately signed. Quick safe warning system considered. Monitor for gas, contaminated ground and general assessments of all materials to be used. Identify any control methods such as the provision of mechanical ventilation. Hard hats, suitable footwear, possible disposable overalls, gloves and high visibility vests. Machine operatives to have good vision of work in progress if possible. Cross reference to confined space generic risk assessment for further information.

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Emergencies

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Communications COSHH

PPE Other

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: HAUL ROAD CROSSINGS ON CONSTRUCTION SITES Significant risks:

Page 28

REF NO. 10

Impact injury due to collision of plant and machinery with private vehicles or pedestrians.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Temporary Traffic Orders for speed restriction on approach to crossing points. Method statements for installation of such schemes will also be required on major schemes, to include all identified requirements of a safe system of work.

Instruction

Appropriate experienced personnel only to be used for actual installation/removal of traffic management works. Specific training for all drivers using crossing points and those who will operate the crossing. An experienced member of staff to be nominated as the Traffic Safety Manager with special responsibility for plant crossings.

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Training

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Crossing to be kept clean and free of debris. Lights and warning signs on both haul road and main road to be cleaned regularly.

Environment

Consideration must be given to poor visibility during adverse weather conditions. Lights and signs soon become observed by dirt. Similarly during extremely dry weather dust will be a problem.

Equipment

All traffic management equipment to conform confirm to current standards and to be regularly maintained/washed.

Emergencies

Emergency call out/liaison list to be established. Standard site first aid, fire protection, evacuation, accident reporting and investigation. Emergency procedures to be detailed in contract safety plan.

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Access

Radios for traffic management team. Mobile phone/radios for traffic safety coordinator. Information signs. Close liaison with police.

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Communications

Other

High visibility clothing, hard hats etc.

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PPE

If using portable generators, noise and handling of fuel.

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COSHH

Provision of shelter and adequate welfare facilities especially for plant crossing operatives well away from temporary offices.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: EARTHWORKS Significant risks:

Page 29

REF NO. 11

Injuries from plant movements, unstable excavations/embankments, tipping vehicles, overhead/underground services, contaminated ground, dust.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Safety Method Statements. Detailed review of available plans for identification of buried services. Detailed review of ground conditions/boreholes before commencement. Desk study, advice from Engineering Department. Operatives to be instructed on safe system of work appropriate to the type of operation. Operatives to sign safety method statements. Induction and Safety Awareness Talks to include the care to be taken on earthworks operations. Supervisors responsible for daily/weekly inspections are to be suitably trained. Operators to be suitably trained and certified for the equipment used and Banks man duties as required. Work is to be controlled by an appropriately competent experienced earthworks supervisor. Inspections before work shift commences. Site register to be completed weekly. Temporary Works coordinator to be appointed.

Instruction

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Training

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Supervision

Designated routes, access points and exclusion zones. Consideration is to be given to separation from, and control of, public and non-earthworks traffic within the working area. Safe haul route.

Environment

Evaluate ground conditions to establish nature, groundwater, nearness of buildings or traffic. Weather and flooding should be considered when planning operations. Consider the stability of stockpiles and batters; and the control of noise, dust and fume. Consider any details of contamination.

Equipment

Plant inspection and periodic testing, buried service detectors, guard rails, barriers, warning signs, adequate lighting. Air monitoring equipment where appropriate. Wheel wash facilities. Reversing alarms.

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Access

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Major incident response plan.

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Communications

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Emergencies

Warning signs, hazard tape, markers, hazards lights and audible warning units. Consider use of radio/transmitters. Use traffic signs.

COSHH

Not applicable, except on contaminated ground where a COSHH evaluation of ground contaminants will be required to determine protection required.

PPE

Hard hats, protective footwear, protective clothing in adverse weather conditions, high visibility clothing etc.

Other

Consider use of speed limits and mobile welfare facilities.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: REDUCED LEVEL DIG AND IMPORTED FILL Significant risks:

Page 30

REF NO. 12

Contact with plant, reversing vehicles, overhead and underground services, dust, noise, contaminated land. DETAILS OF CONTROL MEASURES Equipment to be certificated, inspected and records kept. Underground services drawings. Safety signs, warning notices.

Instruction Training

Competent, certificated and authorised plant operators. Banks men required for reversing vehicles/plant movement. All operatives to sign method statement as understood.

Supervision

Supervisors to ensure plant and equipment only operated by certificated, authorised persons.

Access

Segregate plant from pedestrians.

Environment

Dust suppression methods. Ground conditions. Daily log of dust emissions. Protection of features/foundations/safe batters/support/proper compaction. Good working order, regularly maintained. Overhead power lines to be suitably protected by high/low level barriers. Segregate from pedestrians.

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CONTROL ITEM Information

All plant to be fitted with fire extinguishers.

Communications

Warning signs, barriers and audible warning units.

COSHH

Dependent upon soil analysis/as applicable during breakdown/regular maintenance to plant and equipment.

PPE

Banks men to wear high visibility clothing, safety footwear/safety helmets to be worn at all times. Hearing protection to be worn as applicable.

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Emergencies

Stop blocks required for reversing plant where applicable. Ref contaminated land risk assessment No 9 if appropriate.

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Other

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The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: CONTAMINATED GROUND Significant risks:

Page 31

REF NO. 13

Contact with toxic, irritant corrosive harmful and radioactive materials. Injury through skin absorption, skin puncture, ingestion, inhalation or radiation. Toxic/explosive fumes or materials.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Seek all information available and where this is inadequate obtain the appropriate chemical analysis before commencement/recommencement of the work. Produce detailed hazard risk assessments and Safety Method Statements. Operatives to sign Safety Method Statement. Personnel are to be made aware of the type of contamination and possible dangers. Operatives are to be given safety awareness talks. Operatives to be made aware of procedure if coming into contact with unexpected material/smells. Demonstrations and briefings are to be given to personnel on the method of handling contaminated material, the effects and remedies, the correct use of protective clothing and personal hygiene. This should be updated as necessary.

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Training

A competent person is to obtain the appropriate information on the contaminated material and ensure that operatives are given and adhere to the training information above. Designate a waste controller as appropriate. Regularly monitor the material exposed and ensure adequate testing.

Access

Exclusion zones and designated safe access as necessary related to the type and level of contaminant exposed.

Environment

Evaluate the effects of weather, heat, dust, vibration, corrosion, polluted atmosphere/water, ground conditions (stability).

Equipment

To be individually assessed to suit the operation. Consider gas monitors, breathing apparatus, chemical indicator tubes, wheel washers, decontamination units.

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Supervision

Together with standard procedure for first aid, fire protection, evacuation and reporting; specific procedures are to be considered to suit the operation and contaminants present. Procedures for environmental emergencies i.e. spill, groundwater contamination etc.

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Emergencies

Communications

Warning signs, hazard markings and exclusion zones as appropriate.

COSHH

As appropriate. Specialist advice to be sought where necessary.

PPE

Consider suitable, masks, goggles, gloves, boots, barrier creams, and suits etc. Also consider whether these should be disposable/regularly renewed.

Other

Good welfare, washing and hosing down facilities. Seek advice from Safety & Environmental Department where necessary.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: POTENTIALLY CONTAMINATED GROUND/BUILDING FABRIC Significant risks:

Page 32

REF NO. 13 B

Infection through skin absorption, skin puncture, ingestion or inhalation

CONTROL ITEM Information

Instruction

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Training

DETAILS OF CONTROL MEASURES Seek all information available about the site including site investigation reports, trial pit records, maps and plans. Produce Safety Method Statements. Operatives to sign Safety Method Statements. Personnel are to be made aware of the type of contamination and possible dangers. Operatives are to be given safety awareness talk. Operatives to be made aware of procedure if coming into contact with unexpected material. Demonstrations and briefings are to be given to personnel on the method of handling contaminated material, the effects and remedies, the correct use of protective clothing and personal hygiene. This should be updated as necessary. Give operatives information on the level of residual risk. A designated, competent person is to obtain the appropriate information on the potentially contaminated material and ensure that operatives are given and adhere to the training information above. Designate a waste controller as appropriate. Regularly monitor the material exposed and ensure adequate identification/testing. Effective procedures for health surveillance to enable early diagnosis of infection. Exclusion zones and designated safe access as necessary related to the type and level of contaminant exposed. Evaluate the effect of weather, wind strength and direction, heat, dust, polluted water. Measures to prevent exposure of the general public to wind borne contamination. To be individually assessed to suit the operation. Consider breathing apparatus, wheel washers, and decontamination units. Together with standard procedure for first aid, fire protection, evacuation and reporting, specific procedures are to be considered to suit the operation and contaminants present. Procedures for environmental emergencies, ie spills, groundwater contamination, etc. Prior contact shall be established with a local general practitioner. Warning signs, hazard markings and exclusion zones as appropriate. As appropriate. Specialist advice to be sought where necessary. Check for and protect skin cuts or scratches before using PPE. Consider suitable masks, goggles, gloves, boots, barrier creams and suits, etc. Also consider whether these should be disposable/regularly renewed Facilities for decontamination or disposal of clothing. Adopt procedures for decontamination by heat treatment or chemical disinfecting of any animal remains encountered during the work. Consider immunisation Good welfare, washing and hosing down facilities. Seek advice from Safety & Environmental Department where necessary.

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Other

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Communications COSHH PPE

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

REF NO. 14

Assessment for: Significant risks:

Page 33

ENVIRONMENTAL ISSUES Demonstrations/sabotage, pollution, damage/destruction of flora, fauna, ancient monuments or protected areas etc.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Obtain details of all information and restrictions relevant to the operational area from the Enforcing Authority, the client/employer.

Instruction

Induct personnel appropriately in relation to the information obtained above and any effects on methods of working. Safety awareness talks “environmental awareness” are to be given where applicable. Consideration should be given as to whether further specialist training is necessary for certain operations or localities

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Training

The site manager where appropriate will make personnel aware of information/restrictions and institute suitable controls.

Access

Consideration to be given to restricted zones, security measures and damage caused by equipment/plant movements.

Environment

Consideration to be given to the effects of weather, noise, dust contamination and construction methods upon the local environment/population/watercourses.

Equipment

Fencing, covers, bunds (soil), noise and atmosphere monitors and security equipment as applicable.

Emergencies

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Establish environmental emergency response if applicable.

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Supervision

Warning signs, contact Health and Safety Department, emergency telephone list.

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Communications

Other

As appropriate.

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PPE

As appropriate.

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COSHH

Record photographs, incident/insurance reports. Diesel/oil/flocculants/silt laden water are potentially major environmental problems. Please refer to Safety Department for further guidance.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: Significant risks:

Page 34

REF NO. 15

WORKING ON PUBLIC QATAR ROADS Injury from passing/reversing vehicles, debris, services, Subsidence. Dangers to public from construction operations.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Safety Method Statements Permits to work on highways. Notify and liaise with the appropriate authorities. Traffic management assessment, requirements for emergency routes for vehicle access i.e. ambulance, Civil Defence (Fire Department), Police etc. Wearing of high visibility clothing. Form of traffic control. Access and egress routes. Crossing points, pedestrian routes, specific risks involved requirements of speed limits. Inductions on traffic management and working on public highways.

Instruction Training

To be suitably qualified. Monitor work to Safety Method Statements. Action any non-conformities.

Access

Maintain public and property access where possible or make alternative arrangements. Establish suitably signed works access. Adequate signing of access and egress points.

Environment

Evaluate: noise, dust, fumes, identification of sensitive locations such as schools, hospitals, surgeries, shops, public services when planning works. Consider the hazards to blind persons.

Equipment

Plant/equipment flashing lights (if appropriate).

Emergencies

Standard first aid, fire protection, evacuation, accident reporting and investigation. Liaise with all emergency services, and highways departments – dates, times’ etc., work being carried out. Major incident response plan. Emergency procedures to be detailed in contract safety plan.

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Supervision

Warning and information signs. Hazard markers. Traffic control requirements. Liaise with local residents.

PPE

Other

As required – may include use of various materials such as black top or assessment for dust and fumes generated by traffic.

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Communications

High visibility clothing. Hard hats, protective footwear, ear muffs, goggles, gloves, wet weather clothing. Monitor approved Traffic Diversions Plans on a regular basis and review if needed.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration Qatar Work Zone Traffic Management Guide, all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: WORKING OVER OR ADJACENT TO WATER SOURCES Significant risks:

Page 35

REF NO. 16

Drowning. Shock. (Fatigue with clothing on in water). Possible Weils disease.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Operatives advised on risk of falling/slipping into water while working in and around docks, swimming pools, tanks and water retaining structures/pits. Operatives advised of risk of falling/slipping into water. Safety Awareness Talks. Safe methods of working. Access and egress routes. Rescue procedures. Tide tables, weather.

Instruction

Inductions, Safety Awareness Talks, use of life jacket, harness, lifebuoys, throwing lines, warning systems. Communications. Rescue procedures. First aiders. Rescue boats. Hygiene – Weils disease.

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Training

Competent supervisor to monitor and check safety and rescue equipment and working method.

Access

Scaffold if possible over water. Handrails beside water, or fencing. Safe access and egress route to and from work areas.

Environment

Good lighting. Weather, tides and ground conditions.

Equipment

Safety boat. Life jackets, lifebuoys, safety nets, throw lines, radios, harnesses, scaffolds, pontoons, rescue lines, audible alarms etc.

Emergencies

Trained first aiders. Rescue procedures in place. Audible alarms. Standard site first aid/reporting procedures.

Communications

Good communications, i.e. radios, telephones or hand signals. Post list of emergency contact numbers. Warning signs.

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Other

Life jackets, safety harnesses. Loose, warm, high visibility clothing. Suitable warm footwear. Hard hats, etc.

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PPE

Considerations to be given if water is contaminated - weils disease.

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COSHH

Good welfare facilities. Adjacent water traffic movement to be considered.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 36

RISK ASSESSMENT GUIDE Assessment for: WORKING OVER OR ADJACENT TO RAILWAYS

REF NO. 17 RISK CATEGORY

Significant risks:

BEFORE CONTROLS

Electrocution/Collision of plant and operatives with trains. Possible collapse or subsidence of railway equipment. Derailment.

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Tick as appropriate CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Obtain from the relevant railway authority all information relative to the operation, such as “structural gauge” and fencing. All safety method statements to be agreed with railway before commencement of work. Possessions, if required, to be agreed with railway authority.

Instruction

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Training

Ensure all rail procedures and Safety Method Statements are adhered to.

Access

Use only identified walking routes and work areas as agreed in Safety Method Statements. Possessions to be agreed with railways. Establish exclusion zones as necessary.

Environment

Consider the effect of dust, weather and construction operations upon the railway. Good lighting required.

Equipment

Check requirement for structural barriers. Consider the limitation of construction plant adjacent to railway operations. Comply with railway authority requirements for non-conductive equipment such as wheelbarrows, ladders, approved CAT scanner, etc.

Emergencies

Standard site first aid (with particular reference to electric shock), fire protection, evacuation, accident reporting and investigation. Major incident response plan.

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Supervision

Site wardens and lookouts to be used as required. Warning signs and hazard markers as required by railway authority. Consider use of approved radio/transmitters. Rail emergency telephone number to be prominently posted. As applicable to the operations.

PPE Other

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Communications

Approved high visibility vests. Hard hats (white), suitable footwear (No Rigger Boots) Harnesses if working at height. Only personnel with good hearing and eyesight are to work on or adjacent to railways

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: REINFORCEMENT Significant risks:

Page 37

REF NO. 18

Collapse of reinforcement. Poor housekeeping, falls when accessing structures. Access across reinforcement DETAILS OF CONTROL MEASURES Relevant drawings and reinforcement/structural engineers recommendations N.B. temporary requirements relating to stability especially in wind.

Instruction/Training

Ensure all personnel are subject of induction and are briefed in method statement/risk assessment content.

Supervision

Competent supervision to be in attendance for duration of operation. Ensure method statement content is applied at workface.

Access

Ensure board walkways 600mm wide are provided across slab reinforcing. Ensure guarded and boarded platforms are provided for fixing reinforcement at height: prohibit the use of ladders. Provide scaffold stair towers. Prohibit the climbing of reinforcement. Expedite the installation of permanent staircases. Provide protection to exposed starter bars.

Environment

Caution required on damp plywood decks or following application of release agents. Limit and control mechanical and manual handling of shutters in high wind.

Equipment

Cut off wheel operations to be certificated.

Emergencies

See site general emergency procedure.

Communications

Works to be closely coordinated with erection of false work and form work. Formal paperwork system to be applied for control of loading and striking formwork.

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CONTROL ITEM Information

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PPE

Low risk for handling steel, tying wire and spacers. Assessment as appropriate for any other substances.

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COSHH

Other

Safety helmet, boots, eye protection and rigger gloves. Full body harness only when attachment location identified and agreed in method statement. Eye protection recommended when using tying wire. Agree methods of attachment of slings when mechanically lifting fabricated cages. See Risk Assessment No19 for concrete works.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 38

RISK ASSESSMENT GUIDE REF NO. 19 Assessment for: CONCRETING, CONCRETE REPAIR, CONCRETE FINISHING. Significant risks: Plant and equipment, noise/vibration, concrete burns, dermatitis, working at heights, protruding reinforcement, manual handling, failure of materials/equipment. CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Method statements. Safety signs. Warning notices.

Instruction/Training

Operatives to sign method statements. Operator certificated and competent to use items of plant/equipment. Manual handling/vibration training. Constantly monitoring concreting operations, particularly situations where point loading/collapse could occur. Rotate workers on vibratory tools where feasible.

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Supervision

Consideration of mechanical access equipment. Provision of safe means of access/egress suitably secured. Segregate pedestrians from plant and equipment. Edge/hole protection.

Environment

Consider noise produced from plant and equipment particularly for out-ofhours working on curing concrete. Dust suppression methods. Adequate lighting. Dust from mixing dry concrete – locate mixers externally. Protect vertical ends of protecting starter bars.

Equipment

Good working, least vibration order, regularly maintained and records kept. Operators to be certificated / competent.

Emergencies

Suitable First Aid facilities to be available, particularly eye-bath stations to be situated nearby. Operatives aware of emergency procedure and location of assembly points. Establish systems of work/emergency contact numbers for out of hours working.

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Access

Communications

Provision of suitable safety signs warning and barriers.

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PPE

Assessments/information and instructions to be given to operatives on materials. Personal hygiene essential when dealing with concrete/content.

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COSHH

Suitable protective footwear, including wellington boots where necessary. Hand, head and eye protection. Hearing protection where necessary. Safe system of work for dismantling/stripping formwork to prevent falls onto persons to be included in method statement.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 39

RISK ASSESSMENT GUIDE REF NO. 20 Assessment for: PRE-CAST CONCRETE, STAIRS, WALLS AND FLOORS Significant risks: Falls from height, crushing, collapse, handling, access, lifting appliances, heavy plant. CONTROL ITEM Information

Instruction/Training

DETAILS OF CONTROL MEASURES Operatives to be given appropriate information to ensure full knowledge of possible hazards associated with the fixing of pre-cast concrete units. Details of designed safe Method Statements to include specific risks. Where applicable, operatives to be inducted on the construction methods. Operatives to be trained by competent person in use of plant and equipment. The installation and fixing of pre-cast units to be controlled by experienced supervisor.

Access

Designated safe access/egress to be provided to all work areas. Control of access of pedestrians and plant to be in place to prevent unauthorised work under pre-cast flooring/wall installation.

Environment

Monitor for noise. Consider the effect of wind loadings on hoisted sections, and ground conditions to be checked for cranage equipment.

Equipment

All cranage/lifting gear/mobile and static scaffolds to be properly maintained and inspected.

Emergencies

Emergency procedures to be drawn up for the recovery of persons working at height, to include contact numbers and location of first-aider. Standard first aid equipment and accident reporting.

Communications

Radios to be used if possible. Systems to be in place for tandem lifting on heavy/large pre-cast sections. Signs and hazard markers.

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Supervision

COSHH

N/A

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Other

Hard hats, boots, high-visibility vests and harnesses.

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PPE

Transportation of long/wide loads to be planned with Police if applicable. Unique Method/Risk Assessments to be drawn up for individual erection processes with sub-contractor.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: SCAFFOLD (ALL TYPES) Significant risks:

Page 40

REF NO. 21

Injury from falling equipment and materials. Danger of collapse in exposed places, falling from height.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Usage of scaffolding and adequate materials/fittings. Equipment to be used. Safety Method Statements. Evaluate ground and loading conditions. Assess the need for any design requirements. Operatives to be provided safe access and egress. Prevent unauthorised access. Prevent access to any incomplete areas. Tie-ins. Drawings of system being erected. Number/width of platforms. Provision of handover certificates on completion. Inductions. Safety Awareness Talks – Working at Heights. Interpretation of scaffold design drawings. No scaffold to be erected modified or dismantled, except under the supervision of a competent person.

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Instruction Training

All scaffold erection must be under the supervision of a competent person. Thoroughly examine before first use, after substantial alteration after bad weather, or every 7 days. Receive scaffold handover certificate as appropriate. Keep platforms and area base clear.

Access

Keep access area to scaffold clean and tidy. Notice warning of dangers. Identify incomplete scaffold. Adequate widths of access platforms. Further consideration required if access by hoist, etc.

Environment

Evaluate ground conditions. Proximity to water/buildings or traffic. Overhead services. Consider the general public. Consider weather conditions such as wind loadings on sheeted scaffolds.

Equipment

To suit requirements.

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Supervision

Standard first aid. Accident reporting and investigation. Contract safety plan emergency procedures.

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Emergencies

Inform others working in area of proposed scaffolding to be erected. Supply information to other employees who may be using the scaffold. Warning signs and hazard tape and markers (lighting/traffic protection in urban areas). N/A Hard hats, protective footwear, harnesses, gloves.

COSHH PPE Other

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Communications

Review scheme if modification takes place. Ensure that a scaffold handover certificate is issued where appropriate. Secure scaffold against unauthorised access. Carry out manual handling assessment of the work.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: STRUCTURES (WORKING AT HEIGHTS) Significant risks:

Page 41

REF NO. 22

Injuries from falls, falling materials and equipment, reinforcement instability, structural failure, harmful substances, pressure bursts, power tools, entrapment, plant instability, splinters, dust, fragments, excessive noise, vibration, fumes, confined spaces. DETAILS OF CONTROL MEASURES Operatives are to be given the appropriate information to ensure that they are conversant with the hazards of operations and equipment associated with false work, reinforcement, concrete placement, scabbling / grit-blasting, working at heights, roof work as applicable to the type of structure. Details of design risk assessment to be incorporated into Safety Method Statement. Hierarchy of secure platform/workplace – safety nets – safety harnesses to be determining fall protection measures. Where applicable, operatives are to be inducted on the construction methods, and given potential hazard details. Operatives to sign Safety Method Statements. Operators to be trained by competent person in use of plant and equipment.

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CONTROL ITEM Information

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Instruction Training

Work is to be controlled by a competent experienced supervisor and temporary works coordinator as required. Appropriate registers to be completed.

Access

Designated safe access is to be provided to all areas of work.

Environment

Monitor for noise, vibration, dust atmosphere. Evaluate access, wind loading, weather, ground conditions, watercourses, nearness of buildings, traffic or services, stacking of materials at ground level and above.

Equipment

Access equipment/platforms, guard rails, adequate lighting, false work / scaffold design and inspection, lifting equipment.

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Supervision

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Major incident response plan. Emergency procedures to be detailed in contract safety plan for recovery of persons injured at heights.

COSHH

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Emergencies

Emergency contact names, organisations, telephone numbers. Warning signs. All materials to be assessed for COSHH.

PPE

Hard hats, protective footwear, protective clothing, goggles, high-visibility clothing, masks, harnesses, etc., as appropriate.

Other

Management individual to be appointed to have responsibility for coordination of design and procurement of false work and access scaffold, etc.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: STEEL ERECTION (GENERAL) Significant risks:

Page 42

REF NO. 23

Lifting, Work at Heights. Injuries from falls/falling objects

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Detailed Safety Method Statements particularly in respect of lay down facilities sequence, access, temporary stability and safety are required. Location of anchor points.

Instruction

Site Induction, safety awareness, unique Safety Method Statement briefing. Operatives to sign Safety Method Statements. Competent steel erectors only should be used – familiar, as a minimum, with rigging, erection methods, lifting equipment, tools and plant, erection of accesses (mobile and static). Individual training for unique types of plant such as mobile lift platforms. Certification of Banks men.

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Training

Competent supervisors with knowledge of lifting duties, planning, safety equipment as well as general operative training above. Operative training certification verified and registered.

Access

Generally via fixed scaffold system, cradles, mobile platforms or harnesses etc. Fixed access to be properly erected and inspected. Mobile plant to be certificated. Consider exclusion zones.

Environment

Ground conditions to be checked for cranage/mobile access equipment. Services to be marked etc. Monitor weather conditions.

Equipment

All cranage/lifting gear/mobile and static platforms, to be properly maintained and inspected.

Emergencies

Emergency procedures to be drawn up for recovery of persons injured at height including contact numbers and location of first aider. Standard site first aid, fire protection, evacuation, accident reporting and investigation.

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Supervision

PPE Other

N/A

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COSHH

Radios to be used if possible. Signs and hazard markers.

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Communications

High visibility vests, harnesses, helmets and boots. Unique assessments should be drawn up for individual erection processes with sub-contractor.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: WELDING, BURNING, STEEL WORK Significant risks:

Page 43

REF NO. 24

Fires, explosion, respiratory disease/eye damage. Various occupational health risks.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Use Hot Work Permit System. Welding procedures, details of gases to be used and storage details is included.

Instruction

Site induction, explanation of unique Safety Method Statement.

Training

Welding and burning should only be performed by suitably trained/certificated individuals who can show proof of such training appropriate to the operation. Generally by a suitably experienced supervisor who does not have to be a certificated welder but must be experienced in welding safety, working at heights etc.

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Supervision

As general steel erection, however, due allowance must be made for safe positioning of equipment, screens, hoses and welding leads.

Environment

Storage of bottles must be controlled with oxygen at least 3 meters from LPG/ACETYLENE, in open air, upright, out of sunlight. Firefighting equipment must be present. Flash guards whilst welding.

Equipment

To be regularly maintained with daily checks on hoses, regulators, leads, flashback arrestors leak tests, etc. Only proprietary fittings to be used. Secure bottle storage as above. Handling to be via trolleys etc.

Emergencies

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Additional firefighting facilities locally.

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Communications

N/A

Materials to be welded / cut should be identified and full COSHH assessment performed. Give particular attention to coatings on materials to be welded / cut. Iron oxide (vapour), carbon monoxide and nitrous fumes may be created, natural ventilation generally OK, but induced ventilation may be required in confined spaces.

PPE Other

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COSHH

Specialist welding visors, goggles, helmets, masks, gauntlets and overalls to protect bare skin. Assess the need for fire watchmen, screen the public from welding. Unburnt gas builds up in voids behind work piece from preheating operations.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: ROOF WORK/WORK NEAR FLOOR ETC OPENINGS Significant risks:

Page 44

REF NO. 25

Falls from height. Falls of materials/tools etc. DETAILS OF CONTROL MEASURES Loading sequence/Lifting arrangements. Operatives advised of contents of risk assessment/Safety Method Statements. Operatives to sign Safety Method Statements.

Instruction/Training

Instruction on fall arrest equipment, edge protection, wearing of harness, fragile materials, equipment/material control.

Supervision

Competent supervisor to be present for all associated works. Supervision to implement Safety Method Statement requirements.

Access

Guard rails/toe boards/material guards provided and used. Adequate ladder access etc.

Environment

Weather implications i.e. winds, sand factors etc.

Equipment

Adequate access. Where used safety netting properly secured. Anchorage points for clip-on facilities for full arrest equipment.

Emergencies

First aid, evacuation, recovery arrangements for possible injured person and fire control.

Communications

Warning notices and where appropriate segregation at ground level to protect pedestrians.

COSHH

As appropriate to roof work type e.g. Hot Bitumen etc.

PPE

Inertia reels for fall arrest. Full body harnesses, safety helmet, boots, warm clothing etc.

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CONTROL ITEM Information

Material movement onto roof and loading sequence be controlled. Consider point loading.

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Other

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The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: INFILLING OF FLOOR OPENING(S) Significant risks:

Page 45

REF NO. 26

Falls of person, falls of materials, collapse of support work (temporary or permanent). Health risk from contact with materials. Muscular skeletal injuries. DETAILS OF CONTROL MEASURES All persons involved in the work will receive information regarding the hazards associated with the operation and the precautions to be taken.

Instruction/Training

The supplier of bolts and fixings should be requested to instruct installers on the correct procedures to be used for the fixings specified.

Supervision

All work involving the support at floor infill’s shall be under the control of a competent person experienced in the methods used.

Access

Proper access must be provided for installation of support system. Barriers must be provided to the edges of the opening prior to the infilling operations. Where appropriate fall protection to be provided.

Environment

All support work whether temporary or permanent must be subject to a methodical system of checking to include, connections, fixings, access etc and compliance with design drawings and specification prior to loading. Permit system to be introduced prior to loading system with concrete.

Equipment

All equipment must be checked for good condition and suitability prior to being used.

Emergencies

Arrangement to be put in place for recovering persons injured etc whilst carrying out work on high level areas.

Communications

All relevant information including Safety Method Statements and Risk Assessments, Manufacturer’s Instructions and design drawings should be communicated to all persons involved.

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CONTROL ITEM Information

Other

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PPE

Assessments should be made for materials classified under COSHH which should be communicated to all persons.

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COSHH

May include, eye protection, clothing, footwear, safety helmet and hearing protection. Safety Method Statements must be produced for all elements of the works including preparation of existing structure, installation and inspection of support system and access systems. Installation of Formwork and preloading checks.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: ROOF WORK (FLAT) Significant risks:

Page 46

REF NO. 27

Falls from height, falls of materials, fragile materials, unsecured materials, manual handling. DETAILS OF CONTROL MEASURES Sequence of work. Location of materials, raising of materials to roof level. Means of providing fall protection. To elevations leading edge and openings. Handling of large sheets.

Instruction/Training

Operatives and supervisors must be trained and competent. Must be inducted and briefed in method statement content.

Supervision

Competent supervisor to be in attendance for duration of operation. Ensure method statement is formally discussed with all roofing operatives. Supervision to review roof operations daily.

Access

Provide ladder or access tower or identify other means of access.

Environment

Confirm maximum safe working wind speed for type of roofing. Be aware of increased risk in dusty conditions.

Equipment

NB the options for protection are (in order of preference):1 –safety nets; 2 –Lead guard type leading edge protection trolley systems; 3 –Safety harnesses/running lines/ fall arrestors. Adequate access. Where used safety netting properly secured by certificated erectors. Anchorage points / clip-on facilities for full arrest equipment. Anemometer.

Emergencies

Agree emergency procedure for recovery and treatment of person injured at a height. Ensure adequate firefighting and first aid provision available.

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CONTROL ITEM Information

Warning notices and where appropriate segregation or protection at ground level to protect pedestrians.

PPE

Other

Assessments as appropriate for materials to be used.

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Full body harnesses, safety helmets, boots, warm clothing. Gloves, eye protection

Confirm controls for hot works and storage of flammables at height.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: ROOF STRUCTURE (including wall plates/trusses/timber) Significant risks:

Page 47

REF NO. 28

Falls, falling objects, manual handling, fire.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Agree safety method statement. Store materials in a safe manner. Provide suitable working platform. Precautions to be taken to prevent operatives falling whilst installing trusses e.g. safety nets or boarding. Visually check electrical tools and leads. Obtain COSHH assessments. Ensure circular saws are in good working order with guard and dust extraction bag in place. Carry out manual handling assessment, use lifting appliances to lift trusses into position. Complete crane checklist. Inspect lifting gear before use. Keep work area free from tripping hazards. Store waste material in the proper bins. Operatives to receive risk, manual handling and COSHH assessment. Carry out induction, all relevant assessments to be given as Tool Box Talks. If using Mobile Elevated Work Platforms adequate training must be given. Slingers to be properly trained.

Instruction

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Training

Competent person to inspect working platforms and work areas before work starts. Inspection of working platforms to be entered in Site Register. Crane controller to complete crane checklist. Provide suitable ladders, properly secured. Keep access free of materials and electrical leads.

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Weather implications i.e. winds and dusty conditions.

Equipment

All electrical equipment to be inspected on a regular basis by a competent electrician, these should be tagged with details of last inspection. Carry out manufacturers instructions for maintaining Mobile Elevated Work Platforms. Safety nets to be properly secured. Crane and lifting gear certificates to be kept in site register. Provide first aider. Provide fire extinguishers. Operatives to be informed of all emergency procedures at induction. PPE, “Danger Men Working Overhead”, Scaff tag or similar to be displayed. Assessment for all materials to be obtained.

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Hard hats, safety footwear, gloves, eye protection, dust mask and ear protection. If using mobile elevated work platforms fall body harnesses must be worn. Do not overload scaffold platforms, provide suitable roof truss rack.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: ROOF COVERINGS (felt/batten/slate/tile/cladding) Significant risks:

Page 48

REF NO. 29

Falls, falling objects, manual handling

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Agree Safety Method Statement. Store materials in a safe manner. Provide suitable working platform. Precautions to be taken to prevent operatives falling i.e. safety nets. Visually check electrical tools and leads. Abrasive wheels to be kept in good order and guards in place. Obtain COSHH assessments. Carry out manual handling assessment, use lifting appliances to lift materials into position. Complete crane checklist. Inspect lifting gear before use. Keep work area free from tripping hazards. Store waste material in the proper bins. Operatives to receive risk, manual handling and COSHH assessment. Carry out induction, all relevant assessments to be given as tool box talks, abrasive wheel operator to be trained in its use and how to change the abrasive wheels safely.

Instruction

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Training

Competent person to inspect working platforms and areas before work starts. Inspection of working platforms to be entered in Site Register. Crane controller to complete crane checklist.

Access

Provide suitable pitched roof/ridge ladders, properly secured. Keep access areas free of materials and electrical leads. Access on tile batten to be agreed with roofers. Prohibit walking on tiled areas. Weather implications i.e. winds and dust etc.

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All electrical equipment to be inspected on a regular basis by a competent electrician, these should be tagged with details of last inspection. Safety nets to be properly secured. Crane and lifting gear certificates to be kept in site register.

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Provide First Aider. Operatives to be informed of all emergency procedures at induction.

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PPE, “Danger Men Working Overhead”, Inspection report or similar to be displayed.

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Assessment for all materials to be obtained. Dust generation from cutting tiles with powered abrasive cutters.

PPE

Hard hats, safety footwear, gloves, eye protection, dust mask and ear protection.

Other

Do not overload scaffold platforms, only load out on loading bay. Consider material movement onto roof and load points.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: EXTERNAL CLADDING Significant risks:

Page 49

REF NO. 30

Falls of persons, handling panels at high levels, falling materials, broken glass or unprotected edges of panels.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Instruction for supervisors and operatives in the safe storage and working procedures. Induction training should cover site rules and action to be taken in the event of an emergency. Operatives should be certificated for the erection of mobile scaffolds Where appropriate training must be provided in the operation of Mobile Elevated Work Platforms (MEWP’s). Operatives must be trained in working at heights. Operatives to be instructed to work to Safety Method Statements, operatives to sign Safety Method Statements.

Instruction

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Supervision

Works are to be controlled by an appropriately competent and experienced supervisor. Supervisors to ensure that equipment and plant is operated and erected ONLY by persons who have been trained, certificated and authorised to do so. Supervisors to ensure that Safety Method Statements are being worked to and those materials are being properly handled and stored. Safe means of access/egress must be provided and maintained. If working at height, an assessment should be carried out and suitable control measures employed. Ladders should be tied or footed; mobile scaffolds and access platforms must be properly erected with guardrails fitted and inspection details recorded. Where MEWP’s are used, operatives must wear and use safety harnesses when working at height, operatives must not leave the confines of the MEWP whilst at height. Exclusion zone must be established at work location.

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Access

Works must be restricted in windy conditions. Consideration must be given to working in the vicinity of overhead services.

Equipment

Equipment must be kept in good working order and be regularly maintained with records being kept. Any mobile towers, scaffolding etc. should be checked at least every seven days with a record of inspection being kept. MEWP’s must not be used as a lifting device to transport men or materials e.g. used as a hoist.

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At least one person in any glazing team should have been trained in first aid. Each glazing team should have appropriate first aid equipment available to them. Warning signs, notices and barriers used as appropriate. Assessments must be produced for hazardous materials e.g. sealants and training provided. Safety harnesses, goggles, gloves, safety footwear, helmets must be worn. Consideration must be given to adequate segregation of the works with other contractor’s employees and members of the public. See also Risk Assessment no. 32 - use of lifting appliances/gear to lift/move/store stillages and panels where appropriate.

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Emergencies

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: WATER STORAGE DEVICES Significant risks:

Page 50

REF NO. 31

Falls from heights, falling materials, eye injuries during drilling operations. Inhalation, skin absorption or ingestion of harmful substances.

CONTROL ITEM Information Instruction

DETAILS OF CONTROL MEASURES Instruction for supervisors and operatives in the safe storage and working procedures. Induction training should cover site rules and action to be taken in the event of an emergency. Operatives should be certificated for the erection of mobile scaffolds. Where appropriate training must be provided in the operation of Mobile Elevated Work Platforms (MEWP). Operatives must be trained in working at heights. Operatives to be instructed to work to Safety Method Statements, operatives to sign Safety Method Statements.

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Training

Works are to be controlled by an appropriately competent and experienced supervisor. Supervisors to ensure that equipment and plant is operated and erected only by persons who have been trained, certificated and authorised to do so. Supervisors to ensure that Safety Method Statements are being worked to and that material are being properly handled and stored. Safe means of access/egress must be provided and maintained. If working at height, an assessment should be carried out and suitable control measures employed. Ladders should be tied or footed, mobile scaffolds and access platforms must be properly erected with guardrails, mid rails, and toe boards fitted. Where MEWP’s are used, operatives must wear and use safety harnesses when working at height, operatives must not leave the confines of the MEWP whilst at height. Exclusion zone must be established at work location.

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Environment

Works must be restricted in windy conditions. Consideration must be given to working in the vicinity of overhead services. Equipment must be kept in good working order and be regularly maintained with records being kept. Any mobile towers, scaffolding etc. should be checked at least every seven days with a record of inspection being kept. MEWP’s must not be used as a lifting device to transport men or materials e.g. used as a hoist.

Emergencies

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Provide First Aider. Operatives to be informed of all emergency procedures and first aid provision at induction. Warning signs, notices and barriers used as appropriate i.e. "Danger Men Working Overhead". Assessments must be produced for hazardous materials e.g. sealants and training provided. Safety harnesses, goggles, gloves, safety footwear, helmets must be worn. Consideration must be given to adequate segregation of the works with other contractor’s employees and members of the public.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: LIFTING OPERATIONS Significant risks:

Page 51

REF NO. 32

Injury from falling equipment and materials. Entrapment, personal injury to oneself or others. Failure to check and ensure safe use of equipment. Overturning of crane/excavators used as cranes.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Operatives to be advised of risks from lifting by manual or mechanical means. Proximity of any overhead services. Safety Method Statement required. Advice to be given on any specific control measures including safe systems of work and Safety Method Statements. Colour coding of lifting equipment. Operatives to sign Safety Method Statements. Moving unusual objects. Using correct equipment. Check all crane and lifting test certificates are in date. Check equipment supplied. Visual inspection of equipment prior to any lifting operations. Identify if a dedicated method statement is needed, i.e. over 10 ton. Induction – mechanical and manual lifting, banks man training certificated. The use of competent/certificated drivers. Specifics of individual tasks. Appoint a lifting supervisor. Nominate crane coordinator to assess local conditions and lift requirements. Determine weight, centre of gravity, sharp edges, condition of load. Visual inspection of equipment being used. Reporting. Monitor driver’s performance. Plan route and assess any hazards. Keep work area clear. Ground conditions. Exclusion zones where appropriate. Level area for lifting. Check ground conditions. Closeness of buildings, excavations and services. Monitor lighting and weather (including response actions during high wind conditions).

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Training

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Check valves fitted to excavator. To be suitable for operations being carried out and test certificated. Setting up of equipment to be adequate and verified by crane coordinator. Assess the need for a planned preventative maintenance scheme.

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Standard first aid, evacuations, accident reporting and investigation. Major incident response plan. Emergency procedures in contract safety plan.

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COSHH

Other workers to be informed of lifting operations being carried out. Warning signs. Hazard markers etc. Radio/transmitters. Ability to hear audible warnings during lifting operations. One banks man only directing crane driver. As required.

PPE

Hard hats, high visibility clothing, gloves and footwear etc. Identification of banks man.

Other

Excavators used for lifting must be rated or exempt with current documentation. Provision of equipment such as tag lines. Further considerations for lifting operations in tunneling or for man-riding will be needed.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: MANUAL HANDLING Significant risks:

Page 52

REF NO. 33

Various back injuries (i.e. strains, slipped discs etc.) possible injury through dropping, torn ligaments, tendons, hernias, general cuts and abrasions.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Operatives informed of possible back injury and strains and sprains due to lifting tasks on site and in office. Issue “Manual Handling” information to personnel. Clear labelling of weights if possible. Assess all the details and working practices of the work to be done. Complete specific assessment form as appropriate. Avoid manual handling if possible. Use mechanical means if appropriate. Seek help from others if no mechanical aid available. Follow the control methods detailed in an assessment. Operatives trained in correct method of lifting and handling. Not to exceed personal capability.

Instruction

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Constantly monitor storing and stacking to keep manual handling as minimal as possible. Ensure specific instructions are followed, supervisors to be aware of manual handling requirements.

Access

Good flat, clear, stable ground and scaffolds are free of obstacles and debris.

Environment

Areas to be kept clean and tidy. Free of trip hazards. Well lit. Special attention to areas of restricted space.

Equipment

Various lifting aids available to assist manual handling. Ensure lifting aids are subject to any applicable inspection testing etc.

Emergencies

Standard site first aid, fire protection, spillage control, accident reporting and investigation.

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Possible hazards from material being handled in case of spillage.

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Good communications between operatives in dual handling.

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Gloves, foot protection, hard hats, possible eye protection, masks as appropriate. Size of packaging to be reviewed to give consideration to manual handling. Operatives should be screened to assess the suitability of the person to the task.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: SITE PLANT MOVEMENT/CARE Significant risks:

Page 53

REF NO. 34

Crushing/laceration and entrapment injuries, damage to structures and plant, plant instability, structural failure, reversing vehicles, slewing machinery. Loss of loads.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Operatives and visitors to be aware of dangers of equipment and related locations. Produce Safety Method Statements where appropriate. Ensure that plant manuals are kept with equipment where appropriate. Any traffic/pedestrian routing to be detailed in safety plan and clearly marked. Visitors to be inducted/escorted, operatives to receive appropriate safety awareness talks. Use of banks man in movement areas if applicable. Operators and banks men to be competent suitably trained and certificated. Supervisors to ensure that plant and equipment is operated and banked ONLY by persons who have been trained, certificated and authorised to do so. Ensure that weekly registers and maintenance requirements are performed. Regular inspection of any traffic management systems to ensure safe access etc.

Instruction

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Training Supervision

Safe access to be assessed and provided before movement of plant. Assess requirements for level ground. Consider pedestrian segregation and high visibility clothing.

Environment

Consider weather, ground conditions, adequate lighting, dust, nearness of excavations/buildings, traffic, noise and fumes. Suitably plan any cleaning, wheel washing, sheeting areas, loading. Damp down in dry weather. Bund diesel tanks.

Equipment

Regular inspection, reporting of condition, maintenance procedures and manuals, periodic tests, cleaning. Instructions to be in English. Hazard lights and audible warning units where applicable. Adequate marking.

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Access

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Use warning signs, hazard markers and audible warning units where appropriate. Personnel in the vicinity should be made aware of plant movements. Consider use of radio/transmitters. Use of dedicated banks man using the appropriate signals.

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COSHH

PPE Other

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As applicable to maintenance activities. Specific hazardous loads to be loaded and carried may need assessing. As appropriate to maintenance operations, together with high visibility clothing. Check condition of plant upon arrival on site.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: TOOLS (ELECTRICAL/PNEUMATIC/CARTRIDGE) Significant risks:

Page 54

REF NO. 35

Personal injuries due to misuse and failure such as electrocution and laceration; excess noise, dust and vibration.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Assess tool requirements, location of use and obtain data sheets as appropriate. Any relevant marking requirements e.g. ear protection (symbol visible on the tools). Regular tool box talks with individual reference to unusual tools. Certificate and Authorisation of Plant Operators. Cartridge tool operators are to be certificated by the manufacturer/supplier.

Instruction Training

Supervisors are to monitor condition, inspection records, certification and use. Consider exclusion zones and controlled issue of tools. Adequate working space is to be provided for the safe use of tools.

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Supervision Access

Evaluate weather, water, earthing requirements, vibration, noise, dust, fumes, dry storage area, security etc. Safe storage for cartridges/gas cylinders.

Equipment

Delivery test certificates where appropriate. Maintenance, cleaning, periodic testing and regular inspection. Ensure electrical equipment is 110v and properly earthed.

Emergencies

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Give particular consideration to electrocution in conductive environments.

Communications

Tool box talks, warning signs.

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Environment

As applicable. Consideration to be given to dust, swarf, oils, greases, cleansing fluids, epoxy etc. Consider the presence of asbestos.

Other

Goggles, ear muffs, gloves, masks, etc. Consider ventilation/breathing apparatus.

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Two of the most important considerations with tools are PPE and adequate training.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

Page 55

REF NO. 36

Assessment for:

CONFINED SPACES

Significant risks:

Asphyxiation from lack of oxygen or poisoning of noxious fumes/gases, explosive gases, entrapment, flowing solid material overcome by high heat conditions, drowning if present, fall injuries. All possibly exacerbated by the introduction of mechanical or electrical equipment into confined areas .

CONTROL ITEM Information

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Instruction

DETAILS OF CONTROL MEASURES Seek all available information on the ground/location to be entered and establish safe systems of work. Undertake all appropriate tests to identify the nature of the environment to be entered e.g. sludge’s, rust (lack of oxygen). Procedures to be developed to take account of complexity of confined spaces e.g. tunnels, underground shelters, caverns, vessels etc. and the number of persons within confined spaces. All employees who have involvement with any confined spaces work (including the writing of Safety Method Statements) to be given specific instruction concerning particular spaces to be entered and relevant information. This includes supervision, employees entering confined spaces persons employed as top men and rescue personnel. All personnel to sign Safety Method Statements/Permits to enter and/or work. All employees entering confined spaces are to receive training for entry procedures, atmospheric testing equipment, emergency evacuation, lifesaving equipment and procedures. The practical use of equipment will also be covered. Emergency rescue team to be formed and trained where appropriate. Designate the “category” if space to be entered. A trained competent person is to be appointed to carry out tests before entry and be in continuous attendance during work within confined space. Entry controlled by permit system. Safe and unrestricted access to/from confined spaces to be monitored and ensured by this person at all times. Supervisor to be aware if the requirements of confined space work. Unrestricted access and egress essential. Use tally boards where appropriate to monitor entry and exit. Forces ventilation and requirements must be assessed but they are to be mandatory in any area where any possibility of oxygen deprivation or noxious gases identified or known to exist, unless a system utilising working BA has been established. Traffic management scheme to be drawn up and implemented for protection of access/egress points in roadway. Evaluate for ventilation requirements, consider need for non-spark (intrinsically safe) lighting and equipment. The effects of flooding or weather, hot or cold temperatures, contaminated ground to be established. Identify toxic or flammable atmospheres to ensure that continuous gas monitors are compatible. Consider the effects of noise, dust and fumes. Provide emergency lighting. Saver rescue and working breathing apparatus, ventilation units, gas detectors, man hoist and harness, chemical indicator tubes to identify fumes/gases or substances. Also consider the intrinsic safeness of all electrical systems. Ventilation systems to have visual or audible warning in event of failure. Consider pre-determined system of shouts/whistles/horns etc, between all members of the team. Clear access to be maintained to the working area for emergency services. Standard site first aid, fire protection, recovery, evacuation, accident reporting and investigation. Major incident response plan. Emergency boards, drawings, telephone numbers etc. to be displayed at point of entry. Consider internal telephone/radio/transmitters/bell/rope signals. Consider the hazards of all material such as epoxies, resins, adhesives, fuels, cleansing fluids, solvents, dust, concrete, paints etc, when used in confined spaces.

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Communications

COSHH

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

PPE

Page 56

Hard hats, protective footwear, protective clothing, goggles, masks, hearing protection, harnesses etc. as appropriate and breathing equipment. Gas monitors. Consideration should be given to confined space procedures when personnel enter restricted spaces within form work or reinforcement cages. Contact with Safety and environmental Department.

Other

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The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: NIGHT WORK Significant risks:

Page 57

REF NO. 37

Injury from falling/tripping/fatigue in particular, plus generally increased risks due to limited visibility.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Generally a method statement either unique to a single night’s work or to an activity over a number of nights, should be prepared incorporating the requirements of the preceding shift and personal response alarms. All involved should be given a briefing on the work involved including which accesses are to be used and which areas are suitable for working. Give specific induction and safety awareness talks on night work. Refer to specific risk assessments and Safety Method Statements.

Instruction Training

Plan safe and adequate lighting both in place of work and access there to (i.e. working and background lighting). Ensure all access ways are completely lit, are of good standard and free of materials. Establish exclusion zones and designated working areas. Give particular attention to edge protection and barriers.

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Supervision Access

Good lighting. Special attention to all edges, trip hazards, noise and vibration. Consider weather i.e. low temperatures and slippery surfaces. Avoid lighting that may have stroboscopic effect particularly if using moving equipment. If practical check lighting levels. Prevent nuisance/risk to public from lighting/dust/noisy operations.

Equipment

All equipment required for night work, especially lights, should be checked during prior daylight shift. Special attention to lighting cables.

Emergencies

Checks to be made on availability of night cover from local hospitals etc. Standard site first aid and reporting procedures to apply, list of emergency/night call out numbers. Where applicable emergency lighting shall be provided on emergency access routes.

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PPE

Other

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As required by activity.

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Greater use of radios to minimise unnecessary movements at night. A tally system may be required on certain operations.

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As well as normal helmets and boots, high visibility clothing should be utilised. Attention to warm clothing, as required, should also be made. Shifting of labour resources to be arranged to prevent prolonged day and night shift working. Consider increased supervision in working areas and control of unauthorised access. Consider use of light sensitive cells for lighting systems.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 58

RISK ASSESSMENT GUIDE REF NO. 38 Assessment for: SPECIALIST SUB-CONTRACTOR PROCESSES eg. BITUMINOUS SURFACING, PAINTING, WATERPROOFING, SILANE ETC. Significant risks: Depends on process, however tend to be more COSHH/pollutant orientated. Burns, skin complaints and asphyxiation etc. CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Ensure that a Safety Method Statement risk assessment and COSHH assessment have been supplied by the sub-contractor. Ensure that the sub-contractor is appropriately experienced. Special care in confined spaces and using highly flammable materials. Require the sub-contractor to brief a member of your supervisory staff on ALL safety requirements/hazards etc. Ensure that any employees who may come into contact with the specialist work have been briefed, tool box talks inductions etc. Sub-contract personnel to be trained and certified as appropriate.

Instruction

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Training

Ensure that the sub-contractor adequately supervises his works and works to the Safety Method Statement. Hot work permit to be issued where appropriate.

Access

As required to ensure safe access and egress.

Environment

Monitor environment and set up exclusion zones etc. as appropriate.

Equipment

As required for activity. Consider standoff distances, atmospheric monitoring and ventilation.

Emergencies

Ascertain from the sub-contractor if specialist measures are necessary. Check fire precautions etc. Standard site first aid, fire protection, evacuation, accident reporting and investigation.

Communications

As appropriate, warning signs.

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Supervision

Obtain COSHH information assessment from sub-contractor. Ensure compliance. Check disposal of waste etc.

Other

To be established with sub-contractor/Safety Environmental Department as appropriate.

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Seek advice from Safety and Environmental Department as necessary.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 59

RISK ASSESSMENT GUIDE REF NO. 39 Assessment for: STORAGE AND LIMITED USE OF HIGHLY FLAMMABLE MATERIALS ETC Significant risks:

Explosion, fire, vapours, manual handling injuries.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Assess type and quality of gases/liquid/materials to be used, quantities to be minimised, storage/fire precaution recommendations from suppliers to be obtained as required. Personnel to be briefed on supplier’s information safety precautions. Safety awareness talks. Ensure that all employees who come into contact have cause to use materials and are trained on safe usage, storage disposal and fire procedures. Implement checks on storage and usage. On larger sites with greater usage have formal issue/collection system. Establish demarcated remote storage location.

Instruction Training

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Supervision

Control access to secure storage area.

Environment

Individual outdoor stores to be constructed to recommended type, including all relevant signing and fire points precautions. Ensure no sources of ignition including electrical.

Equipment

Gas cylinders etc. to be obtained from company suppliers only. Any damage being reported and bottles/containers exchanged immediately. Dry powder extinguishers.

Emergencies

Fire – summon Civil Defence (Fire Department) and inform them accordingly of type and quantities of bottles and containers. Ensure that dry powder extinguishers are available but do not endanger life, clear area. Standard site first aid, fire protection, evacuation, accident reporting and investigation.

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Clear signage, including type of materials stored and “no smoking” signs.

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Perform COSHH assessments on individual materials particularly for inhalation of fumes.

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Communications

Depends on materials being stored. In the case of adhesives/resins, particular care to be taken when handling. Flammable paints/resins may not be suitable for external storage. Consider ventilated/controlled temperature stores. Consider storing and removing waste.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: INSTALLATION OF FIRE PROTECTION COATINGS (BOARD) Significant risks:

Page 60

REF NO. 40

Manual handling, falls, trailing leads, electricity, circular saws, noise, housekeeping, storage of materials.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Provide suitable working platform. Visually check electrical tools and leads. Carry out Manual Handling assessment. Obtain COSHH assessment. Ensure circular saw is in good working order with guard and dust extract bag in place, if using bench saw provide push stick and emergency stop button. Store materials in a safe manner. Keep work area free from tripping hazards. Store waste material in the proper bins. Ensure adequate task lighting. Operatives to receive Risk, COSHH and Manual Handling assessment. Carry out Induction, all relevant assessments to be given as Tool Box Talks. Operatives to be trained in the safe use of circular saw. If using Mobile Elevated Work Platforms or Mobile Towers operatives to be suitably trained.

Instruction

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Training

Competent person to inspect working platforms and work areas before work starts. Inspection of working platforms to be entered in Site Register.

Access

Provide suitable ladders, properly secured. Keep access areas free of materials and electrical leads.

Environment

Dust levels to be kept suppressed.

Equipment

All electrical equipment to be inspected on a regular basis by a competent electrician, these should be tagged with details of last inspection. Carry out manufacturer’s instructions for maintaining Mobile Elevated Work Platforms.

Emergencies

Provide First Aider. Operatives to be informed of all emergency procedures at induction.

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Supervision

PPE notices to be displayed and if working at height ‘Danger Men Working Overhead’.

PPE

Other

Assessment for the fire protection coating board and adhesives.

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Communications

Hard hats, safety footwear, eye protection, dust mask and ear protection. If using Mobile Elevated Work Platforms fall body harnesses must be worn. If there is a lot of cutting of boards to be carried out it may be worth considering job rotation to prevent one person being exposed to the noise and dust problem.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 61

RISK ASSESSMENT GUIDE REF NO. 41 Assessment for: INSTALLATION OF FIRE PROTECTION COATINGS (SPRAY) APPLIED

Significant risks:

Materials, inhalation, skin contact, falls.

CONTROL ITEM Information

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Instruction/Training

DETAILS OF CONTROL MEASURES Agree method statement. Store materials in a safe manner. Provide suitable working platform. Visually check electrical tools and leads. Obtain COSHH assessments. Provide and maintain suitable extract equipment. Enclose work area. Keep work area free from tripping hazards. Store waste material in the proper bins. Ensure adequate task lighting. Operatives to receive Risk and COSHH assessment. Carry out Induction, all relevant assessments to be given as Tool Box Talks. If using Mobile Elevated Work Platforms of Mobile Towers operatives to be suitably trained. Competent person to inspect working platforms and work areas before work starts. Inspection of working platforms to be entered in Site Register.

Access

Provide suitable ladders, properly secured. Keep access areas free of materials and electrical leads.

Environment

Provide suitable extract equipment to maintain a clean and healthy environment for all workers. Segregate/enclose work area.

Equipment

All electrical equipment to be inspected on a regular basis by a competent electrician, these should be tagged with details of last inspection. Carry out manufacturer’s instructions for maintaining Mobile Elevated Work Platforms. Screening of scaffolding to prevent overspray will require checks carried out on number of ties.

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Supervision

Provide First Aider. Operatives to be informed of all emergency procedures at Induction.

COSHH

PPE notices to be displayed and if working at height ‘Danger Men Working Overhead’. ‘No Unauthorised Persons Beyond this Point’ notices to be displayed outside the enclosure.

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Communications

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Emergencies

Assessment for all materials to be obtained.

PPE

Hard hats, safety footwear, overalls, gloves, eye protection, dust or fume mask (in poorly ventilated area a Fresh Air Feed mask) and ear protection. If using Mobile Elevated Work Platforms fall body harnesses must be worn.

Other

If operatives are exposed to Man Made Mineral Fibres (MMMF) over a prolonged period there is a danger of serious damage to their health.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: LIFT INSTALLATION Significant risks:

Page 62

REF NO. 42

Falls from height, manual handling, confined spaces, electrocution.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Obtain layout of plant rooms/switchgear/isolation points prior to starting work.

Instruction/Training Working Safety Method Statements are to consider installation dangers. Operatives to sign Safety Method Statements. Tool Box Training to be given on relevant topics. Work to be carried out under the supervision of a competent experienced person.

Access

Access to lift shafts and plant rooms to be strictly controlled. Where scaffolds are used for access these must comply with the relevant requirements.

Equipment

Work equipment e.g. power tools etc. to be tested in accordance with manufacturers requirements.

Emergencies

Method Statement to include procedures for rescue of persons from the shaft in emergency situations.

Communications

Permit to Enter Shafts and Plant room to be in place and displayed. Warning signs and barriers to be in place.

COSHH

As applicable to materials used e.g. Hydraulic Oils.

PPE

As site rules and appropriate to hazard i.e. gloves when lifting machine parts etc.

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Supervision

Refer to Generic Risk Assessment No. 14, 20, 22, and 23.

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Other

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The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: ELECTRICAL/MECHANICAL SERVICES Significant risks:

Page 63

REF NO. 43

Electrocution/fire, fume inhalation, entanglement, vibration, explosion, fall from height, manual handling, paint use/radiation

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Risk Assessments and Safety Method Statements, PPE, Permits to Work (Hot Work), Flash Screens, Fire Precautions, Permits to Work (Electrical Systems), Tower Scaffolds, Display Notices, Locking off Procedures. Documentation for lifting appliances/gear

Instruction/Training Inductions, Safety Awareness Talks, Permit to Work Procedures, Scaffold Erection (Towers), Abrasive Wheels. Permit to Work issue. Competent persons appointment. Electrical Duty Holder. Operation of visible inspection system displayed. Work Place Inspections.

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Supervision

Position of temp. Cables, step ladders inspected and of sufficient length (split head trestles not used as steps). Ladders inspected and secure gangways clear.

Environment

Welding fume control, noise control assessments, non-destructive testing, dust control (drilling), housekeeping (Inc. flammable debris), waste disposal (conduit off cuts), oil drips (threading machines).

Equipment

Guarding of threading machines/welding machines to external air, fire extinguisher adjacent to machines, flash back arrestors, bottle stands/gas storage, equipment inspection procedures.

Emergencies

Evacuation procedures/fire procedures/emergency lighting, access routes, alarm systems, first aid, gas check.

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Access

Communications

Posters, Notices, Tool Box Talks.

Other

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PPE

COSHH assessment for and including welding fume, cutting oils, paints, fluxes, dusts (grinding) oxygen, acetylene propane etc.

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COSHH

Head protection, foot protection, overalls, including visors, eye protection, noise protection, gloves, RPE etc. Ducting installation (Geanie hoists). Special precautions for special welding operation.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: PLUMBING WORKS Significant risks:

Page 64

REF NO. 44

Potential for inhalation, ingestion or absorption of toxic substances (e.g. lead, solvents etc.). Fire whilst undertaking hot work, entanglement with pipe threading machine, vibration from percussion tools. Confined working. DETAILS OF CONTROL MEASURES COSHH assessment details made available. Detailed method statement for pressure testing and non-destructive testing.

Instruction/Training

COSHH, manual handling, fire prevention training required.

Supervision

Effective supervision for hot work and working with lead. Health surveillance required for significant exposure.

Access

Safe access required to all work locations.

Environment

Disposal of waste in accordance with waste procedure.

Equipment

Maintain in good condition.

Emergencies

Site arrangements and local segregation.

Communications

Tool Box Talks.

COSHH

Assessment required for flux, lead, solvents, epoxy resins, maintain.

PPE

Safety helmets, safety footwear, gloves, overalls, RPE where identified in COSHH assessment.

Other

No smoking or eating whilst exposed to lead fume. Specific welfare for specific lead work.

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CONTROL ITEM Information

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The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: CARPENTRY/JOINERY Significant risks:

Page 65

REF NO. 45

Dust (hard and soft wood), fall from height, contact with cutting machinery, glues, manual handling, treated timber, slips and trips. DETAILS OF CONTROL MEASURES Risk assessments, safety method statements, information posters, safety reminders.

Instruction/Training

Inductions, safety awareness talks, cartridge gun training, tower scaffold training, manual handling, wood working machine training.

Supervision

Working at height supervision, scaffold inspections, work place inspections, small tool inspections, tools in good order.

Access

Ladders secured and in good order, gangways clear, staircases as alternative to ladders.

Environment

Housekeeping, dust controlled at source, flammable material, solvent glues.

Equipment

Electrical equipment in good order, hand tools in good condition, vibration (hammer drill) checked.

Emergencies

Induction site plans and notices displayed. Access routes clear. Sufficient staircases.

Communications

Induction/safety awareness, site notice boards, duty holders indicated, supervision training, risk assessments and safety method statements explained.

COSHH

COSHH assessments, materials use training, data sheets, Sypol system.

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CONTROL ITEM Information

Head protection, foot protection, respiratory protection (dust mask), noise protection, gloves, eye protection and overalls.

Other

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PPE

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The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 66

REF NO. 46 RISK ASSESSMENT GUIDE Assessment for: PLASTERING AND EXTERNAL RENDERING Significant risks:

Falls from height, falling objects/material, manual handling, skin contact with wet mortar, dust from mixing unit. DETAILS OF CONTROL MEASURES General safety information on safe access e.g. ladders etc.

Instruction/Training

Manual handling of equipment/materials

Supervision

Scaffold use above 2 meters to be under control of competent person.

Access

Suitable access to be provided to all work locations e.g. hop-ups to full scaffolds etc. segregate lower work areas whilst working in elevated situations.

Environment

Consider weather conditions.

Equipment

Suitable access equipment to work location. Maintain equipment in good condition.

Emergencies

General site arrangements for first aid and evacuation.

Communications

General information and tool box talks.

COSHH

As appropriate to substances in use e.g. mortar.

PPE

Safety helmets, safety footwear, warm clothing, gloves etc. Face mask when mixing.

Other

Maintain good standards of personal hygiene.

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CONTROL ITEM Information

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The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: CEILING FIXING Significant risks:

Page 67

REF NO. 47

Entanglement, fall from height, manual handling, electrocution, hand injuries from sharp components, eye injuries during drilling operations.

CONTROL ITEM Information Instruction/Training

DETAILS OF CONTROL MEASURES Risk assessments and safety method statements, PPE, permits to work, tower scaffolds. Inductions, safety awareness talks, permit to work procedures, scaffold erection (towers), abrasive wheels. Permit to work issue. Competent persons appointment. Electrical duty holder. Operation of a visible inspection system. Work place inspections.

Access

Position of temp, cables, and step ladders inspected and of sufficient length (split head trestles not used as steps). Ladders inspected and secure gangways clear. Erection of suitable scaffold. Use of MEWP’s.

Environment

Noise control assessments, dust control (insulation), housekeeping (inc flammable debris) and waste disposal.

Equipment

Equipment inspection procedures. Scaffold inspection system visible to operatives.

Emergencies

Evacuation procedures/fire procedures/emergency lighting, access routes, alarm systems, first aid.

Communications

Posters, notices, tool box talks, wage packet inserts, videos, supervision.

COSHH

COSHH assessment for and including dusts (grinding) insulation.

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Supervision

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Other

Head protection, foot protection, overalls, eye protection, noise protection, gloves, RPE etc.

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PPE

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: FLOOR AND WALL TILING Significant risks:

Page 68

REF NO. 48

Inhalation, skin absorption or ingestion of harmful substances. Falls from heights, fire or explosions.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Operatives should be made aware of what materials are being used, The associated hazards and the required control measures to be applied. Induction training should cover site rules and action to be taken in the event of an emergency. Where appropriate operatives should be certificated for the erection of mobile tower scaffolds. Training should be provided in the safe use of respiratory equipment.

Instruction Training

Supervisors to ensure that equipment and plant is operated and erected ONLY by persons who have been trained, certificated and authorised to do so. Ensure that COSHH assessments have been produced and training provided. Ensure that suitable access is being provided and used and that all highly flammable materials are being stored in a safe manner.

Access

Safe means of access/egress must be provided and maintained. If working at height, an assessment should be carried out and suitable control measures employed. Mobile scaffold and access platforms must be properly erected with guardrails fitted where required and inspection details displayed. Adequate ventilation must be provided. Consideration should be given to the safe storage of flammable materials. Controlled waste must be properly disposed of. Equipment must be kept in good working order and be regularly maintained, with records being kept. The ventilation system provided should be checked regularly. Any mobile towers, scaffolding should be checked at least every seven days with a record of inspection being kept. If overcome by adhesive vapours, remove to fresh air, keep warm and fetch first aider, contact emergency services if necessary. Suitable fire procedures should be in place and fire extinguishers should be available. Standard site first aid, fire protection, evacuation, accident reporting and investigation procedures should be applied. Warning signs and notices and barriers as appropriate. Alternatives to harmful adhesives should be considered. Adequate ventilation should be provided, backed by respiratory protective equipment where necessary. Barrier cream or suitable gloves can be used to protect hands, overalls to protect remainder of body. Adequate hygiene facilities should be provided. Operatives should not eat, drink or smoke at the work location or when their hands are contaminated. Appropriate respiratory equipment if required. Goggles/glasses, gloves, safety footwear, overalls, helmets must be worn. Consideration should be given to work in confined spaces e.g. small rooms

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Supervision

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Emergencies

PPE Other

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: PAINTING & PAPERING Significant risks:

Page 69

REF NO. 49

Inhalation, skin absorption or ingestion of harmful substances. Falls from heights, falling materials, slips on spillages, fire or explosions.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Operatives should be made aware of what materials are being used, the associated hazards and the required control measures to be applied. Induction training should cover site rules and action to be taken in the event of an emergency. Operatives should be certificated for the erection of mobile scaffolds. Where appropriate training must be provided in the operation of MEWP’s. Training should be provided in the safe use of respiratory equipment. Safety method statement to be signed by all operatives.

Instruction

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Training

Supervisors to ensure that equipment and plant is operated and erected ONLY by persons who have been trained, certificated and authorised to do so. Ensure that COSHH assessments have been produced and training provided. Ensure that suitable access is being provided and used and that all highly flammable materials are being stored in a safe manner. Safe means of access/egress must be provided and maintained. If working at height an assessment should be carried out and suitable control measures employed. Ladders should be tied or footed. Mobile scaffolds and access platforms must be properly erected with guardrails fitted where required and inspection records displayed.

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Emergencies

PPE Other

Consideration should be given to the safe storage of flammable materials. Adequate ventilation must be provided. Controlled waste must be properly disposed of. Equipment must be kept in good working order and be regularly maintained, with records being kept. The ventilation system if provided should be checked regularly. Any mobile towers, scaffolding etc. should be checked at least every seven days with a record of inspection being kept. If overcome by paint vapours, remove to fresh air, keep warm and fetch first aider, contact emergency services if necessary. Suitable fire procedures should be available. Standard site first aid, fire protection, evacuation, accident reporting and investigation procedures should be applied. Warning signs and notices and barriers as appropriate. Alternatives to harmful paints, varnishes or adhesives should be considered. Adequate ventilation should be provided, backed by respiratory protective equipment where necessary. Barrier cream or suitable gloves can be used to protect hands, overalls to protect remainder of body. Adequate hygiene facilities should be provided. Operatives should not eat, drink or smoke at the work location or when their hands are contaminated with paint. Appropriate respiratory equipment if required. Goggles/glasses, gloves, safety footwear, overalls, helmets must be worn. Consideration should be given to work in confined spaces.

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Environment

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 70

RISK ASSESSMENT GUIDE REF NO. 50 Assessment for: USE OF SPECIALIST EQUIPMENT (NUCLEAR DENSOMETERS, THERMIC WELDERS AND LANCES, LASERS) H.P. WATER JETTING Significant risks:

Varies according to equipment i.e. radiation injuries, eye damage, general injuries to public and personnel.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Normally a specialist operation requiring Safety Method Statements. List of specialist equipment likely to be required to be drawn up and discussed with safety adviser. Establish and issue Safety Method Statements. Information from suppliers of equipment. Sub-contractor or manufacturer’s recommendations/training to be sought and personnel instructed as appropriate. Certificated operators. Information obtained will establish the extent of instruction required. As required for the particular type of specialist operation.

Instruction

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Training

Designated responsible person to be nominated to ensure that equipment is correctly used and method statement adhered to.

Access

Exclusion zones where appropriate.

Environment

To be monitored/controlled as required by manufacturers/codes of practice etc.

Equipment

To be obtained and used as manufacturers/specialist recommendations. Appropriate storage required.

Emergencies

Specialist first aid information to be obtained. Specialist emergency procedures to be set up as appropriate (nuclear densometer). Standard site safety reporting procedures apply.

Communications

Warning signs, hazard markers.

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Supervision

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Other

As required by particular process.

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As applicable to particular process.

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COSHH

A specific assessment should always be performed for an item of specialist equipment.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 71

RISK ASSESSMENT GUIDE REF NO. 51 Assessment for: USE OF CLASS 3B LASERS (PREDOMINANTLY IN CONFINED OR RESTRICTED AREAS) Significant risks:

Exposure to non ionising radiation (laser light) being caused by striking persons directly or indirectly (reflection) physical risks include eye damage, production of toxic gases, electrical hazards.

CONTROL ITEM Information Instruction/Training

The requirements for medical supervision should be assessed, in particular in the event of injury due to ocular exposure. Overall supervision shall be controlled by a competent person who has received adequate training. Class 3B lasers are potentially hazardous if a direct beam or specular reflection is viewed by the unprotected eye and therefore access must be strictly controlled to those people who have received the adequate information, instruction and training. The entrance to areas should be posted with a standard laser warning sign. The laser beam should be terminated where possible at the end of its path by suitable diffusion material. Reflections must be avoided. Location and direction of beam must be clearly marked. The equipment must be suitable for use and any maintenance requirements detailed.

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Supervision

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Environment

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Other

Emergency procedures must be linked in with the specific site procedures in particular when considering the hazards that exist including fire, electrocution etc. All relevant information should be communicated to all personnel involved. An assessment must be made if there are any identified hazardous environments in particular contamination from chlorine, hydrogen sulphide and bromine. The need to use PPE against the hazardous effects of laser operation should be kept to a minimum by admin controls, engineering design and beam enclosure. However where the risk exists the PPE may include eye protection, clothing, respiratory etc. A safe system of work should be devised (with all the other controls listed above) that reduces the risk by means of cutting down the operational times.

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Emergencies

PPE

DETAILS OF CONTROL MEASURES All personnel exposed to hazard/risk from the use of class 3B lasers shall receive information, instruction and training regarding the hazards and risks. Information should be sought from the supplier. All the above measures also include the provision, fitting and wearing of PPE.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

Page 72

REF NO. 52

Assessment for:

ARC WELDING

Significant risks:

Fire/flammable atmospheres, electric shock, noise, substances/chemicals/fumes/dusts, burns, radiation, heat, falls, trips and slips, flying particles, vibration, oxygen depletion, asphyxiation, manual handling. DETAILS OF CONTROL MEASURES Permits to work. (Confined space/hot work) Method statements.

Instruction/Training

Operatives trained in fire prevention methods/precautions.

Supervision

Regular inspection of barriers, fireproof screens and notices.

Access

Safe access egress to be provided and maintained. Consideration to be given to restricted access zone.

Environment

Good lighting. Dust and noise suppression methods.

Equipment

Flameproof welding screens. Fire protective equipment sited adjacent to welding set. Earthling of work piece.

Emergencies

Standard first aid, fire protection. Operatives inducted in emergency procedures and assembly points.

Communications

Warning signs and barriers. Permits to work.

COSHH

Local exhaust ventilation and others as required for location/materials used for welding.

PPE

Welding gloves, flameproof overalls, boots, spats, eye protection, and respiratory protection. Local exhaust ventilation.

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Other

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The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

REF NO. 53

Assessment for:

RADIOGRAPHY

Significant risks:

Radioactive substances, burns, inhalation radiation, contamination damaged/lost sources.

CONTROL ITEM Information Instruction/Training

Page 73

DETAILS OF CONTROL MEASURES Risk assessment/method statements. Permit to work. Approved subcontractors. All operatives to sign method statement/local rules. All operatives to receive induction training. Regular inspection of working barriers, signs and notices.

Access

Safe means of access/egress to provide and maintain to work area.

Environment

Safety zones/storage of sources. Audible warning systems available.

Equipment

Good working order regularly maintained. Records kept.

Emergencies

Operatives aware of emergency procedures and assembly points. Details of radiation protection adviser.

Communications

Barricade areas, warning notices posted, audible warnings of exposure of isotope.

COSHH

Assessment, information and instruction to all personnel

PPE

Film badges, safety helmet/footwear worn at all times. Eye/hearing protection as/when required. Hand/body protection as required.

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Supervision

Ensure supervision for out of hours working. Work to be carried out, outside normal working hours. Account will be taken of project standard requirements.

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Other

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The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

REF NO. 54

Assessment for:

COMMISSIONING PLANT

Significant risks:

Electrocution, steam/hot liquid scalds, toxic/flammable gas or liquid release, bursting of vessels/pipes/joints under pressure, falls from height, trapping or being struck by plant in motion.

CONTROL ITEM Information

Page 74

DETAILS OF CONTROL MEASURES Induction training should cover site rules and action to be taken in the event of an emergency. All operatives must be briefed on the hazards, precautions and emergency procedures before testing and commissioning starts. Operatives should be trained in the operation of the permit to work procedure and the actions required by the system. A formal testing/commissioning procedure must be prepared before testing/commissioning commences and operatives signed to confirm understanding. Leak testing will precede pressure testing; pressure testing should be carried out at the lowest pressure acceptable to the specifier / specification and should be avoided unless there are sound technical reasons for carrying out such tests. Hydraulic testing should be the preferred method where practicable. Supervisor must ensure that only authorised, experienced and competent persons will carry out testing and commissioning operations. Supervisor must ensure that the permit to work system is being properly operated and that all appropriate elements of the plant have been isolated locked off and specified safety devices have been provided. Safe means of access/egress must be provided and maintained. If working at height, an assessment should be carried out and suitable control measures employed. Ladders should be tied or footed, mobile scaffolds and access platforms must be properly erected with guardrails fitted and inspection records displayed.

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Instruction/Training

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Access

Access to commissioning and test areas must be restricted. Consideration must be given to the surrounding environment e.g. plant, operations etc. when planning and carrying out the works. Prior to the commencement of electrical testing and commissioning works a check should be made to verify that all switch rooms/control rooms have been cleared of loose materials and that all temporary installations have been removed. Equipment covers and doors are to be closed and guards refitted to machinery. Any circuits to be worked on will be treated as live until verified as dead. Equipment must be kept in good working order and be regularly maintained with a record of maintenance being kept. Only suitable and appropriate equipment must be used for testing and commissioning works. Suitable fire procedures should be in place and fire extinguishers available. Standard site first aid, fire protection, evacuation, accident reporting and investigation procedures should be applied. Warning signs, hazard markings and exclusion zones as appropriate. Assessments produced for material used in testing and commissioning operations, including possible emissions/discharges from plant in operation. Hard hats, protective footwear, gloves, goggles, overalls and any specialist equipment required e.g. insulation mats etc.

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Equipment

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Environment

Emergencies

Communications COSHH PPE Other

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

REF NO. 55

Assessment for:

BLOCK PAVING, FLAGGING KERBS AND EDGINGS

Significant risks:

Manual handling, materials/substances, plant and equipment, power tools, cutting, noise, dust, underground services, public protection (to and from).

CONTROL ITEM Information Instruction/Training

Page 75

DETAILS OF CONTROL MEASURES Necessary permits when adjacent to underground services. Safety signs, warning notices. Operatives to sign method statement as understood. Certification for abrasive wheel changing. Competent supervision, monitoring work activity.

Access

Safe means of access/egress provided and maintained.

Environment

Dust/noise suppression/reduction methods e.g. enclosure for omitting operations. Traffic protection – coning/signing/safety zones.

Equipment

Good working order regularly maintained. Records maintained. Segregate plant from pedestrians. Manholes cover handling equipment. Wet cutting of materials.

Emergencies

Operatives aware of emergency procedures and assembly point.

Communications

Provision of suitable safety signs, warning notices and barriers.

COSHH

Assessments, information and instructions given to operators. Personal hygiene essential.

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Safety helmets, footwear to be worn at all times. Eye/hearing protection to be worn as necessary. Yellow waistcoats adjacent to traffic.

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PPE

N/A

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Other

.

Supervision

m

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

REF NO. 56

Assessment for: Significant risks:

Page 76

ROAD/PATH SURFACING Manual handling, materials and substances, reversing vehicles, plant and equipment, underground services, noise, heat and fumes. Fire/explosion. DETAILS OF CONTROL MEASURES Method statements, safety signs, warning notices.

Instruction/Training

All operatives to sign method statement applicable to their work activity.

Supervision

Supervisors to ensure plant and equipment only operated by certificated authorised persons. Traffic management.

Access

Safe means of access/egress in/around plant and equipment segregate plant from pedestrians/traffic.

Environment

Noise and dust suppression. Traffic protection – coning/signing/safety zones.

Equipment

Good working order regularly maintained. Records kept. Overhead power lines suitably protected. Reversing alarms fitted to equipment.

Emergencies

Operatives aware of emergency procedure and assembly points. First aid treatment for burns.

Communications

Warning signs, audible warnings, suitable barriers.

COSHH

Assessment, information and instructions.

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CONTROL ITEM Information

Safety helmets/footwear to be worn at all times. High visibility clothing to be worn at all times. Eye/hearing protection to be worn when necessary. Hand/body protection as required. Traffic management schemes. Interface/overlap with Client personnel/members of public.

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Other

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PPE

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

REF NO. 57

Assessment for: Significant risks:

Page 77

FENCING (PERMANENT) Manual handling, materials and substances, noise, underground/overhead services, plant and equipment. DETAILS OF CONTROL MEASURES Method statement/utilities drawings/permit to dig.

Instruction/Training

All operatives inducted in site requirements/manual handling/buried services. All operatives to sign method statement applicable to their work activity.

Supervision

Competent supervision. Supervisor to ensure on trained, certificated authorised persons use/operate plant and equipment.

Access

Safe means of access/egress to provide and maintain to work area. Segregate plant/equipment from pedestrians.

Environment

Noise and dust suppression methods. Soil analysis.

Equipment

Good working order, regularly maintained and records kept. Overhead power lines suitably protected.

Emergencies

Operatives aware of emergency procedure and assembly points.

Communications

Warning signs and notices, suitable barriers and audible warnings on plant and equipment. As appropriate to work/location.

COSHH

Assessment, information and instruction given to all operatives e.g. preservatives/paints.

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CONTROL ITEM Information

Safety helmets/footwear to be worn at all times. High visibility clothing when adjacent to traffic routes. Eye hearing protection as necessary. Interface/overlap with Client personnel/members of public.

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Other

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PPE

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

REF NO. 58

Assessment for: Significant risks:

Page 78

LANDSCAPING Manual handling, materials and substances, plant and equipment, overspray of substances, noise. DETAILS OF CONTROL MEASURES Method statements, safety signs, warning notices, buried services, overhead services.

Instruction/Training

Operatives trained in use of pesticides. All operatives to attend induction training. All operatives to sign method statement applicable to their work activity.

Supervision

Competent supervision. Supervisors to ensure only trained certificated and authorised persons use pesticides, plant and equipment.

Access

Safe means of access/egress to provide and maintain segregation of plant from pedestrians.

Environment

Noise and dust suppression methods. Safe storage of pesticides/disposal of containers.

Equipment

Good working order regularly maintained. Records kept. Check gradability of plant on slopes.

Emergencies

Operatives aware of emergency, procedure and assembly points.

Communications

Warning signs, warning notices, suitable barriers and audible warnings.

COSHH

Assessment, information and instruction given to all operatives.

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CONTROL ITEM Information

Safety helmets/footwear to be worn at all times. High visibility clothing to be worn when adjacent to traffic routes. Eye/hearing protection when necessary. Respiratory protection as required. Interface/overlap with Client personnel/members of public.

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Other

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PPE

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 79

RISK ASSESSMENT GUIDE REF NO. 59 Assessment for: TREE SURGERY AND CROSS CUTTING OF TIMBER WITH A CHAINSAW Significant risks:

Falling from heights, falling objects, uncontrolled fall of trees/limbs, personal injury from cutting equipment, injury to members of the public/passing vehicles.

CONTROL ITEM Information Instruction/Training

DETAILS OF CONTROL MEASURES Safety method statement to be signed by operatives. All operatives felling trees to have received training from recognised body in ‘Tree Surgery’. Those engaged in ‘cross cutting’ of timber with a chainsaw are to have received, as a minimum, training in use of chainsaw ‘cross cutting’. Whilst cutting operations in progress a minimum of one person trained as above to supervise. No burning of debris on site.

Access

If possible low level branches to be cut from footed ladders or mobile scaffolds, high level tree cutting to be done using approved harness and lines. Ensure that operative attaches away from cutting point and above.

Environment

Consider noise, refueling away from drains/watercourses. Ensure saw dust/chips not causing airborne hazard. All chainsaws to have chain break. Chains to be sharp. Test certificates for harnesses and ropes.

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Supervision

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Equipment

Rescue from height of injured person. Ensure communications are available on site. First aider to be on site. Fire extinguisher for refuelling operations

Communications

Radio/mobile phones to communicate in the case of emergency.

COSHH

COSHH assessment’s required for petrol, chain oil and two stroke oil. Check type of wood being cut, sawdust of some trees could be a hazard.

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Emergencies

Forestry type safety helmet, visor and ear protection, chainsaw protective trousers, jacket and gloves. Respirator protection as appropriate to type of wood being cut forestry type safety boots. High visibility tabard when working in traffic management. NOTE: harnesses for tree surgery are different from general purpose harnesses.

Other

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PPE

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

REF NO. 60

Assessment for: Significant risks:

Page 80

FIRE PREVENTION WORKING AREAS Burning, explosion, asphyxiation, electrocution and structural collapse.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Obtain material manufacturer’s data where applicable. Provide site fire plan. Liaise with the Civil Defence (Fire Department) as appropriate to the construction undertaken. If applicable fire points to be identified and put on plan and post at relevant positions. Induct employees on methods and procedures where fire risk is apparent. Safety awareness talks. Where applicable employees are to be trained in evacuation and the proper use of the correct types of fire extinguishers.

Instruction

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Training

Site management to ensure that sufficient suitable fire extinguishers are correctly positioned, maintained and inspected and additionally ensure that accesses are kept clear and materials suitably stored. Use of fire watchmen during and after hot work operations. Issue/monitor hot work permit.

Access

Suitable accesses/escape routes are to be kept clear of obstructions.

Environment

Consideration is to be given to the safe storage of flammable materials and fuels. Ensure cleanliness, tidiness, control of burning, regular disposal of waste. Consider damping down where there may be a risk of self ignition. Establish no smoking zones/site where risk is apparent.

Equipment

Site electrical equipment is to be tested and certified at 3 monthly intervals. Monitor plant for leakage/fuel spillage.

Emergencies

Standard site first aid, fire protection, evacuation, accident reporting and investigation. Major incident response plan.

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Supervision

Other

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PPE

N/A

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COSHH

Warning signs and audible alarms where appropriate.

o

Communications

Use as appropriate to operation i.e. welding, burning. Hot work permits will be required in high risk areas.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: FIRE PREVENTION IN OFFICE Significant risks:

Page 81

REF NO. 61

Burning, explosion, asphyxiation, electrocution.

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES Carry out a risk assessment on the premises and produce a fire plan. Induct employees on escape procedures and the hazards of construction, convection, radiation and direct burning. Instruction manuals are to be provided for equipment. Safety awareness talks. Staff must be trained in evacuation and the proper use of the correct types of fire extinguishers.

Instruction

Training

Appoint fire warden as appropriate. The office manager is to ensure that sufficient and suitable fire extinguishers are correctly positioned, maintained and inspected together with carrying out 6 monthly fire drills where applicable. Emergency routes and exits are to be clearly identified and kept clear of obstructions, establish suitable assembly points. Emergency exits are to remain unlocked on the inside at all times.

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Supervision

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Access

Consideration to be given to the effects of weather and in particular dust, externally, rain leakage, wind and flooding. Consideration is to be given to the safe storage and flammability of solvents, fluids and canisters.

Equipment

Electrical equipment is to be electrically tested and certificated at intervals no greater than 12 months, temporary office accommodation every 3 months. Alarms, extinguishers, hose reels, sprinklers, smoke detectors to be tested in accordance with procedures. Emergency lighting is installed/tested where appropriate.

Emergencies

Standard site first aid, fire protection, evacuation, accident reporting and investigation.

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Environment

Other

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PPE

N/A

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COSHH

Warning advisory signs and alarms.

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Communications

Generally not applicable. Ensure tidiness, control of smoking, regular disposal of waste. Give attention to the effects of dust on office equipment. Ensure availability of water and clear access for emergency services.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 82

RISK ASSESSMENT GUIDE REF NO. 62 Assessment for: OFFICE ENVIRONMENT (PERMANENT AND TEMPORARY INSTALLATIONS) Significant risks:

Fire, visual fatigue, manual handling injuries, poor internal environmental i.e. ventilation, temperature etc. Poor design and layout.

CONTROL ITEM Information

Instruction/Training

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Supervision

DETAILS OF CONTROL MEASURES Obtain details of hazards from manufacturers for any special equipment/materials. Assessment on VDU operators and provision of appropriate information. Manual handling review. Regular fire practices, instruction on safe use of specialist equipment/materials. Also instruction on use of fire extinguishers. Safety awareness talks. As appropriate to equipment used and task being undertaken. Appoint a fire warden. Ensure regular checks on firefighting equipment etc. as well as all electrical installations/equipment. Keep register. To be maintained as required by fire precautions also in generally good condition. Prevent trip/fall hazards from trailing leads.

Environment

To be kept clean and clear of debris. Noise to be monitored if immediately adjacent to the works. Consider limitations on smokers. Establish adequate ventilation and temperature controls. Lighting requirements ergonomic layout of work stations. Security/location (access for visitors). No smoking policy.

Equipment

To be kept clean, regularly maintained and tested.

Emergencies

Standard first aid, fire protection, evacuation, accident reporting and investigation.

Communications

Warning advisory signs, hazard markers and use of notice boards as appropriate.

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Access

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Other

Not applicable

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PPE

As appropriate to solvents, fluids and adhesives etc.

o

COSHH

Ensure general welfare conditions such as toilet facilities and heating are to requirements. Give consideration to disabled facilities. Regular inspection.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: YOUNG PERSON IN CLERICAL POSITIONS (SITE) Significant risks:

Page 83

REF NO. 63

Fire, visual fatigue, manual handling injuries, slips trips and falls, overturning filing cabinets, electricity, office machinery.

Training

DETAILS OF CONTROL MEASURES Induction carried out. Site specific induction required. Training required in specific items of office equipment involved in tasks. Manufacturers/suppliers equipment information to be available.

Supervision

Close supervision required.

Access

Safe means of access/egress to be provided and maintained. Trailing cables to be protected / routed to eliminate possible slips/trips/falls.

Environment

Adequate ventilation, temperature. Lighting and cleanliness provided and maintained.

Equipment

Young persons to be trained in use of all types of office equipment involved in tasks. Do not overload electrical sockets. Cabinets to be secured to prevent overturning.

Emergencies

Emergency routes not to be obstructed. Fire test/drills to be observed and acted upon where necessary. All accidents however minor to be reported.

Communications

Use of notice boards as appropriate. Direct contact with line managers.

COSHH

Should not be applicable except in use of solvent based correction fluid.

PPE

Not applicable in present environment – if on site must be closely supervised and wear appropriate PPE i.e. safety helmet, safety footwear.

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CONTROL ITEM Information Instruction

Manual handling assessment to be carried out for replacing paper rolls on large printer. When assessment formulated young person to receive copy and be advised of contents/trained. Work area to be checked by young person at end of each shift to ensure no cigarettes/combustible materials smoldering.

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Other

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: CABLE PULLING OPERATIONS Significant risks:

Page 84

REF NO. 64

Electrocution, falls of persons, falls of materials, fire, manual handling DETAILS OF CONTROL MEASURES Risk assessments and safety method statements. Permits to work (electrical systems). Operatives to work to safety method statements. Operatives to sign safety method statements. Documentation for lifting equipment/gear. PPE. Layout drawings. Design checks.

Instruction/Training

Inductions. Safety Awareness Talks. Permit to work procedures. Mobile tower erection. PPE.

Supervision

Permit to work issue. Competent persons appointment. Electrical Duty Holder. Operation of scaff tag system. Workplace inspections. Work under competent person. Careful planning of cable route.

Access

Provision of adequate access equipment. Inspection training in erection. Use of competent persons to erect.

Environment

Waste disposal of offcuts. Overhead services. Adjacent existing services. Integrity of existing tray supports to be investigated. Suitable anchor points for attaching harnesses. NB Not from tray supports unless properly tested for adequacy. Suitable access for vehicles. Level ground for jack supports.

Equipment

Certification for winches/tirfors. Check SWL. Barriers of suitable construction and design. Adequate number of rollers available. Rollers of correct size and type. Appropriate size cable stacking to be provided. Appropriate support of cable drum.

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CONTROL ITEM Information

Evacuation procedure/fire procedure/emergency lighting. Access routes, alarm systems, first aid.

PPE

Other

Tool box talks, supervision, warning signs, liaison with other contractors/client personnel.

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COSHH

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Communications

o

Emergencies

Assessments as appropriate to operation. Head protection, safety footwear, (high visibility clothing, hearing protection, eye protection as identified in risk assessment). Segregation of third parties from operations.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: WORKING IN CHEMICAL/RADIOACTIVE DRAINS Significant risks:

Page 85

REF NO. 65

Contact with unsealed sources of chemicals and radiation, injury through skin puncture, ingestion, absorption, toxic/explosive fumes, entrapment and fall injuries, spread of contamination, improper disposal

CONTROL ITEM Information

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Instruction/Training

DETAILS OF CONTROL MEASURES Obtain information from the Client and establish a safe system of work within the requirements of a permit to work system. Produce a detailed hazard risk assessment. Operatives to sign safety method statement. Personnel to be made aware of the types of chemicals/radiation and the possible dangers. If classified personnel are to work in radioactive drains their current dosage rates must be assessed and taken into account before entry into the drain is permitted. Operatives to be made aware of procedures for contact with chemicals or radioactive substances. Operatives taking samples or wipe testing ductwork must be made aware of the procedures laid down in the safety method statement and suitable demonstrations and briefings on the methods of handling contaminated materials must take place and must include the correct use of PPE and personal hygiene. A competent person is to obtain appropriate information e.g. previous/current used materials/concentrations on the contaminated substances and supply reports and results of analysis.

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Supervision

Exclusion zones to be set up with permit to work system. Designated safe access as necessary to the type and level of contamination discovered.

Environment

Consider the risk of local flooding to drains especially if ductwork has been stopped with drainage bungs. Special waste to be considered.

Emergencies

Together with standard procedures for first aid, evacuation, fire and explosion. Specific procedures to suit any contaminants present.

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Access

PPE Other

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Specialist advice to be sought from a Radiological Protection Adviser.

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COSHH

Warning signs, Bio-hazard, chemical hazard markings and exclusion zones as are appropriate.

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Communications

Visor, gauntlets, waders/wellingtons, chemical suit as levels demand. Full BA or airflow system. Rescue winch, safety harness, special waste bags for disposal of contaminated equipment, Geiger counter, sample tubes, air monitor, compressor for airflow system, wash down matting, communication system e.g. radio.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: BRICK/BLOCKWORK OPERATIONS Significant risks:

Page 86

REF NO. 66

Falling from height/through work-face, slips, trips and falls, manual handling, contact with hazardous substances, noise/vibration, confined spaces, contact with machinery/transport, dermatitis, falling from ladders, cut/abrasions, eye injury, falling through floor voids.

CONTROL ITEM Information / Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Specific risk assessment and safety method statement explained to operatives, copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Manual handling training including repetitive injury identification. COSHH training identified. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement ensure statutory registers and plant certification is up to date. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement, ensure routes are free of debris and safe. Area free of contaminates including dust, slippery conditions and lighting sufficient. Confined spaces (permits completed). Plant/transport/operative separation. All required edge protection around working platforms in place/precautions in place to eliminate falling through work-face and/or internal fall protection platforms or rails etc. provided. Hop-up systems at suitable width. Brick-guards in place prior to loading out platforms. Other persons not to work below brick/block work operations. Tools, mixers, scaffolding, clippers, fork-lift trucks, low vibration tools obtained. All lifting equipment in good order and certificated /inspected. All emergency notices displayed, all personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Tool box talks on regular basis, safety reminders, no access notices and incomplete notices displayed. COSHH information obtained for all products including MMMF, assessments carried out alternative materials/systems of work identified. Safety helmets, gloves, safety footwear, eye protection, noise protection(noise assessments done), cover-alls.

Access

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Environment

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Emergencies

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Other

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PPE

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COSHH

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 87

RISK ASSESSMENT GUIDE REF NO. 67 Assessment for: CLEANING STRUCTURE INTERNALLY PRIOR TO HANDOVER Significant risks: Falls from heights, slips, trips and falls, cuts/abrasions, contact with hazardous substances(including biological agents), noise/vibration, contact with machinery, contact with electricity, manual handling. CONTROL ITEM Information / Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Specific risk assessment and safety method statement explained to operatives copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Manual handling training including repetitive strain injury identification. COSHH training identified. Training and instruction provided in correct use of plant and equipment. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement ensure statutory registers and plant certification is up to date. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement, ensure routes are free of debris and are maintained in a safe condition. Work to be planned so that only one trade working in an area at a time. Proper and suitable access equipment to be provided. Sufficient lighting to be provided, area to be kept clear of obstructions and all trailing cables managed and minimised. Warning notices to be placed on wet floors, electric shock possible by the overzealous use of water in the vicinity of electrical sockets (isolation of electrical supply maybe required). All sharp tools to be carried in holder/sheath, plant/equipment inspected and maintained in good order, low vibration tools used where possible. All emergency notices displayed, all personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Tool box talks on regular basis, safety reminders, no access notices and incomplete notices displayed. All substances potentially hazardous to health will have COSHH assessments carried out on them and the circumstances of their use, alternative materials/systems of work identified. If biological hazards are encountered COSHH assessment to be carried out. Safety helmets, gloves, safety footwear, eye protection, noise protection(noise assessments done), cover-alls. Do not use plastic overshoes when working from steps or ladders. Limitation of access permits for clean areas.

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Access

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Environment

Equipment

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Emergencies

Communications

Other

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PPE

o

COSHH

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 88

RISK ASSESSMENT GUIDE REF NO. 68 Assessment for: USE OF LADDERS TO CARRY OUT GENERAL TASKS AT HEIGHT Significant risks:

Falls from heights, contact with overhead power lines

CONTROL ITEM Information /

Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Staircases to be used as an alternative to ladders. Ladders are only to be used as a result of a specific risk assessment that shows no alternative can be identified. Safety method statement to be explained to operatives copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Manual handling training, instruction and training in the safe erection, use and lowering of ladders required. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement/risk assessment, ensure routes are free of debris and are maintained in a safe condition, avoid others working below/near the ladder. NB: remember three points of contact rule when working from a ladder. Do not carry equipment/materials whilst climbing ladders. Climb holding onto the rungs when climbing vertical ladders and it is safer using this method on inclined ladders. Sufficient lighting to be provided, area to be kept clear of obstructions, ensure equipment is only used in the correct environment (firm level ground), if un-insulated over-head power lines are present all operatives to be informed of potential contact hazard - do not use metal ladders. Regular inspection of equipment to ensure safe use, all ladders to be tied off or footed when 3m or more high. Always foot the ladder whilst securing. Never climb to very top rung/tread of ladder/step, all damaged equipment to be removed from service immediately, where reasonably practicable use a safe means of access. All emergency notices displayed, all personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Tool box talks on regular basis, safety reminders. Not Applicable Safety helmets, gloves, safety footwear. Ladders should only be used for short term work, and priority must be given to other forms of access particularly if plant or equipment is to be used at height. Operate Permit system.

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Access

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Environment

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Communications COSHH PPE Other

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Emergencies

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

Page 89

RISK ASSESSMENT GUIDE REF NO. 69 Assessment for: LEAD BURNING/PLUMBING WORK - Lead burning(welding) of lead sheet or pipe Significant risks: Inhalation, ingestion or absorption of the toxic substance. Manual handling heavy lead, fire, lead spatter from molten lead. CONTROL ITEM Information / Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Specific risk assessment and safety method statement explained to operatives copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Manual handling training required, operatives should be informed of associated hazards and relevant control measures before work begins, operatives should have received extensive trade &safety training in this work, operatives should be trained in fire prevention and use of fire extinguishers. Managers/supervisors should be adequately trained to monitor work. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement. Ensure that safety equipment provided is used correctly and control measures followed. Ensure "Hot Work" permit system used. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement, ensure routes are free of debris and are maintained in a safe condition. Work to be planned so that only one trade working in an area at a time. Proper and suitable access equipment to be provided. Eating, drinking and smoking prohibited in all areas likely to be contaminated by lead. Adequate washing & changing facilities provided/used by operatives to ensure good personal hygiene, workers must wash hands/arms thoroughly & scrub under nails to remove traces of lead. All equipment must be inspected and maintained in a good condition. Firefighting equipment must be inspected and be of a suitable type. All emergency notices displayed, all personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Tool box talks on regular basis, safety reminders. The degree of exposure to lead should be assessed by a competent person to determine if exposure is significant or not, where exposure significant local exhaust ventilation should be used to reduce exposure levels to an insignificant level. Medical surveillance should be carried out if exposure is significant Appropriate personal protective equipment (PPE) should be issued to and worn by operatives, this will include safety helmets, safety footwear, gloves, eye protection, respiratory protection and cover-alls. No contaminated clothing or PPE should be taken into canteens/welfare facilities.

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Access

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Environment

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Equipment

PPE

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Communications COSHH

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Emergencies

Other

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: MOBILE ELEVATED WORKING PLATFORMS Significant risks:

Page 90

REF NO. 70

Falls of persons, falls of materials, striking against fixed structures, collision with other plant, overturning platform.

CONTROL ITEM Information / Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Specific risk assessment and safety method statement explained to operatives copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Only trained and certificated operatives to operate plant. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement. Ensure that safety equipment provided is used correctly and control measures followed. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement, ensure routes are free of debris and are maintained in a safe condition. Work to be planned so that only one trade working in an area at a time, control traffic and pedestrians, segregate the work area, beware of use of trailing leads for power tools (entanglement or tripping). Ensure ground conditions are suitable Inspected and maintained in a good condition. The manufacturer's maintenance schedule should be followed, proof of maintenance, inspection and testing must be obtained. Ensure MEWP's SWL (Safe Working Load) is adequate for the work. Stabilisers used where necessary, MEWP's should not be moved at height unless designed for it. All personnel induction will include emergency alarms, escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Emergency plan and safety method statement shall include need to get persons from the platform whilst still elevated. (Control key available at ground level where needed to operate controls from that position) Tool box talks on regular basis, safety reminders. Not Applicable Appropriate personal protective equipment (PPE) should be issued to and worn by operatives, this will include safety helmets, safety footwear, gloves, eye protection, respiratory protection and cover-alls depending on work carried out from platform. Safety harnesses must be worn and secured to a suitable anchorage point whilst operatives are in the platform. Collision with any structure or other plant should be reported immediately and the damaged assessed. NB: frequent accidents occur when operatives trap their hands between the upper guard rail of the MEWP and fixed structures. Regularly remind operators of this hazard.

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Access

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Environment Equipment

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Communications COSHH PPE

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Emergencies

Other

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: UNLOADING OF VEHICLES Significant risks:

Page 91

REF NO. 71

Being struck by a maneuvering vehicle, falling objects, falls of persons off the load platform.

CONTROL ITEM Information /

Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Specific risk assessment and safety method statement explained to operatives copies issued as requested and signatures obtained. Daily briefings of operatives by supervisors. Safety induction carried out and signatures obtained. Only trained and certificated operatives to act as banks man. Only trained and certificated operatives to use plant for unloading (cranes, hiab, fork-lift, excavators). Instruction on loads to be obtained, instruction on safe methods required eg. Sequences of unloading and release of restraints. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement. Ensure that safety equipment provided is used correctly and control measures followed. Ensure safe access and egress is provided and of sufficient width. Identify all aspects of access on safety method statement/risk assessment, ensure routes are free of debris and are maintained in a safe condition. Work to be planned so that access by traffic and pedestrians is controlled, segregate the work area. Ensure ground conditions are suitable, ensure offloading area is as level as possible, if unloading area is sloping, extra care must be taken with whole sequence of events. Ensure good standard of lighting for the work area. Minimise number of people in offloading area. All equipment must be inspected and maintained in a good condition. Ensure SWL (Safe Working Load) of lifting equipment and gear is adequate for the work, obtain load weights and centre of gravity before moving anything. Stabilisers to be used where necessary. All personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Tool box talks on regular basis, safety reminders. Delivery driver to be fully consulted and briefed prior to unloading. COSHH assessment should be carried out prior to handling potentially hazardous materials; this should take cognisance of possible spilled materials. Appropriate personal protective equipment (PPE) should be issued to and worn by operatives, this will include safety helmets, safety footwear, gloves, cover-alls and high visibility clothing. Eye protection, respiratory protection may be required depending on materials being handled, Wherever possible, minimise human involvement by using mechanical handling methods, where manual handling is required ensure that enough trained handlers are available. Follow safe system for release of all load restraints and sequence of unloading, inspect load for shift prior to release as load may have worked loose during transit.

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Access

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Emergencies

PPE

Other

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COSHH

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Communications

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: USE OF STEP LADDERS Significant risks:

Page 92

REF NO. 72

Falls from heights, contact with overhead power lines, falling tools & materials

CONTROL ITEM Information

Instruction / Training

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Supervision

DETAILS OF CONTROL MEASURES Safety induction carried out and signatures obtained. Specific risk assessment and safety method statement explained to operatives and signatures obtained. Manual handling training, instruction and training in the safe erection, use and lowering of step ladders required. Stress overstretching as main cause of falls and never to climb to very top tread / step the knees of the person using the step ladder should be kept below the top of the steps. Daily briefings of operatives by supervisors. Adequate levels of competent supervision to be maintained. Supervision to update general risk assessment as project progresses. Ensure workplace is inspected prior to operative placement. Check training/instruction given to all operatives. Ensure clear, well-lit access/egress. Identify all aspects of access on safety method statement/risk assessment Sufficient lighting to be provided, area to be kept clear of obstructions. Step-ladders should only be used on firm, level ground. If un-insulated over-head power lines are present all operatives to be informed of potential contact hazard - do not use metal ladders. Avoid others working near / below the step ladder.

Access

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Environment

Equipment

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Where risk assessment dictates a safer means of access should be

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used, i.e. mobile access scaffold or mobile elevated work platform

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(scissor lift / cherry picker) etc.

Emergencies

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Regular inspection of equipment to ensure the treads /steps, bolts, screws and fixings are sound and secure. Retaining cords or hinges should be equal length and in good condition, all damaged equipment to be removed from service immediately. The step-ladder must be stable when open and standing on a level base. The legs of the step-ladder should be positioned as far apart as the retaining cord or hinges allow, with all four legs firmly on the ground. They should be set at right-angles to the work, whenever possible. All emergency notices displayed, all personnel induction will include emergency alarms escape routes/directional notices. Emergency procedures displayed, first aid identified and drills carried out. Safety awareness talks on regular basis, safety reminders.

Communications COSHH PPE Other

Safety helmets, gloves, safety footwear, overalls. The use of plastic overshoes should be avoided on step-ladders. Step-ladders should only be used for short-term work or where space restricts the use of safer working places particularly if plant or equipment is to be used at height.

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE Assessment for: TRAFFIC MANAGEMENT Significant risks:

Page 93

REF NO. 73

Impact injury to workforce/accidents to public and vehicles

CONTROL ITEM Information

DETAILS OF CONTROL MEASURES A full traffic management scheme detailed out which caters for: flow of public vehicles; access and egress of work vehicles; safety zones; pedestrian routes; provision for Emergency Services. Method statements for installation of such schemes will also be required on major schemes.

Instruction

To include all identified requirements of safe system of work and method statements. Layout drawings, appropriate experienced personnel only to be used for actual installation/removal of traffic management works.

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Training

Supervision

An experienced member of staff to be nominated as the Traffic Safety Coordinator to check all traffic management works and monitor systems. By designated signed access and egress points only. Prevent unauthorised access. Adverse weather to be taken into consideration. Glare, live traffic, lighting, snowing, any obscured traffic signs must be cleaned as soon as reasonably practicable or work stopped if practicable Suitably marked vehicles with flashing lights if required. Assess the need for a planned preventative maintenance scheme. Emergency lane if required. Emergency call out/liaison list to be established. Vehicle recovery to be in attendance if specified. Standard site first aid, fire protection, evacuation, accident reporting and investigation. Emergency procedures to be detailed in contract safety plan. Radios for traffic management team. Mobile phones/radios for traffic safety co-ordinator. Information signs. Close liaison with police. No Applicable

Access

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Environment

Equipment

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Emergencies

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Communications

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COSHH

High visibility clothing, hard hats, etc.

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PPE

Ensure adequate provision of spare signs, cones and markers to cover loss and waste.

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Other

The above controls have been selected to protect the health and safety of operatives and others who may be affected by the work. This assessment must take into consideration all relevant Company Safety Documents and must be used when compiling a site specific method/task statement/procedure.

QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

RISK ASSESSMENT GUIDE

REF NO. 74

Assessment for: Significant risks:

CONTROL ITEM Information

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Instruction Training

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Supervision

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Access

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Environment

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Equipment Emergencies

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Communications

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COSHH

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Other

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PPE

Page 94

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Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

2.4.20.2

Appendix B: Example of a risk assessment for erecting roof trusses

Signature..........................

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Risk and identity of persons who might be harmed

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Hazard

Serious injury, death (anyone working at height)

Level of uncontrolled risk

High

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Working at height (general)

Workers being struck by falling objects

Controls introduced to reduce risk

Assessed level of remaining risk

Work at height only carried out by workers who are competent to do so Low

Injury, possibly serious, or death from being struck by a falling object (anyone on site who might be passing below)

High

Working platform to be fully boarded and adequately sheeted or netted. Entrances to buildings protected by nets or fans. Exclusion zones to be created and monitored where necessary Low Debris guards properly fitted to all elevations of working platform

Electrocution - serious burns and death (anyone working at height)

High

If possible, arrange for supply to be turned off for duration of job. As a minimum, arrange for electricity supply company to sheath the cables Toolbox talk on electrical safety given to all who will be required to work at height, including scaffold contractors If cables remain live, monitoring that safety distances are being maintained

Site manager Before work at height starts

All waste materials transferred to ground level via a waste chute

Presence of live overhead electrical cables

Action placed on, and by when

A safe working platform with edge protection and a safe means of access and egress provided

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Workers falling from height

Position in company..................................

Date risk assessment due a review ..................

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Process

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Risk assessment compiled by......................................

Risk assessment number.................................

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Contract number / name.............................................

Date risk assessment compiled.............................

Page 95

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QCS 2014

Low

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QCS 2014

Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement Risk and identity of persons who might be harmed

Hazard

Level of uncontrolled risk

Controls introduced to reduce risk

Slips and trips at height (anyone working at height)

Medium

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Debris left on scaffold platforms

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Process

Page 96

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Slips and trips at height and during access/egress (anyone working at height)

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Adverse weather conditions

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Working at height (general) (continued)

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Off-loading trusses from delivery Manual handling injuries lorry (delivery driver/carpenters)

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Raising trusses to roof height

Falling through trusses whilst fixing

Manual handling injuries (carpenters)

Cuts, broken bones, serious injury, death (carpenters)

Electrocution - serious burns and death (anyone working at height and crane driver)

Low

Waste skips provided to enable the disposal and segregation of waste

Work suspended during adverse weather conditions. Site manager to monitor

Low Low

Medium

Trusses off-loaded and transported

Low

Medium

High

Roof truss assembly to be prefabricated at ground level and crane to be hired to lift it into place

Close-boarded scaffold platform, complete with guard-rails erected at eaves height. Consider installing safety nets across span of building if suitable fixing points and sufficient clear height below net are available. Otherwise install soft landing system below

Low

Site manager Before handling of roof trusses starts

Low Lifting operation to be under the control of a competent person. Safe working distance between electrical cables and crane to be maintained at all times

Site manager

Low

Electricity supply company contacted to establish minimum safe working distance for crane High

Action placed on, and by when

Before work at height starts

Medium

Erection of roof trusses

Presence of live overhead electrical cables

All contractors instructed to clear up their waste materials within a reasonable time of it being created and before it becomes a hazard

Assessed level of remaining risk

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Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement Risk and identity of persons who might be harmed

Hazard

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Process

Level of uncontrolled risk

Unstable and unsafe lifting operation resulting in equipment failure and/or dropped load (anyone in the vicinity)

Medium

Controls introduced to reduce risk

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Medium

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Other plant activity

Injury to pedestrians caused by insecure load falling from machine (any site worker on foot)

Person injury resulting from the use of defective hand tools (carpenter)

Contract lift organised using the equipment and staff of a reputable crane-hire company

Medium

All plant operated by trained, competent operators

Physical segregation of plant and pedestrians as far as is possible

Low

Toolbox talk on safe plant operations given to everyone on site Low

All tools fit for purpose and maintained in good condition

Use of hand tools and power tools

Low Electric shock resulting from the use of defective power tools (carpenter)

Medium

Battery tools used where practical. Otherwise only 110 volt tools used. Checks made that all power tools have a current PAT test sticker

Action placed on, and by when

Site manager

Persons not involved in lifting operation excluded from the area

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Workers being run over or suffering crush injuries (any site worker on foot)

Assessed level of remaining risk

Low

as

Lifting operations

Erection of roof trusses (continued)

Page 97

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QCS 2014

Before handling of roof trusses starts

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Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement

2.4.20.3

Appendix C: Example of a risk assessment for loading out and fixing tiles

Signature..........................

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Risk and identity of persons who might be harmed

Hazard

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Process

Position in company..................................

Date risk assessment due a review ..................

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Date risk assessment compiled.............................

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Risk assessment compiled by......................................

Page 98

Risk assessment number.................................

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Contract number / Name.............................................

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QCS 2014

Level of uncontrolled risk

Controls introduced to reduce risk

Assessed level of remaining risk

Action placed on, and by when

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Working at height See risk assessment for handling generally and erecting roof trusses

Loading out and fixing tiles

Abrasions to the skin of the hands potentially leading to dermatitis (tiling contractors)

Medium

Manual handling injury from carrying tiles

Rigger gloves to be provided and worn at all times that tiles are being manually handled

Low

Site manager

Palletised tiles to be moved to vicinity of where they will be used by telehandlers Strains and other manual handling injuries (tiling contractors)

Medium

Powered inclined hoist to be used to transfer tiles to roof level. Hoist to be loaded, off-loaded and operated by a competent person Toolbox talk on manual handling to be given to tiling contractors

Before manual handling of tiles commences Low

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Section 11: Health and Safety Part 2.4.01: Risk Assessment Guides and Method Statement Risk and identity of persons who might be harmed

Hazard

Level of uncontrolled risk

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Process

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QCS 2014

as

se

Serious burns and death (tiling contractors)

Assessed level of remaining risk

Action placed on, and by when

Site manager High

Toolbox talks on electrical hazards to be given to tiling contractors

Low

Before manual handling of tiles commences

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Inclined hoist to be positioned to maintain a safe working distance from cables

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Tiling contractors to observe minimum safety distance. Site manager to periodically monitor

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Loading out and fixing tiles (continued)

Controls introduced to reduce risk

Investigate feasibility of electrical supply being turned off. As a minimum, arrange for electricity company to sheath cables

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The presence of live overhead electrical cables

Page 99

Scaffold collapse

Necessary load rating of scaffold agreed at contract stage. Loading bays to be included Serious injuries or death (anyone working at height or at ground level in vicinity of scaffold)

Medium

Scaffold erected and inspected as necessary by a competent scaffold contractor

Low

Tiling contractor informed of loading [imitations around eaves-level working platform. Periodic monitoring by site manager

Person injury resulting from the use of defective hand tools (carpenter)

Low

Site manager

All tools fit for purpose and maintained in good condition

Use of hand tools

Low Slips and trips resulting from tools being left lying around (carpenter)

Medium

All tools returned to tool box or tool-belt when not in use

Before handling of roof trusses starts

QCS 2014

Section 11: Health and Safety Page 100 Part 2.4.01: Risk Assessment Guides and Method Statement

2.4.20.4 Appendix D: Suggested Structure for Written Method of Work (Section 1.1.7 of the Regulatory Document) The structure for a complete written method of work is composed of: (a) Site Checklist template, (b) The Method Statement and (c) The Inspection and Tests plan. A suggested template for the Site Checklist and the Method Statement are given below. A template for the Inspection and Test plan can be found in Section 2.

(A)

SITE CHECKLIST TEMPLATE

Occupational Health and Safety Checklist / Questionnaire Template Department :

Project Manager :

Project Name :

Project Starting Date:

Project Completed Date:

Consultant :

Project No. :

Contractor :

Inspection Date :

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Affairs :

Report No.:

Description

         

2

OH&S plan submitted for approval Within 30 days of the award of the contract? OH&S organization chart available OH&S Policy displayed Regular meetings record Responsibilities defined Near Miss & Hazard reporting and follow up Provision for visitors Monitoring effectiveness implementation of OH&S program Generic Risk Assessment & Management Monitoring & Control Sub-contractor to comply with all existing rules & regulations? In general, contractor following the government rules & regulation.

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MANAGEMENT

Satisfactory Comments / Submission Hold Points Yes No N/A Date (If No) Ref. to: (QCS: 1.10.1.8/9/14 + 1.10.2 + 11.1.1 + 11.2.1 + 11.2.3 + 11.2.4). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 35).

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Item

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Completion & Stamped By Consultant then Reviewed & Approved By Project Manager (Mob: ---------)

SAFETY STAFF  OH&S Safety Staff CV submitted for approval within 30 days of the award of the contract?

Ref. to: (QCS: 1.10.1.3 + 11.1.1.8 + 11.2.1.5).

QCS 2014

Section 11: Health and Safety Page 101 Part 2.4.01: Risk Assessment Guides and Method Statement

Item

Description



Ref. to: (QCS: 11.1.1 + 11.2.2 + 11.2.3.6). (Labor Law: Article 99).

.

Orientation / Site Induction Tool Box Talk (TBT) – daily documented Task specific (Equipment Operators, Scaffolders, Riggers, Fire Watchers, Emergency Drill, … etc) Management Refresher courses

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 

Ref. to: (QCS: 1.10.9 + 1.10.10 + 11.1.2 + 11.2.2 + 11.2.3.15). (Worker Rights Booklet 2009 – Page 41 & 45). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 9 & 10).

WORK ENVIRONMENT

Ventilation Removal of fumes and dust Dust controls preventive measures Noise levels (instrument available?) Vibration Lighting:  General purpose for evening work  For a particular task around construction site  Absence of glare  Work area  Corridors  Exterior Ergonomics - layout of work area The disposal of surplus water and the accompanying growth of trees and the proliferation of insects and rodents Does the site pose danger to the surrounding environment? Site office furniture?



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OH&S Officer available during all working hours OH&S Officer is exclusive for site & for H&S jobs

TRAINING   

Comments / Hold Points

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3

N/A

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Yes

Satisfactory Submission No Date (If No)

WELFARE FACILITIES         

Clean toilets with exhaust fan Toilets & Sanitary in good condition? Potable water provided Eating and resting areas Messing / Canteen facilities Washing facilities Regularly cleaned area Work clothes lockers and hanging areas Prevent the breeding of mosquitoes on the site

Ref. to: (QCS: 1.10.9 + 1.10.10 + 11.1.2) (Labor Law: Article 103,106 & 107).

QCS 2014

Section 11: Health and Safety Page 102 Part 2.4.01: Risk Assessment Guides and Method Statement

Item

FIRST AID & MEDICAL  

Less than 100) First Aider (100) above Nurse (500) Above Doctor &Nurse

Paramedics available & names displayed (according to number of workers) Average Manpower = ---------------------Labor Accident reporting, records available &follow up



Periodic medical examinations for workers and follow up

  

Medical record book existing Paramedics Telephone numbers displayed Adequate first aid kits supplies & expiration dates (as per Hamad Medical Corporation Requirement)



Adequate first aid equipment



Availability of stretcher / ambulance / Standby Vehicle Clean room with potable water supply Doctor, Site Nurse & Site Clinic must be approved from Supreme Council of Health

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First aid box for each 25 labor (500) Above Clinic

      

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Procedures Assembly / Muster point Conducted Emergency Drill Training every 6 month Availability of Fire / Smoke / Gas detection mobile devices Emergency contact telephone numbers / Communications Breathing apparatus and / or respirators (if applicable) Torches Loud Hailer Emergency lighting Adequate and safe Emergency Exit / Doors are provided Escape routes, access ways to assembly points, extinguishers, hydrants and other firefighting equipment's and first aid kits kept clear of obstruction at all times

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  

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EMERGENCY EQUIPMENT

HOUSEKEEPING & TIDINESS  

Ref. to: (QCS: 1.10.7.2). (Labor law: Article 100). (CDD / Fire Safety Handbook / Fire Safety Provisions For Construction Worksites / 2 – Page 16).

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Satisfactory Comments / Submission Hold Points Yes No N/A Date (If No) Ref. to: (QCS: 1.10.6 + 11.1.2.4 + 11.1.6 + 11.2.2 + 11.2.3). (Labor Law: Article 100,104,105 & 115).

Description

Segregation of waste and scrap Sufficient bins

Ref. to: (Labor Ministry Decision No. 20 of 2005). (CDD / Fire Safety Handbook / Fire Safety Provisions For Construction Worksites / 2 – Page 17).

QCS 2014

Section 11: Health and Safety Page 103 Part 2.4.01: Risk Assessment Guides and Method Statement

Item

Description Waste and scrap regularly collected & removed from site No build up of flammable materials Removal of combustibles

Ref. to: (QCS: 11.1.2.7). (Worker Rights Booklet 2009 – Page 45). (CDD / Fire Safety Handbook / Fire Safety Provisions For Construction Worksites / 2 – Page 10). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 12).

STORAGE - RACKS, BINS, SHELVES

Aisles and walkways kept clear Neat and orderly Not too high Heavy items kept low Sufficient space to access items Are chemicals, paints, flammable liquids and gas cylinders stored only in designated areas?

SITE SECURITY & ACCESS  Adequate transportation between working site & accommodations  Security check correctly performed  Guardhouse continuously manned  Round check register updated  Perimeter fence intact  Inspection of materials gate passes  Need for the existence of surveillance cameras inside the site  Need for security personnel within the site

11

PERSONAL PROTECTIVE EQUIPMENT

Ref. to: (QCS: 1.10.9.2 + 11.1.1.12).

12

Coveralls Eye protection Head protection Hand protection Foot protection Hearing Protection Safety reflecting vests Dust mask Any other protection

SAFE WORK PRACTICES   

Ref. to: (QCS: 1.10.9.2 + 11.1.2 + 11.2.3). (Labor Law: Article 101).

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10

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     

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9

Comments / Hold Points

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N/A

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Yes

Satisfactory Submission No Date (If No)

Avoid manual handling (Use mechanical handling equipment) Not working alone Cap (cover) for rebar / reinforcement steel

Ref. to: (Worker Rights Booklet 2009 – Page 45).

QCS 2014

Section 11: Health and Safety Page 104 Part 2.4.01: Risk Assessment Guides and Method Statement

Item

EXCAVATIONS

 

Adequate guarding on machines Inspected regularly with color code sticker & maintenance records Grounding installed to equipment/machine Unused machines electrically isolated Emergency isolation switches Safety devices Heating equipment

ELECTRICAL

      

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Insulation, cables, industrial plugs in good condition Cables suspended using S hooks and lead stands Inspected regularly with color code sticker ELCB provided to site power boards Qualified electrician hired to install (Name & Qualification) Protection of fittings against external damage Trailing leads used? Ovens and furnaces in good condition?

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SCAFFOLDS & LADDER     

Ref. to: (QCS: 1.10.5.14 + 11.1.5.3 + 11.2.2). (Worker Rights Booklet 2009 – Page 46). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 10).

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    

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MECHANICAL

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14

Ref. to: (QCS: 1.10.5.3 + 11.1.1.4). (Worker Rights Booklet 2009 – Page 46). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 10).

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Location of existing utilities confirmed Signs posted Adequate hard barrier installed Adequate warning tape & lighting Bracing & Shoring provided (if applicable) 1m spoil clearance from the excavated pit Sloping maintained (if applicable) Correctly made ladders provided for access into excavation Appropriate access provided (temporary bridges & footpaths)

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       

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13

Satisfactory Comments / Submission Hold Points Yes No N/A Date (If No) Ref. to: (QCS: 1.10.5.5 + 11.1.5.4 + 11.2.2 + 11.2.3). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 19).

Description

Certified scaffold supervisor and scaffolders Scaffolds correctly erected Scaffolds properly secured Toe boards, guardrails (top & mid rail), handrails & access checked Fully boarded platforms

Ref. to: (QCS: 1.10.5.10 + 11.1.3 + 11.2.3.12). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 19).

QCS 2014

Section 11: Health and Safety Page 105 Part 2.4.01: Risk Assessment Guides and Method Statement

Item

Description

Ref. to: (QCS: 1.10.5.13 + 11.1.3 + 11.2.3). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 11, 12 & 19).

Ref. to: (QCS: 1.10.5.3 + 11.1.4 + 11.2.2 + 11.2.3.5/10).

PLANT & EQUIPMENT



LIFTING OPERATIONS       

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 

Qualifications of operators available Available Qatar license for drivers / operators Banks man available Used as per its design (for intended purpose) Vehicle and equipment condition Reverse alarm installed Flashing light installed Generators and welding machine in good condition? Compressors and water pumps in good condition? Oil / fuel leak causing environmentally pollution

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 

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Personnel working above 1.2 m using fall protection devices Fall protection devices condition / Certificate Adequate safe access in place to working height elevations Personnel properly trained in the selection and use of fall protection devices All loose material & tools at heights secured or removed

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 

18

Scaffolds correctly tagged Materials in good condition

WORKING AT HEIGHT 

Comments / Hold Points

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N/A

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 

Yes

Satisfactory Submission No Date (If No)

Ref. to: (QCS: 1.10.5.8 + 11.1.4 + 11.2.3.10). (Worker Rights Booklet 2009 – Page 45). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 19).

Available Qatar license/third party certificate for operators and certificate of training for banks men and riggers Load capacity displayed Certification updated Condition of access and ground Lifting locations barrier off Outriggers/supports fully extended Hoist limiting device and SWL indicator working

LIFTING GEAR

Ref. to: (QCS: 1.10.5.9 + 11.1.4 + 11.2.3.10). (Worker Rights Booklet 2009 – Page 45). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 19).

QCS 2014

Section 11: Health and Safety Page 106 Part 2.4.01: Risk Assessment Guides and Method Statement

Item

Description     

Yes

Satisfactory Submission No Date (If No)

N/A

Comments / Hold Points

Ropes, Chains, Shackles etc. in good condition Identity number and SWL displayed Color-code system in place Available 3rd party certificate for every lifting gear Damaged lifting devices removed from the workplace

COMPRESSED GAS CYLINDERS  Stored upright, valves protected  Regulators Gauges working; hoses inspected  Flashback arrestor fitted  Cylinders are securely tied or with trolley  Type of gas clearly marked on cylinders  Segregation of incompatible gases  Transported on appropriate trolley  Correct signage

Ref. to: (QCS: 1.10.5.12 + 11.1.2.14).

22

SAFETY OF THE PUBLIC (For Road Works)  Approval from Traffic Dep. & Environmental ministry  International Warning signs  Warning yellow lights  Adequate Barricades (to comply with Traffic law no. 19)  Railing  Pedestrians pathway signs & not interacted with work zoon  Adequate safe access to all properties  Night watchman available  To provide road hump to reduce & control speed with approval from Traffic Department.

Ref. to: (QCS: 1.10.5.4 + 1.10.8 + 11.1.1.10).

23

SAFETY SIGNAGE & NOTICE BOARD

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21

Ref. to: (QCS: 1.10.1.6 + 1.10.5.6 + 11.1.8.2). (Labor Ministry Decision No. 20 of 2005).

WORK PERMITS

Ref. to: (QCS: 1.10.5.1/4/11 + 11.2.2 + 11.2.3).

     

24

   

Clearly displayed Shall be in Arabic, English & other languages Clean and legible Enough traffic diversion signboard? Adequate warning signs and guides are provided Shall be fully illustrated and provide details of key safety procedures to be followed

Confined Space Hot Work Excavation Scaffolding

QCS 2014

Section 11: Health and Safety Page 107 Part 2.4.01: Risk Assessment Guides and Method Statement

Item

Description

   

    

  

.

o

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Toxic/ hazardous substance correctly tagged/ labeled and secured Adequate & proper storage provided Appropriate spill containment provided Disposal Spill kit (location, appropriate, easy access) Material Safety Data Sheet (MSDS) present & required training delivered to concerned employees Class B fire extinguisher near by Correct signage Register of chemicals Correct labeling

CONFINED SPACES 

Ref. to: (QCS: 11.1.2.3 + 11.2.2 + 11.2.3). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 15, 16, 17 & 18).

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  

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HAZARDOUS SUBSTANCES 

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Is the firefighting equipment which approved by Civil Defense available at working area? Welding and grinding at working area properly secured Firefighting equipment not obstructed Expiration date of firefighting equipment checked. Monthly firefighting equipment visual inspected & recorded Availability of Fire / Smoke / Gas detection system Alarm and Emergency Evacuation system Are Alarms audible in all areas Minimum quantities of flammable material shall kept on site with full precautions required Access for Fire Brigade cleared

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27

Ref. to: (QCS: 1.10.7 + 11.1.7 + 11.2.2 + 11.2.3.13). (Fire Safety Handbook / Fire Safety Provisions For Construction Worksites / 2 – Page 8).

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Electrical Work Work permit correctly issued and signed Ashghal’ s work permit enforced

FIRE PROTECTION / PREVENTION 

Comments / Hold Points

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N/A

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  

Yes

Satisfactory Submission No Date (If No)

Gas detectors/monitors with rechargeable batteries and battery charger (2 No.) Full body safety harnesses with lifelines and shackles (6 No.) Lifting frame with fall arrest device (1 No.) Constant flow escape breathing apparatus complete with storage cases (2 No.)

Ref. to: (QCS: 1.10.5.7 + 11.1.5.5). (CDD / Fire Safety Handbook / Building Worksite Safety / 3 – Page 13 & 14).

QCS 2014

Section 11: Health and Safety Page 108 Part 2.4.01: Risk Assessment Guides and Method Statement

Item

Description   

N/A

Automatic positive pressure self contained breathing apparatus with storage case (1 No.) To train employee for confined space activity & supervision monitoring All equipment maintained & calibrated up to date with 3rd party certificate (record is available)

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OTHER RELATED SAFETY ITEMS           

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Yes

Satisfactory Submission No Date (If No)

Comments / Hold Points

QCS 2014

Section 11: Health and Safety Page 109 Part 2.4.01: Risk Assessment Guides and Method Statement

Key Performance Indicator (KPI’s)

=

Accumulating up to Date

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Accumulative Accident Rate

No. Per Last Month

.

Description No. of Medical Treatment Cases No. of First Aid Cases No. of Near-Miss No. of Fatal Cases No. of RTA (Road Traffic Accidents) No. of Manpower (Average) No. of Direct Man-hours No. of Hours Lost No. of Man-hours from Last Lost Time Accident No. of Lost Time Accidents No. of Safety Meeting No. of Emergency Drill No. of Audit Kilometres Driven

(Clasue1+4+5+10) x 100,000

=

(Clasue1+4+5+10) x 100,000

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Monthly Accident Rate

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Caluse6 (No. of Manpower Average)

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Caluse6 (No. of Manpower Average)

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Accumulative Frequency Accident =

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Monthly Frequency Accident

(Clasue1+4+5+10) x 1000,000

Caluse7 (No. of Direct Man-hours)

=

(Clasue1+4+5+10) x 1000,000 Caluse7 (No. of Direct Man-hours)

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 Consultant Name:

Mob. No.:

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Filled By: Signature: Date:

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Indicator No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Stamp:

 References:        

QCS (Qatar Construction Specification – Latest Edition). Labor Law No. 14 of the year 2004. Qatar Traffic Law No. 19 of the Year 2007. Environmental Protection Law No. 30 of the Year 2002. CDD (Civil Defense Department) – Fire Safety Handbook. Law No. 13 of 1997 - Civil Defense Law No. 9 of the Year 2012 - Amending some provisions of Law No. 13 of 1997 Concerning the Civil Defense Worker Rights Booklet 2009 (National Human Rights Committee).

QCS 2014

Section 11: Health and Safety Page 110 Part 2.4.01: Risk Assessment Guides and Method Statement

Site Approval Log (Supplementary Element Specific Log) SITE APPROVAL LOG (TITLE / NAME) To be signed before work activity is undertaken

Issue:

REF:

Work Activity:

PROJECT NAME: Corridor No:

Corridor Name: COMMENTS:

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LOCATION FROM:

Approvals: signature/date

Checks

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5

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2

Other

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e.g: Check licenses are received from MOPW, Check TM arrangements, Check utilities (locate & confirm), Check corridor specific Environmental issues, etc

1

Engineer

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Contractor

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Note: Contractor to ensure that checklist is signed off by all relevant parties before work activity can begin Confirmation that work completed in accordance with contract, safety and quality requirements: Construction Manager:

date:

HSEQ Manager:

date:

QCS 2014

(B)

Section 11: Health and Safety Page 111 Part 2.4.01: Risk Assessment Guides and Method Statement

METHOD STATEMENT TEMPLATE

Project Name:

Method Statement Number:

Work Activity:

Date:

Reviewed By:

Date:

Approved By:

Date:

PURPOSE, SCOPE AND LOCATION MAP

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Item

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Prepared By:

BRIEF DESCRIPTION OF THE CONTENT OF THIS MS, THE PURPOSE AND DETAIL ON THE SCOPE OF

Person Responsible INCLUDE PERSONS WITH RESPONSIBILITY FOR TASK

MANDATORY INDUCTION, TRAINING, SUPERVISION AND INSTRUCTION REQUIREMENTS

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WORKS. AND INCLUDE LOCATION MAP AND REFERENCES

FOR MAKING SURE WORKERS ARE INDUCTED, TRAINED



INDUCTION

FOR THE WORK



TRAINING



INSTRUCTION



SUPERVISION

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LIST ALL MANDATORY REQUIREMENTS FOR THE WORK ACTIVITY IN TERMS OF

PRELIMINARIES    

ACTIVITY, WORKS ARE INSTRUCTED AND SUPERVISED E.G. SITE ENGINEER/ SUPERVISOR WHO IS RESPONSIBLE TO MAKE SURE THAT

LICENSES

RELEVANT LICENSES,

TRAFFIC MANAGEMENT

TMS ETC ARE IN PLACE

DETECTION AND ISOLATION OF UTILITIES

AND COORDINATING

DISCONNECTION/ RECONNECTION OF SERVICES

AND MANAGING

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WHO IS RESPONSIBLE

UTILITY WORKS

4

SEQUENCE OF WORKS

INCLUDE PERSONS WITH RESPONSIBILITY



WRITE OUT THE JOB PROCEDURE STEP BY STEP

FOR AUTHORISING A



USE ACTIVE, NOT PASSIVE VOICE

CONTINUATION OF



SEQUENCE IDEAS LOGICALLY

WORKS AT EACH HOLD



KEEP SENTENCES SHORT AND CLEAR

POINT

INCLUDE: PRECAUTIONS TO BE TAKEN HAZARDS HOLD POINTS PERMIT REQUIREMENTS, COORDINATION, APPROVAL AUTHORITIES ETC

QCS 2014 5

Section 11: Health and Safety Page 112 Part 2.4.01: Risk Assessment Guides and Method Statement

IDENTIFIED HAZARDS/RISKS AND CONTROLS IN PLACE

INCLUDE WHO IS RESPONSIBLE TO





LIST ALL IDENTIFIED HAZARDS AND RISK IMPACTING ON THE WORK ACTIVITY AND THE

COMMUNICATE RISKS

CONTROLS IN PLACE

AND CONTROLS IN

INCLUDE REFERENCE TO RISK ASSESSMENT

PLACE FOR THE WORK ACTIVITY

6

ENVIRONMENTAL CONSIDERATIONS AND IMAPCT CONTROL MEASURES

ALSO INCLUDE WHO IS RESPONSIBLE FOR NEIGHBOURHOOD



LIST ENVIRONMENTAL IMPACTS, MITIGATION AND PRECAUTIONS



IDENTIFY PUBLIC NUISANCE AND SOURCES OF NUISANCE FOR NEIGHBOURING

LIAISON

PEOPLE/PROPERTIES

MANDATORY PPE FOR THE WORK ACTIVITY 

EMERGENCY PROCEDURES:

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WHO IS RESPONSIBLE FOR CALLING THE EMERGENCY SERVICES

REGARDING



CONTACT DETAILS FOR OUT-OF-HOURS EMERGENCIES

EMERGENCIES

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IDENTIFY EMERGENCY TYPES AND ARRANGEMENTS INCLUDING SITE EVACUATION

QUALITY CONTROLS REFERENCE TO INSPECTION AND TEST PLAN NUMBERS

INTERFACES 

IDENTIFY ALL INTERFACES AND LIAISON REQUIREMENTS IMPACTING ON THE WORK

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ACTIVITY

SAFETY OF THE PUBLIC AND OCCUPIERS 

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RESPONSIBLE FOR





10

INCLUDE WHO WILL BE

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9

LIST ALL IDENTIFIED MANDATORY PPE FOR THE WORK ACTIVITY

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8

E.G SUPERVISOR

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7

DESCRIBE HOW THE HEALTH AND SAFETY OF THE PUBLIC AND OTHERS AS RELEVANT

COMMUNICATIONS

E.G. QUALITY MANAGER, SITE ENGINEER, QUALITY INSPECTOR WHO RESPONSIBLE TO COORDINATE INTERFACES IMACTING ON AND IMPACTED BY THE WORK ACTIVITY WHO WILL ENSURE THAT THE HEALTH AND SAFETY OF THE PUBLIC

WILL BE PROTECTED.

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RESOURCE PLANNING

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PERSONNEL



PLANT AND EQUIPMENT



13

E.G. SITE ENGINEER, SUPERVISOR

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12

MATERIALS

REFERENCES 

WORK PROGRAMME



DRAWINGS



RISK ASSESSMENTS



COORDINATION PROCEDURE



WORK CHECKLIST



INSPECTION AND TEST PLAN ETC

(C)

INSPECTION AND TEST PLAN

Refer to Section 2 for template Inspection and Test Plan

END OF PART

QCS 2014

Section 12: Earth Works Related to Buildings Part 01: General

Page 1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9

Scope References Ground Investigation Site Clearance Preservation of Property Not to be Affected by the Works Disposal of Historical Artefacts Special Requirements of Utility Authorities Control of Ground Water Record Procedure

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1

2 2 2 3 3 4 4 4 4

QCS 2014

Section 12: Earth Works Related to Buildings Part 01: General

Page 2

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies the requirements for excavation and filling as necessary to facilitate the construction of the Works. It does not include earthworks associated with trenches for pipelines or service ducts.

2

The cost of all operations needed for the excavation and disposal work as required and specified, including temporary and permanent support work, breaking, loading, hauling and dumping in accordance with the provisions of the Project Documentation shall be included in the Contractor’s rates.

3

The Contractor shall be deemed to have examined the site and verified for himself the exact nature and quality of the materials to be excavated. The Contractor shall carry out his own survey of the existing ground levels and satisfy that the quantities of all excavated and imported materials are correct.

4

Removal operations shall be conducted with the least interference to the public and shall not be started until approved by the Engineer.

5

Related Sections and Parts are as follows:

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1

Filling

Section 1 Section 2 Section 6 Section 8 Section 28

General Building Demolition Roadworks Sewerage Landscaping

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This Section Part 3

References

1

The following standards are referred to in this Section:

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1.1.2

BS 812........................Testing Aggregates BS 1377 .....................Methods of test for soils for civil engineering purposes BS 6906 .....................Methods of tests for geotextiles 1.1.3

Ground Investigation

1

The Contractor shall be deemed to have satisfied himself as to the character of the Site and all the various materials, strata, ground water levels, etc., and of all items liable to affect, or be encountered in, the excavations and earthworks.

QCS 2014

Section 12: Earth Works Related to Buildings Part 01: General

Page 3

If a ground investigation is not included in the Project Documentation the Contractor shall immediately after taking possession of the Site prepare a minimum of two trial pits in positions to be agreed with the Engineer. Chemical analysis tests are to be carried out on the materials from each of the pits and the results submitted to the Engineer. Similarly, chemical analysis tests shall be carried out on any water present in the pits and the results submitted to the Engineer. Ground investigation tests in accordance with the relevant provisions of BS 812, BS 1377 and BS 6906 shall be undertaken where geotextiles are to be used for temporary or permanent protection.

3

The Contractor shall inform the Engineer when the trial pits are ready for inspection and shall not commence excavation work until approval to proceed has been given. All trial holes and their subsequent backfilling shall be carried out at the Contractor’s expense and will only be allowed in positions approved by the Engineer. All trial holes shall be backfilled as soon as the required information has been obtained and open excavations shall be adequately protected and cordoned off using temporary lights and barriers or similar method approved by the Engineer.

4

If a ground investigation is included in the Project Documentation, it is provided solely for the guidance of the Contractor and no guarantee is given regarding its accuracy, nor is it guaranteed that similar conditions apply elsewhere on the Site.

1.1.4

Site Clearance

1

Before commencing any excavation or fill, the area shall be cleared of all trees, stumps, roots, bushes, vegetation, debris, materials or other obstructions.

2

Before removal of any trees or shrubs the Contractor shall obtain written consent from the Engineer at least two weeks in advance of the planned removal.

3

All bushes, undergrowth, etc. to be removed shall be grubbed up and disposed of in a manner as agreed with the Engineer. Holes left by stumps or roots shall be filled with suitable material, compacted to the Engineer’s satisfaction in accordance with Part 3 of this Section within one week of the work being performed.

4

The Contractor shall at his own expense make good any damage done to other property during the site clearing. Sweet soil excavated during the course of these works shall be preserved and protected by the Contractor, until removed by the Employer or until the expiration of the Contract.

1.1.5

Preservation of Property Not to be Affected by the Works

1

Attention is directed to the Contractor’s obligations with regards to damage, particularly with regard to protection of property, plants and landscape and to responsibility for damage claims.

2

The form of protection to vegetation within the Site shall be as agreed with the Engineer.

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QCS 2014

Section 12: Earth Works Related to Buildings Part 01: General

Page 4

1.1.6

Disposal of Historical Artefacts

1

Where specified, certain materials arising from site clearance and excavation work are to remain the property of the Owner. All fossils, antiquities and other objects of interest or value which may be found or uncovered on the Site shall remain or become the property of the Owner. Upon discovery of such an object the Contractor shall forthwith: (a)

use his best endeavours not to disturb or damage the object

(b)

cease work which would endanger the object or prevent or impede its removal

(c)

inform the Engineer of the discovery and precise location of the object.

The Engineer will issue an instruction on the procedure to be adopted which may include conditions to permit the examination, excavation or removal of the object by a third party.

1.1.7

Special Requirements of Utility Authorities

1

Prior to commencing excavation work, the Contractor shall ascertain from the responsible Utility Authorities whether any mains or services need to be diverted or cut-off in accordance with the procedure described in Part 19 of Section 1.

1.1.8

Control of Ground Water

1

Prior to the commencement of construction at any particular location, the Contractor shall install and maintain a system of standpipes and other devices to monitor ground water levels in any area, which in the opinion of the Engineer, is likely to be affected by the dewatering. The number, location and depth of all standpipes shall be to the satisfaction of the Engineer.

2

The Contractor shall check ground water levels weekly or when instructed by the Engineer. The results of such checks shall be submitted to the Engineer in a written report within 24 hours of the level being taken. The format of the report shall be as agreed with the Engineer.

3

In the case of uncontrolled flow of water into any excavation, the Engineer reserves the right to order the Contractor to take immediate action to control the inflow of water. Such actions and remedial works shall be to the Engineer’s approval.

1.1.9

Record Procedure

1

If the Engineer requires foundation or formation level depths to be varied from those shown on the drawings it shall be the responsibility of the Contractor to ensure that proper records of the actual excavated levels are kept.

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END OF PART

QCS 2014

Section 12: Earth Works Related to Buildings Part 02: Excavation

Page 1

2

EXCAVATION ................................................................................................ 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2

Scope References

2.2

EXCAVATION FOR STRUCTURES .............................................................. 2

2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8

Excavation Support Removal of Water Approvals Inspection Unsound Materials Over-Excavation Finishing to Excavation Storage of Excavated Material

2.3

MATERIALS .................................................................................................. 4

2.3.1 2.3.2 2.3.3 2.3.4

Excavated Material Common Excavation Rock Excavation Blasting

2.4

DISPOSAL OF SURPLUS MATERIAL .......................................................... 5

2.4.1

General

2 3 3 3 4 4 4 4

4 4 5 5

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QCS 2014

Section 12: Earth Works Related to Buildings Part 02: Excavation

Page 2

EXCAVATION

2.1

GENERAL

2.1.1

Scope

1

This Section specifies the requirements for the excavation for structures, culverts, headwalls, catch basins, manholes, inlets, retaining walls and the like. The work includes all necessary clearing and grubbing and the disposal of all material resulting from such excavation. The work also includes the provision, and subsequent removal, of all necessary bailing, drainage, pumping, sheeting, strutting, coffer dam construction and crib construction.

2

Rates for excavation shall include for excavation in any material. Excavation in any material shall include common excavation, side shoring, support systems, excavation in artificial hard material and shall be inclusive of all encountered impediments, including roots, boulders etc. Blasting will not be permitted without the written approval of the Engineer.

3

Related Sections and Parts are as follows:

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Section 1 Section 6

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2

References

1

The following standards are referred to in this Part;

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BS 1377 .....................Method of test for soils for civil engineering purposes

EXCAVATION FOR STRUCTURES

2.2.1

Excavation Support

1

Prior to Commencing any structural excavation work which is 1.5 m or greater in depth, the Contractor shall design an excavation support system.

2

Details of the excavation support system shall be submitted to the Engineer for review and approval at least one week before any excavation work commences. Details of the excavation support system shall be complete with, but not limited to, the following:

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2.2

(a)

drawings of the structural support members showing materials, sizes and spacing,

(b)

calculations showing the maximum theoretical deflection of the support member.

3

The system is to be designed so that no members extend through surfaces exposed in the finished construction, and no shoring or bracing is placed under permanent structures.

4

The Contractor shall submit to the engineer calculations of lateral earth pressure for the full excavation depths, surcharge loads of any description, equipment loads, forces at various stages of support during excavation, the maximum design loads to be carried by various members of the support system and strut pre-load forces.

5

If the structure support system proposed includes tieback anchors, the Contractor’s submitted details shall include drawings that show the profile of the soil in which each anchor is to be installed.

QCS 2014

Section 12: Earth Works Related to Buildings Part 02: Excavation

Page 3

Tieback anchors that project beyond the vertical limits of the Site boundary on to adjoining property shall only be permitted if permission to do so is given by the owner of the property in writing. Copies of such written permission shall be submitted to the along with excavation support system proposals.

2.2.2

Removal of Water

1

At locations where the excavation extends below the groundwater table, a dewatering system is to be provided which will lower ambient groundwater levels. The resulting groundwater level shall be at a depth which is sufficiently below the excavation level so as to allow the safe and proper execution of the work. The resulting foundation level shall be a stable, dry sub-grade which is suitable for the execution of subsequent operations.

2

The Contractor is to design the dewatering methods and settling basins so that no critical amounts of soil, sand or silt are removed during either the dewatering operations.

3

Complete working drawings showing the type of dewatering and groundwater control system proposed shall be submitted to the Engineer for his review. The Contractor’s submittal shall include drawings that show the arrangement, location and depths of the proposed dewatering system. A complete description of the equipment and materials to be used and the procedures to be followed to be given, together with details of required standby equipment and standby power supply. The Contractor shall also indicate his proposed location(s) for the discharge of extracted groundwater.

4

The dewatering system design should also include the details of measures required to prevent damage due to settlement of roads, pavements, utilities, sewers, buildings and other structures outside the excavation but within the area affected by the dewatering.

2.2.3

Approvals

1

The designs of the structure excavation support system and the dewatering systems specified above is to be prepared by and signed by a qualified engineer experienced in this type of design work. Approval of the designs and shop drawings will not relieve the Contractor of the adequacy and performance of these temporary works.

2.2.4

Inspection

1

In addition to the provisions of Part 13 of Section 1, the Contractor shall also undertake the following described in the following Clauses unless otherwise instructed by the Engineer.

2

Following a detailed inspection of all adjacent structures, the Contractor shall prepare a report on the pre-construction condition of all structures that may be affected during construction of the Works. The report will include photographs, drawings and sketches with levels and dimensions fully illustrating the structure's condition. In particular, it shall note any existing damage or structural inadequacy. Deficiencies and damage are to be suitably marked on the structure in a way that it is not permanently defaced.

3

Three (3) copies of the Report shall be submitted for the approval of the Engineer. Once approved, five (5) additional copies shall be supplied to the Engineer.

4

The Contractor shall carry out a survey of levels of undisturbed ground before commencing any excavations.

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QCS 2014

Section 12: Earth Works Related to Buildings Part 02: Excavation

Page 4

When the excavation has been carried down to formation level the Contractor shall advise the Engineer’s Representative that the excavation is ready for inspection and the Engineer’s Representative shall, without reasonable delay, inspect the excavation unless he considers it unnecessary.

2.2.5

Unsound Materials

1

Any loose, improperly compacted, soft or other unsuitable material which is encountered below or adjacent to structural foundation levels shall be completely removed, backfilled with a suitable material and compacted to 95% of the maximum dry density as determined by BS 1377 Part 4. Backfilling shall be done in layers with an unconsolidated thickness not exceeding 200 mm up to the foundation level. The limits of such work shall be as directed by the Engineer. Alternatively, the Engineer may instruct that removed material be replaced with Class C25 concrete.

2.2.6

Over-Excavation

1

Any over excavation is to be backfilled with Class C25 concrete at the Contractors expense.

2.2.7

Finishing to Excavation

1

All rock or other hard foundation material is to be cleaned of all loose material. All seams or crevices are to be cleaned and grouted. All loose and disintegrated rock and thin strata is to be removed.

2

When the structure is to rest on material other than rock, excavation to final grade should not be made until just before the structure is to be placed/constructed and special care is to be taken not to disturb the excavated surface. The surface required shall be rolled and compacted to 95% of the maximum dry density.

2.2.8

Storage of Excavated Material

1

Excavated material is not to be stored or deposited in such a way as to endanger structures or cause an obstruction of any kind.

2.3

MATERIALS

2.3.1

Excavated Material

1

All excavated material will be the property of the Owner and no material shall be removed, transported and disposed of without the prior written approval of the Engineer.

2.3.2

Common Excavation

1

Common excavation consists of the excavation and satisfactory disposal of all soils, certain strata and rock boulders less than one (1) cubic metre in volume. Strata which are altered and weathered and are in place, but which are not firm enough, or in the opinion of the Engineer are not rigid enough to have all the characteristics of rock excavation is to be classified as common excavation.

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Page 5

Rock Excavation

1

Rock excavation consists of the excavation and satisfactory disposal of all unaltered and unweathered firm and rigid igneous, metamorphic and sedimentary solid rock that in the opinion of the Engineer can only be excavated by the use of pneumatic hammers or other such similar apparatus.

2.3.4

Blasting

1

Blasting will not be permitted without prior approval. (Refer to Section 6: Roadworks).

2.4

DISPOSAL OF SURPLUS MATERIAL

2.4.1

General

1

All materials arising from site clearance or excavation which are surplus, suitable or unsuitable for use in the Works will become the property of the Owner and will not be disposed of by the Contractor either off the Site to an approved tip without written approval from the Engineer. If directed, or otherwise agreed by the Engineer, the Contractor may dispose of surplus material on the Site in an approved manner as directed by the Engineer.

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END OF PART

QCS 2014

Section 12: Earth Works Related to Buildings Part 03: Filling

Page 1

3

FILLING ......................................................................................................... 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2

Scope References

3.2

EARTHWORKS MATERIALS ........................................................................ 2

3.2.1 3.2.2 3.2.3 3.2.4

Top Soil Suitable Material Unsuitable Material Utilisation of Excavation Materials

3.3

MAIN PLANT FOR EARTHWORKS CONSTRUCTION ................................ 3

3.3.1

General

3.4

BACKFILLING ............................................................................................... 3

3.4.1

General

3.5

COMPACTING IMPORTED OR SELECTED EXCAVATED FILL MATERIAL ..................................................................................................... 4

3.5.1 3.5.2

General Water

3.6

FILL BELOW GROUND SLABS .................................................................... 5

3.6.1

General

3.7

FILLING ......................................................................................................... 5

3.7.1

Concrete Blinding

2 2

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3

4 5

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Section 12: Earth Works Related to Buildings Part 03: Filling

3

FILLING

3.1

GENERAL

3.1.1

Scope

1

This Part specifies materials for filling purposes.

2

Related parts and Section are as follows:

Page 2

This Section

.

Roadworks

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Excavation

References

1

The following Standards are referred to in this Part:

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3.1.2

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Part 2

BS 812........................Testing Aggregates

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BS 1377......................Methods of test for soil for civil engineering purposes

EARTHWORKS MATERIALS

3.2.1

Top Soil

1

Top soil is to be fertile, friable soil obtained from well drained arable land and to be free draining, non-toxic and capable of sustaining healthy plant growth.

3.2.2

Suitable Material

1

Suitable material for earthworks shall be approved soil with a liquid limit not exceeding 35% and a plasticity index not exceeding 10%. The material passing the 0.075 mm sieve shall not exceed 20% and the organic matter content shall not exceed 2% (as determined by BS 1377 – Part 3).

2

Where excavated rock is to be used as fill material elsewhere on the site, the Contractor is responsible for ensuring that the excavated rock meets the requirement of the Specification for fill material.

3

The Contractor is responsible for mixing the excavated rock with suitable fill material imported and/or excavated from within the site should it be necessary in order to produce a suitable fill material that complies with the requirements of the Specification and he should allow in his rates and programme for carrying out the work.

4

Sweet soil and any excavated materials which are considered re-usable by the Engineer, shall be preserved and protected by the Contractor, until they are removed by the Owner or until the expiration of the Contract.

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3.2

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Page 3

5

No excavated suitable material is to be removed from the Site without the Engineer’s written permission. Should the Contractor be permitted to remove suitable material from the site to suit his operational requirements, then he is to make good any consequent deficit or filling arising therefrom at his own expense.

3.2.3

Unsuitable Material

1

Unsuitable materials include: rock particle exceeding 75mm in size

(b)

organic material (as defined in BS 1377 Part 3) containing greater than 2% stumps and other perishable material

(c)

material susceptible to spontaneous combustion

(d)

soils of a liquid limit exceeding 35% and/or a plasticity index exceeding 10%.

(e)

material containing more than 5% of water soluble salts by weight of dry soil (individually, water soluble chloride exceeding 1% or water soluble sulphate exceeding 1.5%) or more than 10% of acid-soluble salts (individually, acid soluble chloride exceeding 2% or acid soluble sulphate exceeding 3.0%) as determined by BS 1377: part 3

(f)

any other material which the Engineer may deem to be unsuitable for earthworks

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(a)

Utilisation of Excavation Materials

1

All excavated material determined as suitable by the Engineer, is to be utilised as backfill. The surplus material shall be disposed of as specified in Part 2 of this Section.

3.3

MAIN PLANT FOR EARTHWORKS CONSTRUCTION

3.3.1

General

1

The Contractor is to employ only plant which is suited to the soils to be handled. He should not at any time use plant which damages or reduces the natural strength of the soil either in its in-situ state or during handling and placing or in its final compacted state. Unsuitable or faulty plant shall be removed from the work site and borrow pits at the order of the Engineer.

3.4

BACKFILLING

3.4.1

General

1

Excavation is only be backfilled after the permanent works therein have been approved and after the removal of any building debris or deleterious material from the excavations.

2

Selected excavated material will normally be used or backfilling in the manner described in Clause 3.5 of this Part. Where the excavated material is not considered suitable, selected material form an approved source is to be used.

3

The backfill will be brought to a suitable level above grade to provide for anticipated settlement and unless indicated otherwise, is to be sloped away from the structure.

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3.2.4

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Section 12: Earth Works Related to Buildings Part 03: Filling

Page 4

The bottom of all excavations are to be probed and any poor bearing area shall be reported to the Engineer who will direct remedial work. Soft spots and other unsound materials are to dealt with as specified in Part 2 of this Section.

5

In circumstances where backfill has to be deposited below standing water, only rock, as specified in Section 6, Roadworks, is to be used.

3.5

COMPACTING IMPORTED OR SELECTED EXCAVATED FILL MATERIAL

3.5.1

General

1

Fill to be compacted by a suitable plate type vibrator, pedestrian operated vibrator roller, small tandem roller or other approved compaction plant.

2

The material is to be placed in layers within the effective range of compaction of the plant provided that the maximum loose (uncompacted) thickness of each layer dose not exceed 200 mm.

3

The material is to be watered and mixed as necessary to ensure that prior to compaction the moisture content of the whole layer is ± 3% of the optimum moisture content. Compaction of each layer is to continue until a density of a least 95% of the maximum dry density has been achieved.

4

The dry density/moisture content relationship will be determined by the heavy compaction test (4.5% rammer method) of BS 1377.

5

All fill material used in earthworks shall be compacted as per related Specification by plant approved by the Engineer for that purpose. If required by the Engineer the Contractor shall carry out compaction trials on the material supplemented by laboratory testing to determine the correct plant and number of passes required to achieve the specified requirements.

6

Potable water shall be used for compaction of all fill material within the area of excavation.

7

The Contractor shall carry out moisture content determinations at frequent intervals or when there is a change in the material on the soils undergoing compaction so as to ensure that the moisture content of the soil is within the optimum range for the field compaction determined from compaction trials.

8

All adjustment of moisture content shall be carried out in such a way that the specified moisture content remains uniform through out compaction.

9

No completed fill layer shall be covered by the next layer until it has been tested, inspected and approved by the Engineer.

10

The finished surface of earthworks for paved surfaces (other than public roads) shall be shaped and rolled and then tested for accuracy so that maximum local irregularities in the finished profiles lie within the tolerance of  20mm for formation, as well as  10mm and  5mm respectively for longitudinal and transverse profiles of finished surfaces, when tested by a straight edge or level instrument. The frequency of local irregularities shall be at the discretion of the Engineer.

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Section 12: Earth Works Related to Buildings Part 03: Filling

Page 5

Where fill material is to be deposited in areas where the existing ground is sloping, the Contractor shall excavate benches so that fill material is deposited onto a horizontal surface. The levels of the benching terraces shall match the layers of the fill material that are deposited in the adjacent areas.

3.5.2

Water

1

The water to be mixed with the soil / fill materials to achieve the desired moisture content in the filling / earthworks operations shall be potable.

3.6

FILL BELOW GROUND SLABS

3.6.1

General

1

The installation of cable ducts for service entries and service pipework is to be completed before placing of the fill to receive the ground slab.

2

The compacted fill or hardcore is to be shaped and trimmed to the required levels and dimensions and blinded with sand.

3.7

FILLING

3.7.1

Concrete Blinding

1

Immediately on completion of excavations for concrete structures a blinding layer of concrete Grade OPC 25 not less than 75mm thick shall be placed to prevent deterioration of the formation and to provide a clean working surface for the structure.

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END OF PART

QCS 2014

Section 12: Earth Works Related to Buildings Part 04: Utility Trenches

Page 1

4

UTILITY TRENCHES ..................................................................................... 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2 4.1.3 4.1.4

Scope References Excavation of Utility Trenches Backfilling of Utility Trenches

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Section 12: Earth Works Related to Buildings Part 04: Utility Trenches

Page 2

4

UTILITY TRENCHES

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the requirement for utility trenches. It does not include trenchworks for pipelines and service ducts.

2

Related Sections and Parts are as follows: This Section Filling

Part 3

Excavation

References

1

The following standards are referred to in this Part:

Methods of tests for soils for civil engineering purposes.

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BS 1377

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Part 2

Excavation of Utility Trenches

1

The trench to be excavated with the width and to the depth shown on the drawings or as indicated by the Engineer.

2

The sides of pits and trenches are to be vertical and adequately supported at all times. Excavation may if considered necessary be battered with a safe slope, but only with the Engineer’s written permission.

3

Care is to be taken to excavate to the depths indicated. Where rock is encountered, the rock is to be excavated 150 mm lower than the required depth. Such depth in rock is to be backfilled with approved fill material and compacted as specified and/or as directed by the Engineer.

4

Excavated material will, if found unsuitable as defined in Part 3 of this Section, be disposed of to an approved tip and replaced with suitable material. All surplus material to be disposed of in accordance with Part 2 of this Section.

4.1.4

Backfilling of Utility Trenches

1

After the utilities have been laid, the trench refilling is to commence with approved fill in compacted layers not exceeding 150 mm unconsolidated thickness. Each layer shall be well compacted by hand with iron rammers weighing not less than 5 kg, until the trench has been filled to a height of 300 mm above the top of the utility.

2

The remainder of the trench is then to be refilled in compacted layers not exceeding 250 mm unconsolidated thickness. Each layer being well compacted, with power rammers, vibrating plate compactors or other mechanical means of a type to be approved until the ground is thoroughly consolidated up to the required level for surface reinstatement. Each layer is to be compacted to 95% of its maximum dry density as determined by BS 1377.

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4.1.3

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Section 12: Earth Works Related to Buildings Part 04: Utility Trenches

Page 3

3

Trenches are not to be backfilled until all required tests are performed on the utilities and until the Engineer has verified that the utilities have been installed in accordance with the Project Documentation.

4

Where cover to utilities is less than 400 mm, or where ordered by the Engineer, protection in the form of precast concrete tiles is to be provided according to an approved drawing or as ordered by the Engineer.

5

PVC warning tape shall be laid above the utility or the concrete tiles, after partial backfilling and approximately 300 mm below finished ground level.

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END OF PART

QCS 2014

Section 12: Earth Works Related to Buildings Part 05: Installation of Protective Membranes

Page 1

5

INSTALLATION OF PROTECTIVE MEMBRANES ....................................... 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2 5.1.3

Scope References General Requirements

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Section 12: Earth Works Related to Buildings Part 05: Installation of Protective Membranes

Page 2

5

INSTALLATION OF PROTECTIVE MEMBRANES

5.1

GENERAL

5.1.1

Scope

1

This Part specifies geotextile fabric systems used for temporary or long term stabilisation of earthworks during construction.

2

Related Sections and Parts are as follows: Concrete

Section 6

Roadworks

5.1.2

References

1

The following standards are referred to in this part:

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BS 6906......................Methods of test for Geotextiles

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Section 5

General Requirements

1

In areas where the Engineer deems the use of geotextile fabric necessary, the Contractor is to furnish and place geotextile fabric as specified and as directed by the Engineer.

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The geotextile fabric furnished by the Contractor is to be of an approved grade suitable for placement over fine sand. The geotextile fabric shall be a woven or non-woven fabric consisting only of long chain polymeric filaments or yarns formed into a stable network such that the filaments or yarns retain their relative position to each other. The fabric is to be stabilised against ultra violet light, inert to commonly uncounted chemicals and chemical properties of the in-situ soil and water, and it should conform to the following minimum requirements: Weight

135 g/m 2

m

Thickness under load (2 kN/m )

2

2

0.7 mm

Tensile Strength (200 mm width) ASTM D1682

1.6 kN

Puncture Resilience (DIN 54307)

1.5 kN

Permeability

50 litres/m /s

2

The surface to receive the geotextile fabric is to be prepared to a relatively smooth condition free of obtrusions, depressions, and debris. The geotextile fabric should not be laid in a stretched condition. In the event that the width of the proposed area for fabric requires more than one panel width of fabric, the panels are to be overlapped a minimum 15 percent of the panel width. Longitudinal joints in the fabric are to have an overlap of 500 mm. To prevent slippage of the overlapping fabric, the areas of overlap are to be stabilised as approved by the Engineer with pins, anchor blocks, or aggregate piles. In the event that construction machinery is used to place the fabric, the working platform for the machinery should be the soil and not the previously laid fabric.

QCS 2014

Section 12: Earth Works Related to Buildings Part 05: Installation of Protective Membranes

Page 3

3

Prior to placement of the granular material (stabilising crushed material) the Contractor is to spread a layer of sand over the geotextile fabric as directed by the Engineer. The aggregate material should not be dumped directly on the fabric. Haulage trucks are not to be driven on the fabric. The aggregate is to be spread by a wheeled front-end loader. The blade or bucket is to be kept sufficiently high so that the aggregate is not being pulled over the fabric, but being dropped at a minimum height to the satisfaction of the Engineer.

4

Fabric damaged or displaced before or during installation or during placement of overlaying aggregate material is to be replaced of repaired to the satisfaction of the Engineer at the Contractor’s expense.

5

Where pipes or other elements pass through the geotextile fabric, the openings around such are to be made watertight by methods as approved by the Engineer.

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END OF PART

QCS 2014

Section 13: Masonry Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2 1.1.3

Scope References Definitions

1.2

APPROVAL OF SUPPLY SOURCE .............................................................. 2

1.2.1

General Requirements

1.3

SAMPLES, TESTING AND SUBMITTALS .................................................... 2

1.3.1 1.3.2

General Requirements Sample Panels

1.4

PRODUCT HANDLING.................................................................................. 3

1.4.1

Storage of Materials

1.5

WORKMANSHIP ........................................................................................... 3

1.5.1

General Requirements

1.6

CLEANING .................................................................................................... 4

1.6.1 1.6.2 1.6.3

General Requirements Brickwork Concrete Masonry Units

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Section 13: Masonry Part 01: General

Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section covers the products, erection and all associated accessories for construction of concrete and clay masonry unit blockwork as well as requirements for glass block units, gypsum units, and stonework.

2

Related Sections and Parts are as follows:

References

1

The following standards referred to in this Part:

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Concrete Thermal Insulation of Buildings Finishes to Buildings Painting and Decorating

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Section 5 Section 15 Section 24 Section 26

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BS 6100......................Glossary of building and civil engineering terms Definitions

1

Definitions used in this Section follow the requirements of BS 6100 unless otherwise stated.

1.2

APPROVAL OF SUPPLY SOURCE

1.2.1

General Requirements

1

All products supplied under this Section must be obtained from an approved source.

2

The Contractor will not be permitted to change his source of supply without the permission of the Engineer.

1.3

SAMPLES, TESTING AND SUBMITTALS

1.3.1

General Requirements

1

Samples of each type of masonry unit to be used shall be submitted to the Engineer for approval before use. All subsequent units are to be up to the standard of the approved samples.

2

Initially, twelve (12) units will be selected by the Engineer from the first batch of units manufactured or delivered. The units shall be delivered by the Contractor to an approved independent testing laboratory, or if the Engineer so directed, to the Government Materials Testing Laboratory.

3

The sample is to be accompanied by the following written information:

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1.1.3

(a)

type of unit

(b)

means of identification of unit

QCS 2014

Section 13: Masonry Part 01: General

Page 3

(c)

name of manufacturer

(d)

type of masonry units making machine

(e)

capacity of plant and present stocks available

(f)

certificates stating that the units are suitable for the purpose for which they are to be used.

A number of units to indicate colour range for exposed work to be submitted to the Engineer for approval prior to commencement of the Works.

5

Further samples will be selected and tested as directed by the Engineer.

6

The Contractor shall submit details of his proposed methods for reinforcement to the Engineer for approval. The Contractor shall also submit details of his proposed methods for constructing lintels, anchors and anchor channels.

1.3.2

Sample Panels

1

Before any fair or faced masonry work is commenced, the Contractor is to erect one sample panel, size 1800 mm long x 2000 mm high, of each type of finish to be used.

2

The panels should incorporate a typical opening detail and a typical corner detail, and a typical movement joint.

3

Before starting face brickwork, the Contractor shall lay up a sample panel 2 m long by 1 m high for the Engineer’s approval. Random piles of brick as delivered to the Site shall be used. Brickwork to be incorporated in the Works is to match original sample brickwork panels as approved by Engineer. Sample panels must not be removed until directed by Engineer.

1.4

PRODUCT HANDLING

1.4.1

Storage of Materials

1

Masonry units delivered to the Site are to be carefully unloaded and handled so as to prevent chipping and breakage. Tipping of units will not be allowed.

2

The units are to be stacked on a level area in an orderly manner on planks or other suitable supports to ensure that they are free from contact with the ground. Stored units shall be kept under waterproof covers.

3

Packaged materials shall be stored in their original containers.

1.5

WORKMANSHIP

1.5.1

General Requirements

1

Tops of walls shall be covered with waterproof covering when the work is not in progress.

2

When starting or resuming work, loose mortar and foreign materials shall be cleaned from the top surface of the work. Surfaces of clay type masonry shall be wetted before resuming work.

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Section 13: Masonry Part 01: General

Page 4

Newly laid blockwork and brickwork shall be protected from the harmful effects of sunshine, rain, drying wind, and surface water.

4

Blockwork shall be water cured for a minimum of three days.

5

Units that will be exposed to view in finished work shall be supplied in adequate quantities to permit selection and mixing of brick from several deliveries in advance of laying. Units shall be exposed to the atmosphere for minimum of two weeks before laying.

1.6

CLEANING

1.6.1

General Requirements

1

Clean exposed masonry surfaces on completion. Protect material liable to damage.

1.6.2

Brickwork

1

Cut out defective exposed new joints to a depth of approximately 20 mm and repoint. Remove mortar droppings and other foreign substances from the wall surfaces. First wet surfaces with clean water and then wash down with a solution of soapless detergent specially prepared for cleaning brick. Brush with a stiff fibre brush and immediately after, hose down with clean water. Clean surfaces from any traces of detergent, foreign streaks or stains of any nature. Protect adjoining construction materials during cleaning operations. Use of muratic acid for cleaning brickwork is prohibited.

1.6.3

Concrete Masonry Units

1

Immediately following setting, brush exposed surfaces free of mortar or other foreign matter.

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END OF PART

QCS 2014

Section 13: Masonry Part 02: Mortar and Grout

Page 1

2

MORTAR AND GROUT ................................................................................. 2

2.1

GENERAL DESCRIPTION ............................................................................ 2

2.1.1 2.1.2

Scope References

2.2

MORTAR MATERIALS .................................................................................. 2

2.2.1 2.2.2 2.2.3 2.2.4 2.2.5

Preparation Requirements Cement Aggregates Water Lime

2.3

EPOXY .......................................................................................................... 4

2.3.1

General Requirements

2.4

HIGH BOND .................................................................................................. 4

2.5

GROUTS ....................................................................................................... 4

2.5.1

General Requirements

2.6

PIGMENTS FOR COLOUR ........................................................................... 5

2.6.1

General Requirements

2.7

TUCK POINTING ........................................................................................... 5

2.7.1 2.7.2 2.7.3 2.7.4 2.7.5 2.7.6 2.7.7

General Protection Existing Mortar Joints Installation of Tuck Pointing Mortar Tooling of Joints Replacement of Masonry Units Cleaning

2 3 3 3 3

4

4

5

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Section 13: Masonry Part 02: Mortar and Grout

Page 2

2

MORTAR AND GROUT

2.1

GENERAL DESCRIPTION

2.1.1

Scope

1

This Section specifies mortar and grout for masonry, glass blocks and stone work.

2

Related Parts and Sections are as follows:

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Unit Masonry Reinforced Unit Masonry Masonry Laying Concrete

References

1

The following standards are referred to in this Part:

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2.1.2

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This Section Part 2 Part 3 Part 5 Section 5

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ASTM C270 ................Standard Specification for Mortar for Unit Masonry BS EN 459-1 ..............Building lime. Definitions, specifications and conformity criteria

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BS EN 934-3 ..............Admixtures for concrete, mortar and grout. Admixtures for masonry mortar. Definitions, requirements, conformity and marking and labelling BS EN 998-2 ..............Specification for mortar for masonry. Masonry mortar evaluation

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conformity,

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BS EN 12004 .............Adhesives for tiles. Requirements, classification and designation

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BS EN 12878 .............Pigments for the colouring of building materials based on cement and/or lime. Specifications and methods of test

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BS EN 13888 .............Grout for tiles. Requirements, evaluation of conformity, classification and designation

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PD 6472 .....................Guide to specifying the quality of building mortars PD 6678 .....................Guide to the specification of masonry mortar

2.2

MORTAR MATERIALS

2.2.1

Preparation Requirements

1

The required class of mortar, together with the type of mix, shall be as described in the Project Documentation.

QCS 2014

2

Section 13: Masonry Part 02: Mortar and Grout

Page 3

Mortar shall be mixed only as and when required in the relevant proportions indicated in Table 2.1, until its colour and consistency are uniform. The constituent materials shall be accurately gauged allowance being made for bulking of sand. Table 2.1 Mortar Mixes Nominal Mix by mass and their compressive strength Cement (C), Lime (L) & Sand Cement (C) & Sand (S) Compressive (S) with or without entrainment with or without entrainment strength at 28 days Class (kg) (kg) 2 N/ mm C L S C S 740

85

775

M4

105

35

725

110

755

M6

135

25

700

155

710

M12

190

20

655

190

675

2

.

50

.l. l

70

4 6

12

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M2

The inclusion of mortar plasticisers will not be permitted without approval of the Engineer.

4

All mortar shall be conveyed fresh to the works as required for use. Mortar which has begun to set or which has been site-mixed for a period of more than one hour in the cases of Classes M2, and M6, and two hours in the case of classes M4 and M12 shall not be used.

5

Plasticizing and set retarding mortar admixtures shall comply with BS EN 934-3 and shall be supplied with instructions for use.

6

Ready-mixed lime: sand for mortar and ready-to-use retarded mortar shall comply with the relevant provisions of BS EN 998-2 or ASTM C270.

2.2.2

Cement

1

Cement is to comply with the relevant provisions of Section 5, Concrete.

2

Mortar for use in contact with the ground will be mixed using sulphate resistant cement and comply with the relevant provisions of Section 5, Concrete.

2.2.3

Aggregates

1

Aggregates are to generally comply with the relevant provisions of Section 5, Concrete.

2.2.4

Water

1

Water is to comply with the relevant provisions of Section 5, Concrete.

2.2.5

Lime

1

Lime for mortar shall be in the form of lime putty, complying with the relevant provisions of BS EN 459-1.

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Section 13: Masonry Part 02: Mortar and Grout

Page 4

EPOXY

2.3.1

General Requirements

1

Epoxy grouts shall comply with the relevant provisions of BS EN 12004, BS EN 13888 as applicable.

2.4

HIGH BOND

1

Mortar mixture is to consist of, by volume, one-part Portland cement, three-parts sand with addition of water and liquid acrylic resin.

2

The mortar will have the following properties when tested in accordance with the relevant provisions of PD 6678:

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2.3

compressive strength : minimum 20 N/mm², using 50 x 50 x 50 mm cubes

(b)

tensile strength :

minimum 4 N/mm², using the 25 x 25 x 25 mm briquettes

(c)

flexural strength :

minimum 6 N/mm², using flexural bar

(d)

brick bond strength :

minimum 3 N/mm², using crossed brick.

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(a)

GROUTS

2.5.1

General Requirements

1

The required class of mortar, together with the type of mix, shall be as described in the Project Documentation.

2

Cement grout shall be mixed in the relevant proportions indicated in the Table 2.2 using the minimum quantity of water to ensure the necessary fluidity and to render it capable of penetrating the work.

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Table 2.2 Grout Mixes

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Class G1 G2 G3 G4 G5 G6

Nominal Mix by Mass Cement

Sand

pfa

1 1 1 1 1 1

3 10 -

10 4 ½

3

Cement grout shall be used within one hour of mixing, except where containing a retardant admixture.

4

Sulfate-resisting cement shall not be used as a constituent of grouts containing pulverised fuel ash.

5

Grout to have a compressive strength of 17,500 kPa at 28 days.

QCS 2014

Section 13: Masonry Part 02: Mortar and Grout

Page 5

PIGMENTS FOR COLOUR

2.6.1

General Requirements

1

Mineral pigments only to be used.

2

Any pigments used to colour cement or cement products should meet the requirements of BS EN 12878.

3

Pigments shall be inert, stable to atmospheric conditions, alkali resistant and water insoluble.

2.7

TUCK POINTING

2.7.1

General

1

This Clause specifies the requirements for tuck pointing of existing masonry and stone work.

2

Mortars to comply with the relevant provisions of Clause 2.2 of this Part.

2.7.2

Protection

1

Newly pointed joints are to be protected from rain, until pointed joints are sufficiently hard enough to prevent damage.

2.7.3

Existing Mortar Joints

1

The existing mortar joints (both bed and head joints) are to be cut out and removed by means of a toothing chisel or a special pointer’s grinder, to a uniform depth of 20mm, or until sound mortar is reached. Care is to be taken so as not to damage the edges of existing masonry units.

1

Remove all dust and debris from the joints by brushing, blowing with air or rinsing with water.

2.7.4

Installation of Tuck Pointing Mortar

1

Immediately prior to application of mortar, the joints to be tuck-pointed are to be dampened. After dampening, the masonry units should be allowed to absorb all surface water prior to application of pointing mortar

2

The mortar is to be tightly packed into the joints in thin layers, approximately 5 mm thick maximum.

3

Each layer should become “thumbprint hard” before applying the next layer.

4

The final layer is to be flush with surfaces of masonry units. When the mortar becomes “thumbprint hard”, joints can be tooled.

2.7.5

Tooling of Joints

1

A jointing tool is to be used to produce a smooth, compacted, concaved joint.

2

Tool joints in patch work are to be finished to match the existing surrounding joints.

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2.6

QCS 2014

Section 13: Masonry Part 02: Mortar and Grout

Page 6

Replacement of Masonry Units

1

Mortar joints surrounding masonry units which are to be removed and replaced are to be cutout with a toothing chisel. The units which are to be removed may be broken and removed, provided that the surrounding units to remain are not damaged. Once the units are removed, old mortar is to be carefully chiselled out, and all dust and debris are to be swept out with a brush. If the units are located in a cavity wall, care should be exercised not to allow debris to fall into the cavity.

2

The surface of the surrounding units are to be dampened before the new units are placed. The existing masonry should absorb all surface moisture prior to the installation of the new replacement units. The contact surfaces of the existing masonry and the new replacement masonry units are to be buttered with mortar. The replacement masonry units should be centred in the opening and pressed into position. Excess mortar is to be removed with a trowel head and bed joints are to pointed. When the mortar becomes “thumbprint hard”, joints are to be tooled.

2.7.7

Cleaning

1

Exposed masonry surfaces shall be cleaned on completion.

2

Mortar droppings and other foreign substances shall be removed from the wall surfaces.

3

Surfaces shall be wetted with clean water, and then washed down with a solution of soapless detergent specially prepared for cleaning masonry. Brush with stiff fibre brushes while washing, and immediately thereafter hose down with clean water. Free clean surfaces from any traces of detergent, foreign streaks or stains of any nature.

4

Protect adjoining construction materials during cleaning operations.

5

Use of muratic acid for cleaning brickwork is prohibited.

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2.7.6

END OF PART

QCS 2014

Section 13: Masonry Part 03: Accessories

Page 1

3

ACCESSORIES ............................................................................................. 2

3.1

GENERAL DESCRIPTION ............................................................................ 2

3.1.1 3.1.2

Scope References

3.2

ANCHOR AND TIE SYSTEMS ...................................................................... 2

3.2.1

Cavity Wall Ties

3.3

CONTROL JOINTS........................................................................................ 3

3.3.1

Movement Joints

3.4

JOINT REINFORCEMENT ............................................................................ 3

3.4.1

Reinforcement for Concrete Block Masonry

3.5

LINTELS ........................................................................................................ 3

3.5.1

Precast or Cast In-situ Lintels

2 2

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QCS 2014

Section 13: Masonry Part 03: Accessories

Page 2

ACCESSORIES

3.1

GENERAL DESCRIPTION

3.1.1

Scope

1

This Part specifies anchor and tie system, joint control, reinforcement and lintels associated with masonry works.

2

Related Parts and Sections are as follows: General Masonry Laying

Section 1 Section 6

General Concrete

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.

3

References

1

The following standards are referred to in this Part:

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BS EN 845-1:2003+A1:2008 Specification for ancillary components for masonry. Ties, tension straps, hangers and brackets

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BS EN 10346:2009 ....Continuously hot-dip coated steel flat products. Technical delivery conditions

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BS EN 10143:2006, ...Continuously hot-dip coated steel sheet and strip. Tolerances on dimensions and shape

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BS EN 13658-2:2005 .Metal lath and beads. Definitions, requirements and test methods. External rendering

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GSO ISO 4998:2007, .Continuous hot-dip zinc-coated carbon steel sheet of structural quality

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ISO 14657:2005, .......Zinc-coated steel for the reinforcement of concrete

3.2

ANCHOR AND TIE SYSTEMS

3.2.1

Cavity Wall Ties

1

Cavity wall ties to comply with BS EN 845-1 and be of one of the following types as directed by the Engineer or as noted in the Project Documentation: (a)

Butterfly wall tie fabricated from stainless steel wire

(b)

Double triangle wall tie fabricated from stainless steel wire

(c)

Vertical-twist tie fabricated from stainless steel strip.

2

Ties fabricated from wire are not be used for cavities exceeding 75 mm.

3

All connections between masonry walls or partitions and concrete columns or walls shall be made using propriety stainless steel ties secured to stainless steel fixing channels embedded in the concrete.

QCS 2014

Section 13: Masonry Part 03: Accessories

Page 3

CONTROL JOINTS

3.3.1

Movement Joints

1

Movement joints to be 12 mm wide and formed where indicated or where continuous runs of block walling exceed 8 metres in length.

2

The joints are to be straight and vertically formed with uncut faces of the blocks to each side and filled with an approved compressible material manufactured specifically for building into movement joints.

3

External joints are to be sealed with a mastic compatible with the joint filling material when the block walling is thoroughly dry and the joint surfaces have been cleaned with a wire brush or mechanical tool.

4

A primer is to be applied to the joint surface if specified by the manufacturer of the mastic.

5

Mastic sealing to unfilled movement joints to be on an approved foam backing strip placed to ensure the correct depth of sealant.

3.4

JOINT REINFORCEMENT

3.4.1

Reinforcement for Concrete Block Masonry

1

Expanded mesh lath reinforcement is to be fabricated from minimum nominal thickness 0.3 mm as per BS EN 13658-2:2005 , or welded wire lath or mesh with a minimum weight of 0.87 kg/m² as per BS EN 13658-2:2005; or Zinc coated steel with one of the surface quality Types "B" or “C” with minimum zinc coating - 225 g/m² as per BS EN 10346:2009, as directed by the Engineer or Project Documentation.

2

The widths of reinforcement for various wall thicknesses to comply with Table 3.1.

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3.3

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Table 3.1 Expanded Steel Mesh Joint Reinforcement Widths

Block Thickness (mm)

Reinforcement Width (mm)

100

50

150

60

200

110

3.5

LINTELS

3.5.1

Precast or Cast In-situ Lintels

1

Precast or cast in-situ lintels to be manufactured in accordance with the relevant provisions of Section 5.

QCS 2014

Section 13: Masonry Part 03: Accessories

Page 4

2

An open joint not less than 12 mm are to be left between the ends of precast or cast in-situ concrete lintels and the blocks adjacent to these ends. These open joints should be left as long as possible during construction and not be filled in until plastering or other works necessitate such filling.

3

Lintels are to have a minimum end bearing of 200 mm.

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END OF PART

QCS 2014

Section 13: Masonry Part 04: Unit Masonry

Page 1

UNIT MASONRY ...................................................................................................................... 2

4.1 4.1.1 4.1.2 4.1.3

general ..................................................................................................................................... 2 Scope 2 References 2 Definitions: 3

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7

clay masonry units ................................................................................................................... 3 Clay Bricks 3 Clay Blocks 3 Classification of Clay Masonry Units 3 Requirements of Clay Masonry Units 3 Marking of Clay Blocks 5 Testing of Clay Blocks 5 Criteria of Technical Conformity of Clay Blocks 5

4.3 4.3.1

Calcium Silicate Bricks ............................................................................................................. 6 General Requirements 6

4.4 4.4.1 4.4.2 4.4.3 4.4.4

concrete masonry units ............................................................................................................ 6 Concrete Blocks 6 Manufacture of Concrete Blocks 8 Block Dimensions 9 Precast Concrete Bricks 9

4.5 4.5.1 4.5.2 4.5.3 4.5.4

glass units .............................................................................................................................. 10 General Requirements 10 Submittals 10 Material Storage and Handling 10 Laying 10

4.6 4.6.1

gypsum units .......................................................................................................................... 11 General Requirements 11

4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6 4.7.7 4.7.8 4.7.9 4.7.10

STONE Work ......................................................................................................................... 11 General Requirements 11 Anchorage Devices 11 Mortar 12 Fabrication 12 Installation 12 Wall Cladding 13 Paving and Flooring 13 Erection Tolerances 14 Submittals 14 Visual Mock-ups 14

4.8 4.8.1 4.8.2 4.8.3 4.8.4

CASt stone ............................................................................................................................. 15 General Requirements 15 Submittals 15 Product Delivery, Storage and Handling 15 Anchorage Devices 15

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QCS 2014

Section 13: Masonry Part 04: Unit Masonry

Page 2

4

UNIT MASONRY

4.1

GENERAL

4.1.1

Scope

1

This Part specifies clay and concrete masonry units.

2

Approval from Qatar Standards shall be obtained for masonry units intended to be used in elements subject to thermal insulation.

3

Related Parts and Sections are as follows: General Mortar And Grout Accessories Masonry Laying

Section 1 Section 5 Section 15

General Concrete Thermal Insulation of Buildings

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This Section Part 1 Part 2 Part 3 Part 5

References

1

The following standards are referred to in this Part:

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ASTM C270 ................Standard Specification for Mortar for Unit Masonry

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ASTM C1364 ..............Standard Specification for Architectural Cast Stone BS 187........................Calcium silicate bricks

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BS 1217 .....................Cast stone

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BS 6073-2 ..................Precast concrete masonry units. Guide for specifying precast concrete masonry units

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BS EN 771 .................Specification for masonry units BS EN 772-2 ..............Methods of test for masonry units. Determination of percentage area of voids in masonry units (by paper indentation) BS EN 771-3 ..............Specification for masonry units. Aggregate concrete masonry units (dense and light-weight aggregates) BS EN 771-5 ..............Specification for masonry units. Manufactured stone masonry units EN 771-1 ....................Specification for masonry units. Clay masonry units EN 771-2 ....................Specification for masonry units. Calcium silicate masonry units EN 998-2 ....................Specification for mortar for masonry. Masonry mortar PD 6678 .....................Guide to the specification of masonry mortar

QCS 2014

Section 13: Masonry Part 04: Unit Masonry

Page 3

Definitions:

1

Aggregate: granular material used in construction and may be natural, manufactured or recycled.

2

Natural aggregate: aggregate from mineral sources which has been subjected to nothing more than mechanical processing.

3

Manufactured aggregate: aggregate of mineral origin resulting from an industrial process involving thermal or other modification.

4

Recycled aggregate: aggregate resulting from the processing of inorganic material previously used in construction.

5

Lightweight aggregate: aggregate of mineral origin having a particle density not exceeding 2,000 kg/m3 or a loose bulk density not exceeding 1,200 kg/m3.

4.2

CLAY MASONRY UNITS

4.2.1

Clay Bricks

1

A clay brick is a masonry unit not exceeding 290 mm in length and 115 mm in height.

2

Semi-solid bricks are bricks having up to 25 % holes or cavities of their gross volume.

3

Cellular bricks contain the same voids as hollow bricks but with the cavities closed at one end.

4

Clay bricks to conform to the requirement of EN 771-1.

4.2.2

Clay Blocks

1

A clay block is a masonry unit which exceeds in any of its normal dimensions the maximum dimensions given for clay bricks in Clause 4.2.1-1.

4.2.3

Classification of Clay Masonry Units

1

Units shall be classified as follows:

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4.1.3

(a)

non-load-bearing blocks

(b)

blocks produced for use in non-load-bearing walls

(c)

load-bearing blocks

(d)

blocks produced for use in load-bearing walls.

4.2.4

Requirements of Clay Masonry Units

1

Clay masonry units shall be of a uniform shape, free from surface cracks which decrease its properties. Its outer surface shall be serrated to increase the bonding force with the mortar. It should be well burnt, of a uniform texture and free from pebbles of lime.

2

The dimensions of the clay masonry blocks for walls to be as given in Table 4.1.

QCS 2014

Section 13: Masonry Part 04: Unit Masonry

Page 4

Table 4.1 Dimensions of Clay Masonry Blocks Nominal Dimensions (mm) Length

Width

Height

Length

Width

Height

300

100

200

290

100

190

300

150

200

290

150

190

300

200

200

290

200

190

400

100

200

390

100

190

400

150

200

390

150

190

400

200

200

390

200

190

The tolerance in the actual dimensions of the blocks shall be ±4 %, provided that the difference between the largest actual dimension and the smallest one in the same consignment does not exceed 5 % as shown in Table 4.2.

Width

390

406

375

20

290

302

278

15

200

208

192

10

156

144

7.5

198

182

10

Smallest

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190

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150 Height

Permissible difference between largest actual size and smallest one in one (consignment)

Largest

as

Length

Permissible size (mm)

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Size (mm)

se

Dimension

ta

Table 4.2 Dimensional tolerance

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3

Actual Dimensions (mm)

Adjacent faces of the units are to be at right angles, and the tolerance of the squareness not to exceed 2 mm for each 100 mm length.

5

The faces should have a plain surface, and the tolerance not to exceed 5 mm from the straight line.

6

Water absorption of the units shall not exceed 25 % by weight for the individual block and 20 % by weight for the average of tested blocks.

7

The compressive strength of the units, calculated for the total area including holes shall not to be less than the limits shown in Table 4.3.

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Table 4.3 Compressive Strength Class of Block

Minimum Value for Compressive Strength of One Block

Minimum Average of the Compressive Strength

N/mm²

(kg/cm²)

N/mm²

(kg/cm²)

6

6

(60)

7.5

(75)

Class 12

12

(120)

15

(150)

Class

QCS 2014

Section 13: Masonry Part 04: Unit Masonry

Page 5

4.2.5

Marking of Clay Blocks

1

Every clay block is to be marked with the name of the manufacturer and/or his registered mark.

2

The class of block should be shown on every load-bearing block.

4.2.6

Testing of Clay Blocks

1

The following tests are to be carried out on the representative sample taken according to Clause 4.2.6-3 of this Part: appearance

(b)

dimensions

(c)

compressive strength

(d)

water absorption (optional)

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(a)

Appearance and dimension tests are to be carried out on the same units that are to be tested for compressive strength and water adsorption. Appearance and dimension tests are to be carried out before the other referenced tests.

3

A representative sample is to be taken from the consignment not exceeding 15,000 blocks as shown in Table 4.4. As for consignments exceeding that number, one excess block is to be taken for each 1,000 additional blocks. The sample is to be taken at random during loading or unloading by dividing the consignment into a convenient number of real or imaginary sections. From each section, a corresponding number of units are to be taken, provided that the total number of samples units is equal as shown in Table 4.4.

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Table 4.4 Sample Sizes Number of units for each test Appearance and size measurements (mandatory) Compressive strength (mandatory)

Water absorption (optional)

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Number of units in consignment

5,000 or less

5

3

More than 5,000 and up to 10,000

10

5

More than 10,000 and up to 15,000

15

10

4

The methods of test for clay bricks shall be in accordance with the relevant provisions of EN 771-1.

4.2.7

Criteria of Technical Conformity of Clay Blocks

1

The consignment is to be accompanied with a certificate indicating its conformity with all the requirements of this standard.

2

The consignment is to be considered complying with this standard if the representative sample passes all the mandatory tests mentioned in this standard.

QCS 2014

3

Page 6

Compressive test : the consignment will be considered complying with this standard if the following two conditions are fulfilled: (a)

each of the tested blocks meets the minimum limit of compressive strength mentioned in this standard

(b)

the tested blocks meet the minimum limit of the average compressive strength mentioned in this standard.

Water absorption : the consignment is to be considered complying with this standard if the following two conditions are fulfilled: (a)

each tested block should meet the minimum limit of water absorption mentioned in this standard

(b)

the average water absorption for the tested blocks will meet the minimum limit of the average water absorption mentioned in this standard.

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Section 13: Masonry Part 04: Unit Masonry

If the tested units do not comply with the requirements of the appearance, dimension and/or absorption tests, other units may be taken for testing. If these units do not pass the test(s), the consignment is to be considered non-complying with this standard.

4.3

CALCIUM SILICATE BRICKS

4.3.1

General Requirements

1

Calcium silicate bricks are to conform to the requirements of EN 771-2.

2

The brick is to be constructed of sand consisting mainly of quartz or uncrushed siliceous gravel or crushed siliceous gravel or crushed rock or a combination of such materials.

3

Suitable pigments may be mixed into the constituents to produced bricks of the required colour.

4.4

CONCRETE MASONRY UNITS

4.4.1

Concrete Blocks

1

Blocks are to be made with Portland cement unless used below ground level in which case sulphate resisting Portland cement shall be used.

2

All blocks are to be manufactured, supplied and tested in accordance with BS EN 771-3, BS 6073-2, and approved by Qatar Standards.

3

Recycled Aggregates may be used to replace up to 50% of natural coarse aggregates when 2 the average compressive strength is equal to or greater than 7.0 MPa (N/mm ).

4

Recycled Aggregates may be used to replace up to 100% of natural aggregates (fine and 2 coarse) when the average compressive strength is less than 7.0 MPa (N/mm ).

5

Aggregate shall meet the following requirements:

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(a)

The manufacturer shall declare the materials to be used, the percentage of each material, their grading and shall be responsible for their suitability.

QCS 2014

6

Section 13: Masonry Part 04: Unit Masonry

Page 7

(b)

The acid soluble sulphate, as measured by BS EN 1744-1, shall not exceed 0.8% by weight of aggregate.

(c)

The acid soluble chloride, as measured by BS EN 1744-5, shall not exceed 0.2% by weight of aggregate.

The use of blocks shall comply with Table 4.5. The minimum compressive strength of the average of 3 blocks shall be as given in Table 4.5. The associated mortar requirements for use with different applications for blocks is also provided in Table 4.5. Details of mixes for the class of mortar specified is provided in Part 2 of this Section. Table 4.5 Compressive Strength

.

Uses for which Blocks are Suitable

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Minimum Compressive 2 Strength (N/mm )

Class of Mortar

Average of 3 Blocks

Lowest Individual Block

1

7.0

5.6

External non-load bearing walls

2

10.4

8.3

Load bearing walls

3

17.4

14

4

14.0

11.2

5

4.0

3.6

Internal non-load bearing walls

M6

5

4.0

3.6

Roof Block

M4

5

4.0

Protective skins to foundations

M6

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Classes

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Classification

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M6

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M6 M12

Soakaways and manholes

M12

as

Load bearing walls below ground

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3.6

Manufacturer should label or clearly define the classification or the uses of the blocks in factory.

8

Consultant or contractor should also mention the classification or the uses of the blocks in request sheet when the samples submit for testing in laboratory.

9

The volume of the cavities in the block shall not exceed 50 % of the gross volume of the block. The overall dimensions and wall and web thicknesses shall comply with Table 4.6.

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Table 4.6 Block Dimensions and Wall and Web Thicknesses Minimum Thickness (mm)

Coordinating (nominal) size (mm)

Work size (mm)

400 x 200 x 100

Wall

Web

390 x 190 x 100

19

19

400 x 200 x 150

390 x 190 x 150

25

25

400 x 200 x 200

390 x 190 x 200

32

30

Notes: (a) (b)

Co-ordinating size is the size of the space allocated to the block including the joints and tolerances. Work size is the actual size for manufacture within the tolerances specified.

QCS 2014

10

Section 13: Masonry Part 04: Unit Masonry

Page 8

Subject to the tolerances specified in Table 4.7 and to any requirement for blocks with special faces, all surfaces should be flat and rectangular and adjacent surfaces are to be at right angles to one another with clearly defined undamaged arises. Table 4.7 Block Tolerances Dimensions

Work Size of Block

Length

+ 3 mm to - 5 mm

Height

+ 3 mm to - 5 mm

Thickness

 2 mm for any measurement  1.5 mm for the average of 7 measurements in any one block.

Unless otherwise specified, all block faces are to provide a satisfactory bond for mortar, plastering or rendering.

12

Each block manufactured from sulphate resisting cement is to be colour coded with an identifying mark.

13

All connections between masonry walls or partitions and concrete columns or walls shall be made using propriety stainless steel ties secured to stainless steel fixing channels embedded in the concrete.

14

Full Water Absorption:

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11

Water absorption by capillarity method:

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The average water absorption of the tested sample shall not exceed 7% and no individual block shall have a water absorption greater than 7.5% (in accordance with CML Method 997).

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The manufacturer shall declare in g/m²s the maximum water absorption coefficient due to capillarity action of the exposed face of the unit.(according to EN 771-3:2003 ) Manufacture of Concrete Blocks

1

Blocks are to be manufactured in a vibrated/pressure block making machine using cement and aggregate in the proportions required to produce the minimum strengths given in Table 4.5.

2

The design of the cavities and webs in hollow blocks is to be submitted to the Engineer for approval before production commences.

3

The materials to be mixed in a mechanical mixer and placed in the block-making machine in layers not exceeding 100 mm, each layer being thoroughly vibrated and compacted before the addition of the next.

4

Immediately after manufacture the blocks are to be stacked on clean, level, non-absorbent pallets in honeycomb fashion. The pallets are to be marked with the date of production (in English and Arabic) and stored in a level curing and stacking area in such a manner that one day’s production is separated from the next.

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Blocks manufactured from mobile machines are to be cast on to a clean concrete hardstanding. Each day’s production shall be easily identifiable and kept separate from the next.

6

All blocks, however manufactured, are to be immediately protected from the effects of the sun and wind by suitable moisture retaining coverings.

4.4.3

Block Dimensions

1

Block dimensions are to be measured in accordance with BS EN 772-2.

2

Blocks not exceeding 75 mm thick and blocks for use in the ground are to be solid unless otherwise directed. All other blockwork is to be hollow.

4.4.4

Precast Concrete Bricks

1

Precast concrete bricks are to conform to the requirements of BS 6073-2.

2

Precast concrete bricks are to be manufactured by compacting concrete under high pressure into a mould.

3

The pressure employed is to be such that a high initial strength is achieved, enabling the brick to be removed immediately, by extrusion, from the mould.

4

The cement used should be rapid hardening Portland cement and conform to the requirements Part 3 of Section 5.

5

The aggregate used to be sand or manufactured sand.

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GLASS UNITS

4.5.1

General Requirements

1

Glazing units shall incorporate expansion-contraction thermal foam tape, sealants, flashings, and other items necessary for complete installation.

4.5.2

Submittals

1

The Contractor shall submit assembly instructions and installation drawings as required to indicate methods on construction, location and spacing of anchorage, joinery, finishes, sizes, shape, thickness of all materials and relationship to the adjoining work.

4.5.3

Material Storage and Handling

1

Material shall be stored in a dry place, off the ground, where temperature will not exceed 32 ºC handle material to prevent damage to finished surfaces. Do not install scratched or damaged components.

2

After installation, finished surfaces shall be protected from damage caused by ensuing work.

4.5.4

Laying

1

The Contractor shall verify all applicable field dimensions and adjust as necessary to accommodate the glazed wall.

2

The glass block grid system for the wall shall be assembled and sealed in accordance with instructions furnished by the manufacturer.

3

The assembled glass block grid system frame shall be placed into a properly prepared and sized rough opening and adjust until plumb and level. The grid system shall be screwed or nailed into place utilising all predrilled holes in the nailing flange.

4

A foam tape gasket shall be adhered to each of the glass blocks according to instructions furnished by manufacturer of the glass block grid system. The glass blocks shall be carefully inserted into the grid system from the exterior side of the wall so that each block is pressed against the T-Bar and the foam tape does not roll back.

5

Sealant to completely fill the channel shall be applied around each glass block and wipe flush with the surface. The sealant shall be applied to the exterior frame corners according to instruction furnished by the grid system manufacturer.

6

All exposed surfaces of the glass block grid system shall be cleaned with a clean, soft cloth and mild hand soap using gentle rubbing action. Abrasive or solvent-type cleaner, detergents or paint removers shall not be used.

7

All labels shall be removed from the glass blocks and cleaned with a soft cloth and water.

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4.6

GYPSUM UNITS

4.6.1

General Requirements

1

Blocks for claustra walls are to be manufactured and built generally in accordance with the preceding clauses for blockwork, except where otherwise noted below.

2

Blocks may be constructed of either white gypsum plaster

(b)

concrete

(c)

white concrete using white Portland cement and white aggregates, as described in the relevant provisions of Section 5, Concrete, or as described in the Project Documentation.

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All blocks are to be finished with a fine finish to an approved ornamental pattern and are to be 100 m thick unless otherwise noted with slots in ends of blocks to receive reinforcement.

4

Claustra walls should be built with vertical straight joints reinforced with 12 mm mild steel reinforcing bars vertically at each straight joint pinned to structure at each end and surrounded solid with mortar.

5

Blocks are to be bedded in a mixture of white cement and sand (1:4) and struck pointed to approval.

4.7

STONE WORK

4.7.1

General Requirements

1

Stone work includes rough cut stone, marble, limestone, granite.

2

Stone work shall be executed by an approved specialist sub-Contractor

3

Stone should be sound and free from defects which would impair strength, durability or appearance. Each species of stone is to be provided from a single quarry. Quarries and fabrication plants should be available for inspection by the Engineer.

4

All stone to be of soundness (hardness and density), texture, graining colour, tone and range matching the Engineer’s sample.

5

Dielectric separator: Bituminous paint is to be used in accordance with the manufacturer’s instructions and shall be approved by the Engineer.

6

Cushions: Clear plastic or neoprene, 25 by 50 mm, thickness as required.

4.7.2

Anchorage Devices

1

Anchors, dowels, cramps, plug anchors, angles, relieving anchors: Fabricated of stainless steel or non ferrous metal (e.g. bronze) complying with thickness as required to system imposed loads but not less than 5 mm.

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Embedded items shall be of malleable iron castings or steel fabrications, thickness as required to sustain imposed loads but not less than 5 mm thick products to be stainless steel or non-ferrous. Devices embedded in concrete or masonry include the following: (a)

edge inserts with tee-shaped wedge-action slot, with askew head bolt, washer and nut

(b)

dovetail anchor slots of size to receive specified anchor, filled with waterproof filler and open face sealed

(c)

adjustable insert with square nut slinging in integral track.

Reinforcing mesh used for anchorage shall be stainless steel.

4.7.3

Mortar

1

Mortar shall comply with the relevant provisions of Part 2 of this Section. The cement used for stone work mortar shall be white Portland cement. The Class of mortar

2

Mortar for setting stone flooring, steps and treads shall be Class M7 mortar. The grout shall incorporate a waterproofing additive for wet area flooring.

3

Mortar for setting all other stone shall be Class M3 mortar. The mortar shall incorporate a waterproofing additive for wet areas and exterior stone. The mortar shall incorporate a shrinkage-reducing accelerator diluted with water in the ratio as recommended by the manufacturer.

4

Pointing mortar: shall be Class M5 mortar with a mineral colouring admixture as required to match the stone. The mortar shall incorporate a waterproof additive for exterior and wet area pointing.

4.7.4

Fabrication

1

The Contractor shall accurately cut, dress, drill, fit and finish stonework to shapes and dimension shown on the approved Shop Drawings. Exposed plane surfaces shall be made true in line and exposed curved surfaces true in radius. The thickness of the stone shown is the minimum thickness.

2

For wall facings, the Contractor shall do the following:

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(a)

cut exposed external corners of stone as shown

(b)

ease exposed external edges where shown

(c)

cut all other joints and edges square and at right angles to face, and with backs parallel to face

(d)

make arises straight, sharp, true and continuous at joints

(e)

cut curved stone panels true to radius as shown to produce an even, flush curved surface.

4.7.5

Installation

1

Dovetail anchor slots, wedge type inserts, and other items requiring building in to concrete or masonry work shall be furnished in sufficient time so as not to delay the progress of the work. Tie inserts shall be wired into reinforcing to prevent displacement. No forced entry anchorage device will be allowed.

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Stone shall be set in accordance with the approved Shop Drawings, level, plumb, square and true with uniform joints, accurately aligned with grain running in the direction as approved by the Engineer unless otherwise stated elsewhere in the Project Documentation. The work shall match mock-ups.

3

Dowels, anchors and ties in shall be provided in sufficient quantity to eliminate “rattle” or loose pieces and to ensure a rigid installation. The extent of the anchorage and installation details shown are intended to indicate minimum requirements. In general, a minimum of one 2 anchor per 0.18 m is required, with additional anchorage provided where necessitated by the size, thickness and setting or shape.

4

Steel backup support shall be provided for the stone work where shown on the Project Drawings and as required to provide rigid installation. Steel support framing shall be anchored securely to the building structure.

4.7.6

Wall Cladding

1

Relieving angles shall be set as required for the proper support of stone. Before setting, the Contractor shall clean the stones and the backing. The stone shall be saturated with water before setting in mortar in order to prevent total absorption of moisture from the mortar.

2

Stone shall be set with two cushions per stone in every horizontal joint, extending full depth of the stone and to within the dimension from the face as shown. Secure with anchors, dowels, and cramps of approved construction, as required for a rigid and secure installation. Fill anchorage holes with accelerated setting mortar. Rigidly secure strap anchors to the backing.

3

Flashing materials shall be repaired to their original condition where they have been punctured by anchorage or damaged during setting.

4

Cavities shall be kept behind the facing free of mortar or other foreign material.

5

Fill and seal joints as indicated in the Project Documentation.

4.7.7

Paving and Flooring

1

The following shall be performed by the Contractor when laying paving and flooring:

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(a)

place reinforcing mesh in the setting bed

(b)

tamp the stone into the setting bed with mallet until firmly bedded to the proper level

(c)

remove stone, cover the back of the stone with wet cement and return to position on the setting bed; before applying the wet cement, wet the back of the stone to prevent major absorption of moisture from the cement

(d)

use cushions and spacers to maintain uniform jointing and setting.

Joints shall be grouted with water and neat cement by buttering the edges of the stones as they are laid. Surplus joint cement cleaned from face of the stone immediately.

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3

Where grinding is required to completely align and level joints, permit a minimum of six days of setting time to elapse before commencing grinding. Perform grinding by wet abrasion, in a manner as to retain the finish, to match the balance of stone paving, and so as to be free of depressions and grind marks. The Contractor shall exercise care to avoid damage to or soiling of adjacent work.

4.7.8

Erection Tolerances

1

The following maximum non-cumulative erection tolerances shall be complied with: variation from plumb

+/- 3 mm in storey height

(b)

variation from level

+/- 3 mm in any bay

(c)

variation in location

+/- 6 mm in any bay

(d)

edge alignment

1.5 mm

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Submittals

1

Submittals shall be made in accordance with the relevant provisions of Section 1, General and the following Clauses.

2

Shop Drawings: The Contractor shall submit shop drawings of the stonework showing in detail the layout, jointing, anchors and dowels, dimensions, sizes and locations of cut-outs, adjoining work, etc. Each piece on the Shop Drawings is to correspond to the identification number on the back of each stone. The Contractor shall co-ordinate all components which are specified elsewhere (flashing, insulation) which comprise the system into this submittal. Shop Drawings shall be co-ordinated with all related trades.

3

Samples: The Contractor shall submit to the Engineer 600 x 600 mm sample panels with cross-joints to show the sealant materials of each type and finish of stone required. The samples shall show the full range of colour and texture expected in the finished work. In addition the Contractor shall submit one (1) full size sample of each type and finish, falling in the average colour and texture range. The Engineer’s review and approval of the sample is to be for colour, texture and pattern only. Compliance with all other requirements is the exclusive responsibility of the Contractor.

4.7.10

Visual Mock-ups

1

Following the approval of the samples, the Contractor shall construct mock-ups for approval by the Engineer prior to installation. Mock-ups to be provided shall be as follows:

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4.7.9

(a)

wall facing: assembled to simulate the final condition, direction of graining, and indicating joint conditions, use of spacers, shims, anchorage, relieving angles, supports, and all other features of the final work

(b)

flooring: samples of flooring/skirting, etc, of each type of stone work specified is to consist of a full pattern and be complete with all anchors, bedding, jointing, sealers, etc., in accordance with approved shop drawings

(c)

provide mock-up for any other stonework as shown on the drawings and as required by the Engineer.

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CAST STONE

4.8.1

General Requirements

1

The requirements for manufactured stone for vertical applications and for trim, including copings and sills shall comply with the relevant provisions of BS 1217 or ASTM C1364 and reconstructed masonry shall comply with the relevant provisions of BS EN 771-5.

2

Cast stone work is to be executed by an approved specialist subcontractor.

3

All cast stone is to be sound and free from defects which would impair strength, durability or appearance. Each type of stone is to be supplied from the same quarry. Quarries and fabrication plants are to be available for inspection by the Engineer.

4

Joint sealing compounds used with stone will conform to Section 24, Part 15.

4.8.2

Submittals

1

Samples: The Contractor shall supply cast stone sample panels, size 200 x 200 x 300 mm, for each colour and finish of stone for approval by the Engineer.

2

Shop Drawings: The Contractor shall provide drawings of cast stone work showing anchorages for the approval of the Engineer.

3

Certificates: The Contractor shall provide certification documentation as necessary, describing in detail testing laboratory facilities and qualifications of its principals and key personnel. The Contractor shall also provide certification that the cast stone meets requirements of the Project Documentation.

4.8.3

Product Delivery, Storage and Handling

1

Cast stone shall be cured for a minimum of 30 days before delivery. Each unit is to have the date of manufacture impressed in the back of the stone.

2

Cast stone shall be stored under waterproof covers on boarding clear of the ground and shall be protected from handling damage, dirt, stain, water and wind.

4.8.4

Anchorage Devices

1

Coping stones shall be anchored to the masonry with no less than two dowels to each stone. Dowels may be either 8 mm stainless steel pipe 75 mm long or 12 mm diameter stainless steel bars 75 mm long.

2

Course stones shall be anchored to the backing with one metal anchor for each 600 mm in length. Each stone shall have not less than two anchors. Anchors are to be stainless steel 4 mm x 30 mm with the end in the stone turned down 25 mm and other end turned up to 50 mm

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4.8

END OF PART

Section 13: Masonry Part 05: Masonry Laying

Page 1

5

MASONRY LAYING....................................................................................... 3

5.1

INTRODUCTION ........................................................................................... 3

5.1.1 5.1.2

Scope References

5.2

WORKMANSHIP ........................................................................................... 3

5.2.1

General Requirements

5.3

BLOCKWORK................................................................................................ 3

5.3.1 5.3.2 5.3.3

Setting Out of Blockwork Wetting Blockwork Units Laying of Blockwork

5.4

BRICKWORK ................................................................................................. 5

5.4.1 5.4.2

Brickwork Wetting and Brick Wetting Test Brickwork Laying

5.5

REINFORCEMENT........................................................................................ 6

5.5.1 5.5.2 5.5.3 5.5.4 5.5.5

General Requirements Placing Reinforcing High Lift Grouting of Cavity Walls Low Lift Grouting of Cavity Walls Water Penetration Testing

5.6

FAIR FACED BLOCK WALLS ....................................................................... 8

5.6.1

General Requirements

5.7

OPENINGS .................................................................................................... 8

5.7.1

General Requirements

5.8

INTERSECTING WALLS AND PARTITIONS ................................................ 8

5.8.1

General Requirements

8

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QCS 2014

CONNECTIONS BETWEEN WALLS OR PARTITIONS AND COLUMNS .... 9

5.9.1

General Requirements

9

5.10

JOINTS BETWEEN PARTITIONS AND FLOOR SOFFITS ........................... 9

3 3

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9 9

CAVITY WALLS ........................................................................................... 10

5.12.1 General Requirements 5.13

5 5

FILLING HOLLOW BLOCK WALLS............................................................... 9

5.11.1 General Requirements 5.12

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5.10.1 General Requirements 5.11

3

10

SERVICES ................................................................................................... 10

5.13.1 General Requirements 5.13.2 Fixings

10 10

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5.14

Section 13: Masonry Part 05: Masonry Laying

Page 2

DAMP-PROOF COURSES .......................................................................... 10

5.14.1 General Description 5.15

10

PROTECTION OF FINISHED WALLING..................................................... 11 11

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5.15.1 General Description

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Page 3

5

MASONRY LAYING

5.1

INTRODUCTION

5.1.1

Scope

1

This Part specifies workmanship and setting out of masonry works.

2

Related Parts and Sections are as follows: Mortar and grout Unit Masonry

Section 6

Concrete

5.1.2

References

1

The following standards are referred to in this Part:

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This Section Part 2 Part 4

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BS 743........................Materials for Damp-Proof Courses

BS 6398:1983 ............Specification for bitumen damp-proof courses for masonry

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BS 6515:1984 ............Specification for polyethylene damp-proof courses for masonry

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BS 8215:1991 ............Code of practice for design and installation of damp-proof courses in masonry construction

WORKMANSHIP

5.2.1

General Requirements

1

Work is to be performed by experienced workers under the direction of a qualified supervisor who is fully aware of the Project requirements. Final work is to be equal to any sample panels submitted to, and approved by, the Engineer.

5.3

BLOCKWORK

5.3.1

Setting Out of Blockwork

1

All blockwork is to be fully set out before laying commences to ensure:

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(a)

correct bonding over all lengths of wall particularly at openings and piers

(b)

minimum cutting

(c)

compliance with Table 5.1

The average thickness of both vertical and horizontal mortar joints is to be 10 mm exclusive of any key in the joint surfaces of the unit.

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Page 4

Table 5.1 Setting Out of Blockwork Item of Construction

Permissible Deviation (mm)

Type of Dimensions

Size and shape of wall elements

20

At Soffit

30

Height up to 3,000 mm

40

Straightness in 5,000 mm

8

Verticality up to 2,000 mm

15

Level of bed joints in 3,000 mm

15

Position in plan of any point or specified face in relation to nearest grid line on the same level

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At floor

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Space between walls

Position in elevation from design position

15

Level of sill or soffit for each 1,000 mm of width

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Door, window and other openings

15

with maximum of

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Verticality of any point for each 1,000 mm of height

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with maximum of

15

Wetting Blockwork Units

1

All blocks are to be adequately wetted with water before they are laid and the tops of walls left off from the previous day’s work are to be similarly wetted before the new work commences.

5.3.3

Laying of Blockwork

1

Block walls are to be built from undamaged blocks in stretcher bond unless otherwise specified.

2

All bed and vertical joints are to be spread with mortar to ensure complete and solid bedding and grouting through the full thickness of the wall. All keys in jointed surfaces must be completely filled.

3

Mortar extending into the cavities of hollow blocks which are to be reinforced and filled shall be removed.

4

Each block is to be adjusted to its final position in the wall whilst the mortar is still plastic. Any block which is moved after the mortar has stiffened shall be removed and relaid with fresh mortar.

5

Half blocks and special blocks are to be used as required to ensure correct bonding.

6

All perpends, quoins and joints are to be kept true and square, other angles are to be plumbed and bed joints levelled as the work proceeds.

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The work is to be carried out course by course not leaving any part more than 800 mm lower than another. Work, which is left at different levels, is to be racked (stepped) back to the approval of the Engineer.

8

In cavity wall construction both leaves are to be carried up together, not leaving any leaf more than 400 mm below the other.

9

Partitions shall be 100 mm thick unless otherwise noted. Partitions having lavatories or other plumbing fixtures secured to them back-to-back (or approximately so) are to be a minimum of 150 mm thick. Solid concrete masonry units shall be built in where full units cannot be used or where needed for the fixing of accessories. Bells or hubs of pipes must be completely enclosed.

10

Reinforced masonry partitions are to fully extend to the underside of slabs.

11

When pipes or conduits or both occur in plastered partitions, at least one web of the hollow masonry units must be retained.

12

When new masonry partitions start on existing floors, the existing floor finish material is to be cut down to the concrete surface. New masonry partitions are not to abut any existing plastered surfaces, except suspended ceilings.

5.4

BRICKWORK

5.4.1

Brickwork Wetting and Brick Wetting Test

1

Bricks shall be laid dry unless the following test indicates the need for wetting:

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draw a 30 mm circle with wax crayon on bed surface of dry brick. Using a medicine dropper, place 20 drops of water inside the circle and measure the time required for absorption of the water

(b)

if water is absorbed in less than 1½ minutes the brick must be wetted before being laid.

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Bricks are to have no visible moisture when laid.

5.4.2

Brickwork Laying

1

Unless otherwise specified elsewhere in the Project Documentation, bricks are to be laid in a running bond with each course of masonry bonded at the corners. The bond of facing bricks in existing buildings shall be matched. Before starting work, facing bricks shall be laid on the foundation wall and the bond adjusted as needed for openings, angles, corners, etc. Exposed brickwork joints are to be symmetrical about centre lines of openings. No brick smaller than a half-brick shall be used at any angle, corner, break, or jamb. The bond pattern shall be maintained plumb throughout. Jumping of the bond is prohibited. Brickwork shall be anchored to concrete columns, beams and walls, to steel stud construction and to masonry backup with ties and anchors in accordance with the relevant provisions of BS 5628.

2

Bricks shall be laid in a full bed of mortar. The mortar shall be spread over a few bricks at a time and shall not be furrowed. The mortar bed shall be slightly levelled to incline towards the cavity. The brick shall be placed before the mortar has had chance to stiffen. Head joints in stretcher courses are to be completely filled with mortar. Bricks shall be pushed into place so that the mortar oozes out at the top of the joints.

3

Before connecting new masonry with masonry previously laid masonry, loose bricks or mortar shall be removed, and the previously laid masonry shall be cleaned and wetted. New work is to be toothed into unfinished work.

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Brick headers are not to project into the grout space.

5

Cleaning holes are to be left in double cavity walls during construction by omitting units at the base of one side of the wall. In general, clean-out holes are to be provided at each location of vertical reinforcement.

6

Cavities shall be kept clean of mortar and debris. The cavity shall be cleaned every day using a high pressure jet stream of water, compressed air, industrial vacuum, or by laying wood strips on the metal ties as the wall is built. If wood strips are used, lift strips with wires or heavy string as the wall progresses and before placing each succeeding course of wall ties.

7

Exterior walls shall be built with 100 mm of facing brick, backed-up with inner leaf of brick or concrete masonry units. Solid brick jambs shall be constructed not less than 200 mm wide at exterior wall openings and at recesses.

8

Joints are not to be tooled until mortar has stiffened enough to retain a thumb print when the thumb is pressed against the mortar, however, mortar is to be soft enough to be compressed into joints. Joints in exterior face brick work shall be finished with a jointing tool to produce smooth, watertight concave joints. Exposed interior joints in finished work shall be tooled to a concave profile.

5.5

REINFORCEMENT

5.5.1

General Requirements

1

Expanded stainless steel mesh joint reinforcement, if specified, will be embedded in the horizontal mortar joints not closer than 20 mm from the external face of the wall and, except at movement joints, is to be continuous and lapped at least 75 mm at all passings. Full lap joints are to be provided at angles.

2

Vertical bar reinforcement is to be properly positioned and secured against displacement. The cavities containing the reinforcement are to be completely and solidly filled with the specified concrete. The whole surface of the reinforcement is to be in contact with the mortar or concrete. The minimum clear distance between the vertical bars and the block is to be 12 mm.

5.5.2

Placing Reinforcing

1

At the time of placement, steel reinforcement is to be free from loose flaky rust, mud, oil, or other coatings that will destroy or reduce the bond.

2

Steel reinforcement is to be in place at the time of grouting. Horizontal reinforcement shall be placed as the masonry work progresses.

3

The minimum clear distance between reinforcing and masonry units shall be 12mm.

4

The minimum clear distance between parallel bars shall be one bar diameter.

5

Vertical steel reinforcement shall be held in place by centring clips, caging devices, or other approved methods.

6

Vertical bars shall be supported near each end, and at intermediate intervals not exceeding 80 bar diameters.

7

Horizontal reinforcement shall be set in a full bed of grout.

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8

Reinforcement shall be spliced or attached to dowels by placing in contact and wiring together.

9

Splices shall be staggered in adjacent reinforcing bars. Reinforcing bars shall be lapped at splices at a minimum of 40 bar diameters.

5.5.3

High Lift Grouting of Cavity Walls

1

Grout shall be placed by hand bucket, concrete hopper, or grout pump. Each lift of grout shall be consolidated after free water has disappeared but before plasticity is lost.

2

When placing grout by the high lift method, the Contractor shall: not pour grout until the masonry wall has properly cured for a minimum of 72 hours

(b)

close cleaning holes with masonry units

(c)

place grout in one continuous operation (grouting of any section of a wall between control barriers is to be completed in one day with no interruptions greater than one hour)

(d)

provide vertical solid masonry dams across the grout space for the full height of the wall at intervals of not more than 9 m

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(a)

High lift grouting of double cavity walls should be undertaken in a single, continuous pour of grout to the top of the wall in 1 m layers or lifts in the same working day, with a minimum waiting period of 10 minutes between each 1 metre layer or lift. Each layer or lift of grout is to be vibrated. The vibrator is to be extended 300 mm to 450 mm into the preceding lift to close any shrinkage cracks or separation from the masonry units.

4

Grout for cavities of double cavity walls less than 50 mm wide should not be poured from a height exceeding 300 mm.

5.5.4

Low Lift Grouting of Cavity Walls

1

Grout shall be placed by hand bucket, concrete hopper, or grout pump. Each lift of grout shall be consolidated after free water has disappeared but before plasticity is lost.

2

Double cavity masonry walls are to be constructed and grouted in lifts not to exceed 200 mm. Slushing with mortar will not be permitted.

3

The grout space shall be kept clean from mortar droppings and clean the space before placing the grout.

4

All grout is to be puddled with a grout stick during and immediately after placing.

5

The cores of concrete masonry units containing reinforcing bars shall be grouted as the masonry work progresses. Slushing with mortar will not be permitted.

5.5.5

Water Penetration Testing

1

Seven days before plastering or painting, the Contractor shall test exterior masonry walls for water penetration. The number and location of tests shall be as stated in the Project Documentation or as directed by the Engineer.

2

Water shall be directed at masonry for a period of one hour at a time when wind velocity is less than eight kilometres per hour.

3

The areas showing moisture on the inside of the walls shall be corrected and re-tested to insure that moisture penetration has been stopped.

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Section 13: Masonry Part 05: Masonry Laying

Page 8

4

Unless otherwise instructed, testing shall take place in the presence of the Engineer.

5.6

FAIR FACED BLOCK WALLS

5.6.1

General Requirements

1

Fair faced block walls and walls built of facing blocks are to be constructed generally as Clause 5.3.3 with particular care being taken to ensure: (a)

the specified bonding or joint pattern is consistent

(b)

the perpends are truly plumb for the full height

(c)

the blocks used are of the same texture and appearance to avoid a patchy effect

(d)

the colour of the mortar is consistent.

When a block has been placed in the wall, the extruded mortar is to be struck off flush, extra care being taken to avoid smearing the mortar on the face of the block.

3

Joints are to be left to stiffen slightly (thumb print hard) and then be firmly compacted with a jointing tool to the required profiles. The tooling of wet mortar will not be permitted.

4

If mortar droppings have struck to the blocks it must be allowed to dry and the surplus removed by a trowel. The remaining residue shall be cleaned by rubbing with a small piece of block and subsequent brushing down.

5

Where the cutting of blocks in fair face work is unavoidable, this should be done using a mechanical saw.

6

The cutting of facing blocks will only be permitted where this can be achieved without a visible alteration to the facing pattern.

5.7

OPENINGS

5.7.1

General Requirements

1

Openings are to be square and the jambs, vertical and formed with the uncut faces of the blocks.

2

If door and window frames are to be built-in the requirements of Clause 5.3.4 of Section 18 shall be complied with and the fixing cramps built-in solid in the mortar joints.

3

The jamb walling is to be built up against the frame all round as the work proceeds.

5.8

INTERSECTING WALLS AND PARTITIONS

5.8.1

General Requirements

1

Walls and partitions are to be bonded or tied to one another at junctions, unless movement joints are indicated.

2

If ties are used they should consist of 3 x 20 mm stainless or galvanized steel as directed by the Engineer fully embedded in the horizontal mortar joints at vertical spacings not exceeding 600 mm.

3

The ends of the ties are to project a minimum of 75 mm into each wall or partition.

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QCS 2014

Section 13: Masonry Part 05: Masonry Laying

Page 9

CONNECTIONS BETWEEN WALLS OR PARTITIONS AND COLUMNS

5.9.1

General Requirements

1

All connections between block walls or partitions and concrete or steel columns are to be reinforced at maximum 400 mm centres by means of stainless steel or zinc coated expanded metal as directed by the Engineer or approved proprietary ties shot fired to the column and built into and fully embedded in the mortar joints of the block walls or partitions.

2

Stainless steel or expanded metal ties as directed by the Engineer are to be a width that will allow 20 mm clearances from each face of the wall or partition and be embedded for a minimum distance of 200 mm in the mortar joint.

5.10

JOINTS BETWEEN PARTITIONS AND FLOOR SOFFITS

5.10.1

General Requirements

1

Non-load bearing internal walls and partitions shall be built-up to leave a 20 mm joint between the top of the wall or partition and the soffit of the slab.

2

After the walling has thoroughly dried out and after the expected deflection in the slab due to dead load has taken place, the joint is to be filled solid with a Class M7 mortar in accordance with the relevant provisions of Part 2 of this Section.

3

Where concrete slabs are supported on blockwork, a layer of polythene sheet is to be provided between the top of the wall and the slab for the full width of the wall.

5.11

FILLING HOLLOW BLOCK WALLS

5.11.1

General Requirements

1

In the following situations, the cavities of hollow block walls are to be filled solid with either Class M7 mortar in accordance with the relevant provisions of Part 2 of this Section or concrete Grade C15:

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5.9

jambs of all openings

(b)

ends, angles and junctions of walls and partitions

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junctions of walls and partitions with columns

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(c)

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(a)

(d)

at sills

(e)

at tops of partitions, if so specified

(f)

to provide a solid fixing for false ceiling perimeters

2

The filling to courses is to be supported on a strip of expanded metal lathing embedded in the joint below.

3

Walls which are to be filled solid are to be built up in lifts not exceeding 1,200 mm and be filled after allowing a minimum period of 24 hours to elapse to enable the mortar to harden. The initial compaction of the concrete is to be carried out by hand using a 25 x 50 mm wooden rod or by vibrator. The final compaction shall take place 10-15 minutes after initial compaction.

QCS 2014

Section 13: Masonry Part 05: Masonry Laying

Page 10

CAVITY WALLS

5.12.1

General Requirements

1

Cavity walls are to consist of two walls separated by a minimum space of 50 mm and bonded together with stainless steel or approved other cavity wall ties.

2

The air space between the walls is to be kept clear and clean of mortar droppings by the use of laths drawn up the cavity as the work proceeds or by other approved methods.

3

Any mortar which inadvertently falls on wall ties is to be removed.

4

Wall ties are to be spaced at the intervals given in the Table 5.2 unless otherwise indicated elsewhere in the Project Documentation. Additional ties are to be provided in each course within 250 mm of openings or at end wall situations and on each side of movement joints.

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Table 5.2 Spacing of Wall Ties in Cavity Walls

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5.12

Maximum Horizontal Spacing (mm)

Maximum Vertical Spacing (mm)

50 - 75

1,000

75 - 100

800

400

100-150

500

400

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Cavity Width (mm)

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Notes:

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(a) The spacing of ties may be varied providing that the number per unit area is maintained. (b) The Table is applicable to cavity walls constructed of two blockwork skins.

SERVICES

5.13.1

General Requirements

1

Where walls are constructed of hollow blocks, the mechanical and electrical services are to be run in the cavities of the blocks wherever possible. No services are to run within the cavity of a cavity wall.

2

Where chases have to be cut, suitable power tools, as approved by the Engineer, are to be used.

5.13.2

Fixings

1

Where fixing blocks, anchors, accessories, wall ties, etc., are specified they are to be built into the walls or partitions and solidly bedded in mortar.

2

Fixings which are not built-in are to be drilled or shot fired to the blockwork.

3

Expanded bolt fixings are only to be drilled into solid blocks or blocks having their cavities filled solid.

5.14

DAMP-PROOF COURSES

5.14.1

General Description

1

Damp-proof courses shall comply with the relevant provisions of BS 743 or one of the other references mentioned in 5.1.2.

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QCS 2014

Section 13: Masonry Part 05: Masonry Laying

Page 11

Damp-proof courses are to extend through the full thickness of the wall, including pointing, applied rendering or any other facing material.

3

The mortar bed upon which the damp-proof course is to be laid is to be even and free from projections liable to cause damage to the damp proof course.

4

Where the damp-proof course is situated in a hollow block wall, the blocks are to be filled solid in the course below the damp proof course.

5

All damp-proof courses are to be solidly bedded in mortar.

6

Joints of all damp-proof courses shall be lapped a minimum of 100 mm at all passings and sealed.

5.15

PROTECTION OF FINISHED WALLING

5.15.1

General Description

1

All newly or partially built walls are to be protected against drying out too rapidly in the sun’s heat by covering with hessian or other approved material which is to be kept wet for a minimum of 3 days.

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END OF PART

QCS 2014

Section 14: Roofing Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2 1.1.3

Scope References Definitions

1.2

PREPARATION WORK ................................................................................. 4

1.2.1 1.2.2

General Requirements Storage of Materials

1.3

GUARANTEE ................................................................................................ 4

1.3.1

General Requirements

1.4

PROTECTION ............................................................................................... 5

1.4.1

General Requirements

1.5

TESTING ....................................................................................................... 5

1.5.1

General Requirements

2 2 3

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4 4 4 5 5

QCS 2014

Section 14: Roofing Part 01: General

Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies general requirements for various types of roof covering materials and accessories.

2

Related Sections are as follows: Carpentry, Joinery and Ironmongery Thermal Insulation of Buildings

References

1

The following standards are referred to in this Section:

-------- Black paint (tar based) -------- Wood wool cement slabs up to 125 mm thick -------- Concrete flooring tiles and fittings -------- Nails -------- Wood screws -------- Wrought aluminium and aluminium alloys for general engineering purposes: Bars, extruded round tube and sections BS 1494 -------- Fixing accessories for building purposes BS 1521 -------- Water proof building papers BS 3083 -------- Hot-dip zinc coated and hot-dip aluminium/zinc coats corrugated steel sheets for general purposes BS 3379 -------- Flexible polyurethane cellular materials for load bearing applications BS 3416 -------- Bitumen based coatings for cold application, suitable for use in contact with potable water BS 3690 -------- Bitumens for building and civil engineering BS 3797 -------- Lightweight aggregates for concrete BS 3837 -------- Expanded polystyrene boards BS 3869 -------- Rigid expanded polyvinyl chloride for thermal insulation purposes and building applications BS 3927 -------- Rigid phenolic foam (PF) for thermal insulation in the form of slabs and profiled sections BS 4016 -------- Building papers (breather type) BS 402 ---------- Clay plain roofing tiles and fittings BS 4154 -------- Corrugated plastic translucent sheets made from thermo-setting polyester resins (glass fibre reinforced) BS 4841 -------- Rigid polyurethane (PUR) and polyisocyanurate (PIR) form for building applications BS 4868 -------- Profiled aluminium sheet for building BS 5075 -------- Concrete admixtures BS 5284 -------- Methods of sampling and testing mastic asphalt used in building and civil engineering BS 5534 -------- Code of Practice for slating and tiling BS 6229 -------- Flat roofs with continuously support coverings BS 6515 -------- Polyethylene damp-proof courses for masonry

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BS 1070 BS 1105 BS 1197 BS 1202 BS 1210 BS 1474

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Section 18 Section 15

QCS 2014

Section 14: Roofing Part 01: General

Page 3

.

BS 6676 -------- Thermal insulation of cavity walls using man-made mineral fibre batts (slabs) BS 680 ---------- Roofing slates BS 747 ---------- Roofing felts BS 8000 -------- Workmanship on Building Sites BS 812 ---------- Testing aggregates BS 8217 -------- Code of Practice for built-up felt roofing BS 882 ---------- Aggregates from natural sources for concrete BS EN 485 ----- Aluminium and aluminium alloys – Sheet, strip and plate BS EN 490 ----- Concrete roofing tiles and fittings-product specifications BS EN 491 ----- Concrete roofing tiles and fittings-test methods BS EN 538 ----- Clay roofing tiles for discontinuous laying-flexural strength test BS EN 539 ----- Clay roofing tiles for discontinuous laying-determination of physical characteristics.

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EN 197-1 ------- Portland cement Definitions

1

For purposes of this Section, certain terms are designated in the following paragraphs:

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1.1.3

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BASE SHEET is one layer of felt or combination sheet secured to the deck over which may be applied additional felts, a cap sheet, organic or inorganic fibre shingles, smooth coating or mineral aggregate.

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BUILT-UP ROOF COVERING is two or more layers of roofing consisting of a base sheet, felts and cap sheet, mineral aggregate, smooth coating or similar surfacing material

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CAP SHEET is roofing made of organic or inorganic fibres, saturated and coated on both sides with a bituminous compound, surfaced with mineral granules, mica, talc, ilmenite, inorganic fibres or similar materials

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CEMENTING is solidly mopped application of asphalt, cold liquid asphalt compound, coal tar pitch or other approved cementing material COMBINATION SHEET is a glass fibre felt integrally attached to kraft paper

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CORROSION-RESISTANT is any non-ferrous metal or any metal having an unbroken surfacing of non-ferrous metal, or steel with no less than 10 % chromium or with not less than 0.20 % copper FELT is matted organic or inorganic fibres, saturated with bituminous compound FELT, NONBITUMINOUS SATURATED is matted asbestos fibres with binder for use with wood shingle and wood shake assemblies GLASS FIBER FELT is a glass fibre sheet coated on both sides with bituminous compound INTERLAYMENT is a layer of felt or non-bituminous saturated asbestos felt not less than 450 mm wide, shingled between each course of roof covering INTERLOCKING ROOFING TILES are individual units, typically of clay or concrete, possessing matching ribbed or interlocking vertical side joints that restrict lateral movement and water penetration

QCS 2014

Section 14: Roofing Part 01: General

Page 4

METAL ROOFING is metal shingles or sheets for application on solid roof surfaces, and corrugated or otherwise shaped metal sheets or sections for application on solid roof surfaces or roof frame works NON-NAILABLE DECK is any deck, which is incapable of retaining an approved fastener PREPARED ROOFING is any manufactured or processed roofing material, other than untreated wood shingles and shakes, as distinguished from built-up coverings SPOT CEMENTING is discontinuous application of asphalt, cold liquid asphalt compound, coal tar pitch or other approved cementing material

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UNDERLAYMENT is one or more layers of felt or non-bituminous saturated asbestos felt over which the finish roofing is applied.

PREPARATION WORK

1.2.1

General Requirements

1

Before commencing installation of the roof, waterproofing and insulation system all construction work and installations above roof level are to be completed as far as possible. Particular care is to be taken to ensure:

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1.2

all rainwater, plumbing, air-conditioning and ventilation duct outlets have been fixed in position and are protected against blockage or accidental damage

(b)

supports to ductwork, pipework, cable trays and the like have been installed

(c)

all kerbs to roof lights, access doors, plant and water tanks have been installed

(d)

all chases for skirtings, etc., have been prepared.

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(a)

The surface of the roofing substructure is to be clean and dry, free from ridges or indentations, laid to falls as required and not contaminated with oil or other deleterious matter.

3

No waterproofing membrane is to be applied until the roofing substructure has been inspected and approved by the Engineer.

1.2.2

Storage of Materials

1

Polystyrene insulation boards are to be protected against prolonged exposure to sunlight.

2

Blanket type insulation is to be protected from moisture.

1.3

GUARANTEE

1.3.1

General Requirements

1

The Contractor is to provide the Engineer with a seven (7) year unconditional guarantee against failure of the roof waterproofing system whether caused by defective materials or workmanship. The guarantee should be valid from the date of completion of the installation and must be provided to the Engineer in accordance with Section 1, General.

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QCS 2014

Section 14: Roofing Part 01: General

Page 5

PROTECTION

1.4.1

General Requirements

1

Adequate protection against damage to the roof waterproofing system is to be provided where further construction work is necessary in the area.

1.5

TESTING

1.5.1

General Requirements

1

On completion of application of new roof waterproofing material to an existing roof but before application of insulation and protection, the Contractor shall seal off all rainwater outlets and flood the roof to a depth of 25mm. After 48 hours, visual inspection of the roof shall be undertaken from inside the building in the presence of the Engineer's Representative to establish that there are no leaks in the structure. The Contractor shall make up any loss of water during the test due to either evaporation or leakage. The Contractor shall be responsible for the locating and sealing of any leaks found. The test shall be repeated, at the Contractor's expense, until no leaks exist.

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END OF PART

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1.4

QCS 2014

Section 14: Roofing Part 02: Membrane Roofing

Page 1

2

MEMBRANE ROOFING ................................................................................ 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3

Scope References General Description of Workmanship

2.2

BUILT-UP BITUMINOUS FELT ROOFING.................................................... 3

2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.2.10 2.2.11 2.2.12

General Requirements Delivery, Storage and Marking Materials Execution of Work Surface Preparation Existing Roofs and Repair Areas Installation of Built-Up Roofing Membrane Base Flashing Stripping Roof Pour Coat and Aggregate Roof Walkways Alterations to Existing Roofs

2.3

COLD APPLIED BITUMINOUS COATING .................................................. 12

2.3.1

General Requirements

2.4

PREPARED ROLL ROOFING ..................................................................... 13

2.4.1

General Requirements

2.5

MODIFIED BITUMINOUS SHEET ............................................................... 13

2.5.1

General Requirements

2.6

SINGLE LAYER MEMBRANE ..................................................................... 13

2.6.1

General Requirement

2.7

FLUID APPLIED MEMBRANES .................................................................. 13

2.7.1 2.7.2

General Description Liquid Applied Waterproofing Systems

2.8

COATED SPRAY APPLIED FOAM ............................................................. 15

2.8.1 2.8.2

Description Installation

2.9

PERMEABLE FILTER MEMBRANE ............................................................ 15

2.9.1

General Requirements

2.10

PROTECTED MEMBRANE ......................................................................... 15

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2.10.1 General Requirements 2.11

2 2 3 3 3 4 5 8 8 8 10 11 11 11 11 12 13 13 13 14 14 15 15 15 16

TORCH APPLIED WATERPROOF MEMBRANE ....................................... 16

2.11.1 General Requirements

16

QCS 2014

Section 14: Roofing Part 02: Membrane Roofing

Page 2

2

MEMBRANE ROOFING

2.1

GENERAL

2.1.1

Scope

1

This Part specifies requirements for flexible roof coverings of various types.

2

Related Sections are as follows: Section 5 Section 15 Section 18

Concrete Thermal Insulation of Buildings Carpentry, Joinery and Ironmongery

References

1

The following standards are referred to in this Part:

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ASTM D412 - 06ae2 Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers—Tension

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ASTM D1227 ..............Standard Specification for Emulsified Asphalt Used as a Protective Coating for Roofing

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ASTM D2240 ..............Standard Test Method for Rubber Property—Durometer Hardness ASTM E96 ..................Standard Test Methods for Water Vapor Transmission of Materials

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ASTM G154................Standard Practice for Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials BS 747 ........................Specification for roofing felts

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BS 812 ........................Testing aggregates

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BS 882 ........................Aggregates from natural resources BS 1070 ......................Black paint (tar based) BS 1197 ......................Concrete flooring tiles and fittings

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BS 1202 ......................Nails

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BS 1210 ......................Wood screws BS 1494 ...................... Fixing accessories for building purposes

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BS 1521 ......................Waterproof building papers BS 3416 ...................... Bitumen based coatings for cold application, suitable for use in contact with potable water BS 3690 ......................Bitumens for building and civil engineering BS 4016 ......................Building papers (breather type) BS 5284 ...................... Methods of sampling and testing mastic asphalt used in building and Civil Engineering BS 6229 ......................Flat roofs with continuously supported coverings BS 6920 ......................Suitability of non-metallic products for use in contact with water intended for human consumption with regard to their effect on the quality of the water BS 7263 ......................Pre-cast concrete flags, kerbs, channels, edgings and quadrants BS 8000 ......................Workmanship on Building Sites BS 8217 ......................Code of practice for built-up felt roofing

QCS 2014

Section 14: Roofing Part 02: Membrane Roofing

Page 3

General Description of Workmanship

1

The roof coverings are not to be applied to a damp base and care is to be taken to ensure that no moisture is trapped between successive layers.

2

Skirtings are to be a minimum of 150 mm above the roof finish at any point.

3

Protective finishes and surface treatments are to be applied as soon as possible after completion of the roof coverings.

4

Projections passing through the roof covering are to be provided with hoods or caps to permit the roof covering to terminate beneath the hood and be protected by it from weather elements.

5

Outlets for surface water, whether in gutters or roof areas, are to be set slightly below the adjacent roof surface and be suitably flashed to allow a bonded lap of roofing felt and flashing material of 100 mm (minimum).

6

Roof waterproofing materials shall be applied by specialist personnel or a specialist subcontractor having previous experience of the system and approved by the Engineer's Representative. The specialist sub-contractor shall provide the guarantee specified in Part 1 of this Section in favour of Public Works Authority.

7

On completion of application of waterproofing material to an existing concrete roof but before the application of insulation and protection, the Contractor shall seal off all rainwater outlets and flood the roof to a depth of 25mm. The Contractor shall make up any loss of water due to evaporation or leaks. After 48 hours, visual inspection of the roof shall be undertaken from inside the building in the presence of the Engineer’s Representative to establish if there are any leaks in the structure. The Contractor shall locate and seal any leaks. The test shall be repeated at the Contractor’s expense until no leaks exist.

8

On new roofs the test detailed in sub-clause 7 shall be carried out prior to application of lightweight screed and waterproofing membrane.

2.2

BUILT-UP BITUMINOUS FELT ROOFING

2.2.1

General Requirements

1

This section specifies built-up bituminous felt roofing on new roofs and for repairs to existing roofs.

2.2.2

Delivery, Storage and Marking

1

Roofing materials shall be delivered to the Site in original sealed packages or containers marked with the name and brand, or trademark of the manufacturer or seller.

2

Roofing materials shall be kept dry and stored in weathertight facilities or under canvas tarps. Use of polyethylene or plastic tarps to cover materials is not permitted. Roofing materials shall be stored above ground or deck level on wood pallets. Ground under stored materials shall be covered with a plastic cover.

3

Rolled materials (felts, base sheets, paper) shall be stored on end. Materials shall not be stored on top of rolled materials.

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2.1.3

QCS 2014

Section 14: Roofing Part 02: Membrane Roofing

Page 4

4

Aggregate are to be maintained in a surface dry condition as defined by BS 812 and BS 882.

5

Materials shall be protected from damage from handling, weather and construction operations before, during, and after installation.

2.2.3

Materials

1

Built-up bituminous materials are to conform to applicable Standards listed in Clause 2.1.2.

2

Asphalt materials (general) include:

organic felt

(c)

asphalt

(d)

glass reinforced felt

(e)

venting asphalt base sheet

(f)

mineral surface roll roofing

(g)

roof cement

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(b)

Coal tar materials include: primer

(b)

organic felt

(c)

coal-tar bitumen

(d)

roof cement

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(a)

Miscellaneous component requirements are as follows: (a)

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primer

aggregate requirements include: aggregates to comply with requirements of BS 882.

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(i)

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(a)

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(ii)

(iii)

(b)

(c) 5

chippings are to be approved, clean, crushed white or pale grey aggregate size 15 to 30 mm. (rounded gravel shall e free of sharp angular or broken pieces.

roof walkway requirements include: (i)

prefabricated asphalt plank consisting of a homogeneous core or asphalt, plasticizers and inert fillers, bonded by heat and pressure between two saturated and coated sheets of felt. The top side of planks shall be surfaced with ceramic granules.

(ii)

concrete masonry paving units shall comply with BS 1197 and BS 7263.

building paper (sheating paper) shall comply with BS 1521 and BS 4016.

Fasteners to be used include the following: (a)

nails and staples shall comply with BS 1210 and BS 1202

(b)

nails for securing built-up flashing and base sheets to wood deck shall be either:

QCS 2014

(c)

Section 14: Roofing Part 02: Membrane Roofing

Page 5

(i)

zinc coated steel roofing nails with a minimum head diameter of 9 mm through metal discs at least 25 mm across

(ii)

one piece nails with an integral flat cap at least 24 mm across.

fasteners for securing building paper and dry felt edge strips to wood nailer and decks shall be either: (i)

zinc coated steel roofing nails with a minimum head diameter of 16 mm

(ii)

flat top crown, zinc coated staples

(d)

nails for plywood are to be annular thread type and shall penetrate plywood by at least 19 mm

(e)

nails for securing built-up flashing to masonry shall be either: hardened steel nails through metal discs at least 25 mm in diameter

(ii)

one piece nails with an integral flat cap at least 24 mm across.

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(i)

nails for securing venting base sheet to insulating concrete shall be galvanized steel self-clinching type having a integral flat cap at least 25 mm across. They are to have a holding power of not less than 130 kg when pulled from approximate dense concrete

(g)

nails for securing base sheet, building paper, or first layer of vapour retarder to structural wood fibre decks shall be the self-clinching type having an integral flat cap not less than 25 mm across. They are to have a holding power of not less than 85 kg per fastener

(h)

nails for securing base sheet to poured gypsum roof deck shall be specially shaped nails providing a diverging or hooking point. They shall have a flat cap not less than 32 mm across and have a withdrawal resistance of not less than 85 kg per fastener.

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(f)

Execution of Work

1

Roofing materials shall not be applied if the deck will be used as a subsequent work platform, for storage of materials, or if staging or scaffolding will be erected thereon.

2

The entire roof deck construction of any section of the building is to be completed before roofing work is begun including: installation of curbs, blocking, edge strips, fillets, and other components where insulation, roofing and base flashing is attached shall be in place ready to receive insulation and roofing

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(a)

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2.2.4

(b)

co-ordination of roof operations with roof insulation and sheet metal work so that insulation and flashing is installed concurrently to permit continuous roofing operations.

3

Roofing materials are to be dry when applied.

4

Surfaces, including the flutes of metal deck, that become wet from any cause during progress of the work shall be dried out before roofing work is resumed. Materials shall only be applied to dry substrata.

5

Except for temporary protection, materials shall not be applied during damp or rainy weather, during excessive wind conditions, nor while moisture (dew or fog) is present in any amount in or on the materials to be covered or installed.

6

Materials shall not be applied when the temperature is below 10 ºC.

QCS 2014

Section 14: Roofing Part 02: Membrane Roofing

Page 6

7

Phased construction is not permitted. The installation of all layers is to be completed in the same day, including insulation, base flashings, and the layers surfaced with either the flood coat and aggregate or with a glaze coat except for the area where temporary protection is required when work is stopped.

8

Temporary protection shall comply with the following requirements: install temporary protection consisting of glazed coats and water cut-offs at the end of each day’s work and when the work is halted for an indefinite period or work is stopped when precipitation is imminent

(b)

glaze coat all exposed surfaces of felts to seal in the bitumen coating. No felt surfaces or edges are to be left exposed

(c)

install temporary cap flashings over the top of base flashings where permanent flashings are not in place. Temporary cap flashings are to provide complete protection against moisture entering the roof system through or behind the base flashing. Securely anchor in place to prevent blowing off and damage by construction activities

(d)

provide for removal or drainage of water away from the work

(e)

provide temporary protection for roofing by means of duckboard walkways, plywood platforms, or other materials, as approved by the Engineer, for roof areas that are to remain intact, and that are subject to foot traffic and damage.

(f)

provide notches in sleepers to permit free drainage.

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Heating of bitumen for installation of roofing shall comply with the following requirements: (a)

heat the asphalt to the equiviscious temperature 1 °C; at the time of application

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asphalt should not be heated greater than 35 °C above the equiviscous temperature coal-tar bitumen is not to be heated above 215 °C with an application temperature ranging from 160 °C to 200 °C

(c)

at no time should bitumen be heated above the flash point temperature

(d)

provide heating kettles with a thermometer kept in operating condition at all times. Kettlemen are to be in attendance at all times during heating to insure that the bitumens are heated within the temperatures specified.

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(b)

Asphalt or coal-tar products shall be used, except as specified below: (a)

use asphalt only with asphalt-saturated or asphalt-impregnated felts

(b)

use coal-tar pitch and coal-tar-saturated felts in conjunction with coal-tar roofing

(c)

Asphalt-saturated felts may be used for flashings.

Installation of roofing materials with hot bitumen shall comply with the following requirements: (a)

apply bitumen in quantities required, immediately followed by felts or other materials to be embedded therein before bitumen cools below the application temperature limit

(b)

do not apply more material than can be covered at one time

(c)

re-coat cooled bitumen areas with hot bitumen

(d)

roll felts into bitumen, rolling, squeezing or brushing down to firmly embed in the hot bitumen free of wrinkles, blisters, bubbles, voids, air pockets or other defects that prevent complete adhesion. Use squeegees only on glass felts

QCS 2014

Page 7

(e)

felts shall be lapped shingle fashion for the number of layers specified starting with starter strips at right angles to slope of roof

(f)

the laying of the roofing materials should commence at the low points

(g)

bitumen is to separate all felts or substrata so that subsequent layers do not touch previous placed layers of felt or substrata unless noted specifically

(h)

cut the felt to fit closely around pipes, roof drains, bitumen stops, and similar roof projections.

Laps for felts and base sheet shall be as follows: base sheet shall be lapped 75mm

(b)

two layers of felt with 500 and 900 mm starting widths shall be lapped 600 mm

(c)

three layers of felt with 300, 600 and 750 mm starting widths shall be lapped 600 mm

(d)

four layers of felt with 225, 500 mm and 750 starting widths shall be lapped 700 mm.

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Section 14: Roofing Part 02: Membrane Roofing

Primer shall be applied with 3.5 litres of primer per 10 m2 of surface area unless otherwise recommended by the manufacturer and approved by the Engineer.

14

Quantities of bitumen used shall be as follows:

coal tar, 44 to 66 kg/m

2

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asphalt, 9 to 13 kg/m

glaze coats:

2

(i)

asphalt, 33 to 55 kg/m

(ii)

coal tar, 44 to 66 kg/m

2

pour or flood coats:

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(ii)

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between substrata and layers of glass fibre felts

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(d)

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asphalt, 33 to 55 kg/m

(i) (c)

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(b)

between substrata and layers of organic felt:

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asphalt, 122 to 144 kg/m

2

coal tar, 155 to 177 kg/m

2

Nailing or anchorage of felts or base sheets to nailable decks shall include the following requirements: (a)

nails or fasteners appropriate for type of deck to be covered shall only be used.

(b)

two layers of felt shall be laid as follows:

(c)

(i)

nail down both layers along bottom edges at intervals not to exceed 225 mm

(ii)

nail down both layers at both edges at intervals not to exceed 225 mm

anchorage of base sheets shall be as follows: (i)

nail along laps and edges at intervals not to exceed 225 mm with end and edge laps solidly sealed with roof cement

(ii)

stagger nails down centre of sheet in two rows 300 mm apart at intervals of not more than 500 mm in each row.

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Page 8

Building paper shall be laid as follows: (a)

lay paper smoothly without buckles or wrinkles at right angles to the roof slope starting at the low point

(b)

lap each sheet of paper at least 50 mm over proceeding sheet, and at the ends

(c)

staple or nail sufficiently to hold in place until the roofing is installed.

Surface Preparation

1

Sweep decks and remove all dust, dirt and debris.

2

Remove projections that might penetrate or damage roofing felt materials.

3

Preparation of concrete decks, (except insulating concrete) for installation of roofing shall comply with the following requirements:

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2.2.5

test concrete decks for moisture prior to application of roofing materials. Heat bitumen as specified and pour approximately 0.5 litres of bitumen on surface to which roofing materials are to be applied. If bitumen foams upon contact with the deck or if after bitumen has cooled and bitumen is stripped from deck leaving no residue, the deck is not dry enough for application of prime coat or roofing

(b)

prime concrete decks, including precast units, with primer as recommended by the manufacturer for certification. Keep the primer 100 mm back from the joints in precast units

(c)

allow primer to dry before application of bitumen.

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(a)

Roof surfaces of wood sheathing, gypsum, gypsum plank and cement wood fibre plank shall be covered with a layer of building paper.

2.2.6

Existing Roofs and Repair Areas

1

Where new penetrations occur and in areas where repairs are required, loose aggregate and aggregate that is not firmly embedded shall be removed.

2

Where new work to be installed, the existing membrane should be cut out and removed and a temporary seal to cut surfaces installed. The temporary seal shall consist of roof cement and one layer of 33 kg/m2 glass fibre felt or fabric strip. The glass fibre felt or fabric strip shall extend 150 mm on each side of cut surface and shall be completely embedded in the roofing cement.

3

If the existing built-up base flashing is to be repaired, either bend up the cap flashing or temporarily remove the cap flashing. Brush and scrape away all deteriorated and loose bitumen, felts, or surface material of built-up base flashing, and repair as necessary in accordance with the requirements of this Section.

4

A venting base sheet shall be used over all insulating concrete and poured gypsum decks to relieve possible vapour pressures that may occur.

5

The same bitumen shall be used for roof repairs and alterations as used in the existing roofing construction.

2.2.7

Installation of Built-Up Roofing Membrane

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Page 9

1

The built-up roofing membrane is to be aggregate surfaced, three layer, glass fibre felt construction using asphalt or four layer organic felt and coal tar bitumen. Building paper or a base sheet is not considered as a layer.

2

General requirements of installation of built-up roofing membrane are as follows: where nailers occur at roof edges under gravel stops or penetrations to receive metal base flashing, nail a continuous strip of 400 mm wide dry organic felt envelope over the nailers before the first layer sheet is applied. The organic felt strip is to be installed on top of the venting base sheet. After the membrane is installed, turn the dry felt back over the roofing, and secure in place with hot bitumen before gravel stops or other metal flanges extending out onto the membrane are installed

(b)

where fillets occur at vertical surfaces, cut off layers of the membrane 50 mm above, the top of fillet strips. At prefabricated curbs, scuttles and other roof accessories having integral fillets, extend the membrane over the fillet and up the vertical surface to the top of the curb or nailer as shown in drawings

(c)

where a fascia-fillet occurs at the roof edges, extend the membrane beyond the outside fillet face and cut off at the outside after the base flashing is installed. Do not cut off the venting base sheet outside the fillet face, extend it down over the outer fillet face to allow for venting

(d)

where a recessed flashing occurs at vertical surfaces, extend layers of roofing up into recessed flashing the full depth of the recessed flashing.

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Built-up roofing installed over on insulation shall be sealed down as specified Clause 2.2.7-3.

4

Built-up roofing installed on concrete and precast concrete Units shall comply with the following requirements:

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prime deck as specified Clause 2.2.4-13

(b)

keep bitumen back 100 mm from joints in precast units

(c)

seal down membrane as specified Clause 2.2.4.

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(a)

Built-up roofing installed on nailable decks shall include requirements as follows: (a)

on insulating concrete decks, install one layer of venting base sheet with the mineral aggregate surface down. Fasten base sheet to deck as required, followed by membrane as specified

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(b)

(c)

termination venting base sheet: (i)

at vertical surfaces: extend venting base sheet up vertical surface over fillets to top of base flashing or curb

(ii)

at the roof edges under gravel stops install a venting base sheet over the blocking. The base sheet shall be extended not less than 50 mm beyond the outer edge and it shall be turned down so that venting can be accomplished

(iii)

at the roof edge over a fascia-fillet: extend the base sheet over the top of the fillet and turn it down over the outer face of the fillet to permit venting at the edge.

on poured gypsum, precast gypsum plank, cement-wood fibre plank, wood plank or plywood decks, install one layer of building paper followed by either:

QCS 2014

Section 14: Roofing Part 02: Membrane Roofing

Page 10

(i)

two layers of 33 kg organic felt laying both layers down dry to deck except to seal between laps. Lap and nail as specified to deck. Follow immediately by the membranes sealed down to the felt

(ii)

one layer of base sheet or venting base sheet. Lay base sheet down dry on the deck. Lap as specified and seal the edge laps with roofing cement. Nail as specified followed by the roofing membrane sealed down to the base sheet.

Cover the exposed surface of the last layer of felt, except on fillets and under concrete pavers or runners of wood roof walkways, with bitumen and aggregate as specified.

2.2.8

Base Flashing

1

Provide built-up base flashings over fillets and wherever necessary to make the work watertight.

2

Install flashing before final bituminous coat and roof aggregate is installed.

3

Prime vertical surfaces of masonry and concrete with asphalt primer except where the vented base sheet is required to provide edge venting.

4

When applying a flashing on top of built-up roofing, up the face of fillets and up the face of the vertical surfaces, between 200 mm and 300 mm above the built-up roofing, the following shall apply:

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at fascia-fillets, extend the flashing to the top of fillet and cut off at the top of fillet

(b)

at recessed flashings, extend the flashing full depth into the recessed flashing

(c)

where venting base sheet is used with insulating concrete, do not seal edges of venting base sheet with bitumen in order to allow for venting.

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(a)

extend the first layer of flashing 100 mm out on the roofing, and the second layer of flashing 75 mm beyond the first layer. Lap ends 75 mm with joints broken 500 mm in each layer

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Flashing is to consist of two layers of 33 kg/m2 glass fibre felt or fabric, surfaced capped as specified.

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(b)

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cap sheet is to be mineral surfaced roll roofing or modified bitumen sheet extending from toe of fillet to top of base flashing. Lap the ends 75 mm with joints not coinciding with joints in under layers.

Base flashings may be set either in asphalt (hot applied method) or in roof cement (cold applied method), with only one method only used throughout. Application of either method shall be as follows: (a)

(b)

cold applied method: (i)

embed each layer of flashing in roof cement so layers do not touch felt

(ii)

cover the last layer of flashing with a troweled on coat of the roof cement, into which embed the cap sheet from toe of the fillet to top of the base flashing and seal laps with roof cement

(iii)

Use cold applied method with coal tar roofing.

hot applied method:

QCS 2014

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Section 14: Roofing Part 02: Membrane Roofing

Page 11

(i)

embed each layer of flashing and cap sheet in asphalt so that the layers do not touch

(ii)

set the cap sheet in hot bitumen with laps sealed with hot bitumen.

except for venting roof edges, seal the top edge of the base flashing with roof cement.

Except at metal fascia fillets, secure top edge of the base flashing with nails on a line approximately 25 mm below the top edge, and at not more than 200 mm centres. All nail heads shall be covered with roof cement. The top of the base flashing shall be covered with counter flashing. At fascia fillets, secure the top edge of the flashing with fascia compression clamps.

2.2.9

Stripping

1

Before the final bituminous coat and roof aggregate is installed, cover that portion of the horizontal flanges of metal base flashings, gravel stops, and other flanges extending out onto the roofing with a composition flashing consisting of two layers of glass fibre felt or fabric. Use organic felt with coal tar bitumen for stripping.

2

Extend the first layer of flashing out on the roofing 100 mm beyond the edge of the flange and the second layer 75 mm beyond the edge of the first layer. Cut edges to fit tight against vertical members of the protruding flange.

3

Each layer of flashing shall be embedded in hot bitumen or roofing cement.

2.2.10

Roof Pour Coat and Aggregate

1

After bituminous base flashing and stripping have been installed uniformly coat the entire roof surface except fillets with hot asphalt or coal-tar bitumen poured on, as directed in Clause 2.2.4 of this Part.

2

While still hot, embed necessary amount of aggregate to cover the roofing felt completely without bare spots, but not less than 888 kg/m2 of dry gravel or 666 kg/m2 of dry slag. The aggregate cover shall be such that no bitumen is left exposed.

3

Placing the aggregate material in piles or rows on bare or glaze coated felt before placement is prohibited.

2.2.11

Roof Walkways

1

Walkways may be concrete masonry units or prefabricated asphalt planks.

2

Place concrete masonry units on top of the pour coat. Aggregate shall not be embedded under runners of wood roof walkways. Butt concrete masonry units to provide a continuous walkway surface.

3

When prefabricated asphalt planks are used, sweep away loose roof aggregate from the areas to receive planks. Set the planks in hot bitumen poured over the firmly embedded roof aggregate as specified for pour coat. Maintain a minimum of 75 mm to a maximum of 150 mm space between planks.

2.2.12

Alterations to Existing Roofs

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Section 14: Roofing Part 02: Membrane Roofing

Page 12

1

Roof repair and alteration work is to match existing roofing material and construction. Bitumen compatible with the existing bitumen shall be used for roof repair and alterations.

2

Make cut-outs of existing roof system to confirm the condition of the roof. Cuts are to be made in the presence of the Engineer in locations as directed by the Engineer. Each cut-out opening shall be photographed. The cut-out area shall be repaired immediately upon confirmation of the condition of the roof. Any moisture found in the roof membrane or insulation shall be reported to the Engineer.

3

Repairs to existing membrane and base flashing shall be carried out as follows: (a)

remove temporary patches prior to starting repair work

(b)

blisters and fish mouths:

heat membrane to facilitate bending and to dry out surface of blistered areas exposed

(iii)

seal down turned back membrane in hot bitumen. Roll to insure full adhesion and embedment in substrata

(iv)

cover cut areas with two layers of felt. Extend first layer 100 mm beyond cut area edge. Extend second layer 100 mm beyond first layer. Seal down in hot bitumen as specified for new work. Resurface as specified.

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cut away exposed deteriorated edges of organic felt

(ii)

glaze coat felt edges

(iii)

resurface as specified.

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(i)

built-up base flashing:

restore felts and cap sheet removed, lapping 100 mm over existing remaining

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install new felts and cap sheet as specified for new work.

horizontal metal flanges:

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exposed felts:

(i)

(e)

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(ii)

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(d)

cut blisters open and turn membrane back to fully adhered portion. Cut fish mouth so membrane can be turned back and subsequently laid flat

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(c)

(i)

(i)

remove loose, buckled, or torn stripping

(ii)

remove loose fasteners and install new fasteners

(iii)

restrip flanges as specified for new work.

resurfacing: (i)

over repaired membrane, re-pour and embed new or cleaned aggregate as specified for new work

(ii)

cover all membrane areas. Do not leave any exposed membrane surface.

2.3

COLD APPLIED BITUMINOUS COATING

2.3.1

General Requirements

QCS 2014

Section 14: Roofing Part 02: Membrane Roofing

Page 13

The Contractor is to clean and prepare roofing surface areas immediately prior to application of bitumen coating. Black bitumen coating solutions to be applied in accordance with BS 3416, BS 6920.

2

Application of cold applied bituminous solution is to be done by a qualified experienced personnel.

3

All openings and roof vents are to have watertight flashings.

2.4

PREPARED ROLL ROOFING

2.4.1

General Requirements

1

Prepared roll roofing is the top layer in a built-up roofing membrane. Standard prepared roll roofing material consists of a glass fibre mat coated on both sides with a stabilised asphalt coating and surface coated with non-combustible ceramic granules.

2

Prepared roll roofing material is to be compatible with, and manufactured by the supplier of, the built up roofing membrane.

3

Prepared roll roofing is to be sealed with hot bitumen or cold adhesive as recommended by manufacturer.

4

The Contractor shall guarantee roll roofing for fifteen (15) years.

2.5

MODIFIED BITUMINOUS SHEET

2.5.1

General Requirements

1

Modified bituminous sheet is a cold applied membrane composed primarily of modified bituminous material prefabricated in sheet form.

2

Modified bituminous sheet is reinforced with glass fibre, polypropylene, or polyester fabric which may be bonded to a plastic sheet, and supplied in this form by the manufacturer.

3

The standard sheet thickness shall be 4 mm.

4

The sheet is to be provided with a release sheet to prevent bonding of the sheet to itself.

2.6

SINGLE LAYER MEMBRANE

2.6.1

General Requirement

1

A single layer membrane is a 4mm (minimum) single layer bituminous felt membrane and is torch applied.

2

Overlaps in the applied membrane are to be in the same direction as the roof slope.

3

Base flashing items as specified in Clause 2.2.8 of this part are to be completed prior to the installation of the single layer membrane.

2.7

FLUID APPLIED MEMBRANES

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Section 14: Roofing Part 02: Membrane Roofing

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2.7.1

General Description

1

Liquid applied membranes shall be non-aqueous and should consist of a one component high quality polyurethane elastomeric coating or a two component coal tar polyurethane elastomer.

2

If polyurethane elastomeric coating is used then it shall cure by reacting with the humidity to form an elastic strong film with excellent adhesion to different substrate.

3

Elastomeric waterproofing liquid membrane shall have the minimum following properties or equivalent standards:-

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If two component coal tar polyurethane elastomer used then it shall cure, when mixed, to form a flexible, elastomeric waterproof membrane having the following minimum properties after ageing:

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Tensile strength: Elongation: Shore Hardness: Total Solids: Moisture vapour transmission:

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4

> 5 N/mm² > 500 % > 70 0.8 gr/m² (2000hrs) Passed o -40 to 80 C

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Tensile Strength, ASTM D412: Elongation, ASTM D412: Shore A, ASTM D2240: Vapor transmission, ASTM E96: QUV accelerated weathering test, ASTM G154: Service Temperature:

2

4.0 N/mm . 300-400 % I.R.H.D. 70 %. 90-95 % 2 8.5 ml/m /24 hours

The waterproofing membrane is to incorporate the sealer/primer, reinforcing and reflective coating materials recommended by the manufacturer of the membrane.

6

The Contractor is to submit to the Engineer the manufacturer’s literature concerning the shelf life of each component material of the system to be used, together with authoritative evidence of the dates of production

2.7.2

Liquid Applied Waterproofing Systems

1

Surfaces receiving the waterproof membrane are to be treated with the recommended primer. sealer and allowed to dry.

2

When all the surfaces receiving the membrane and the equipment to be used are ready, the materials are to be mixed in strict accordance with the manufacturer’s instructions using a mechanical mixer. Only that amount which can be used within the pot life of the material is to be prepared.

3

Reinforcing strips at construction and movement joints, shrinkage cracks, pipe inlets/outlets, electrical conduit, air-conditioning ducting etc., must be applied in the widths and thickness recommended by the manufacturer prior to final applications of the membrane.

4

When the reinforcing strips and expansion joint covers have cured, the membrane is to be applied using an airless spray, trowel, squeegee or any other recommended method producing the required membrane thickness.

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Section 14: Roofing Part 02: Membrane Roofing

Page 15

Site operatives are to be kept off the membrane until it has cured sufficiently to accept foot traffic. Tackiness of the surface may be neutralised by dusting with dry cement. Areas where labourers will be working applying topping materials should be covered with a protective layer of fibreboard.

6

Surfaces which are not to receive a permanent protective covering are to be treated with a solar reflective finish recommended by the manufacturer of the membrane.

2.8

COATED SPRAY APPLIED FOAM

2.8.1

Description

1

This Clause specifies general requirements for spray applied foam insulation which is covered with a protective coating.

2.8.2

Installation

1

Prior to spray application of the foam all welding or other hot work required on the roof is to be completed and all surfaces not to receive the insulation are to be securely wrapped or otherwise protected with suitable covering.

2

The equipment used by the Contractor is to provide thorough mixing of components and be calibrated prior to commencing work to ensure correct metering of the material components.

3

Under no circumstance should spraying be carried out in the presence of water or when the wind speed is in excess of 25 kilometres per hour.

4

The foam to be applied in minimum 12 mm layers to build up the specified thickness.

5

The first coat or layer of the protective covering is to be applied the same day the foam insulation is installed.

6

If for any reason more than 48 hours elapses between application of the foam and a protective coating, the foam surface is to be inspected for contamination or oxidation. Should either be present, the surface is to be brushed with a stiff broom or mechanically scoured and reformed prior to application of the protective covering.

2.9

PERMEABLE FILTER MEMBRANE

2.9.1

General Requirements

1

Permeable filter membrane are to be chemically stable and made of rot resistant fabric, manufactured from synthetic, thermally bonded, non woven fibre weighing not less than 140 g/m2 and minimum 0.7 mm thick. The membrane is to be capable of freely passing water but preventing the passage of salt and clay particles.

2

Application and execution of workmanship must comply with procedures recommended by the manufacturer.

3

Fabric must be applied around projections or areas of reinforcement in the widths and thickness recommended by the manufacturer prior to final applications of the membrane.

2.10

PROTECTED MEMBRANE

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Page 16

2.10.1

General Requirements

1

Protective membranes to membrane roofing shall be as specified in Part 4 of this Section.

2.11

TORCH APPLIED WATERPROOF MEMBRANE

2.11.1

General Requirements

1

Torch applied waterproofing membrane shall consist of a reinforced bitumen-polymer membrane having the following minimum properties: Thickness

3mm BS 2782

7.5N/mm

Elongation

BS 2782

40%

Tear Resistance

ASTM D1004

100N

Moisture Vapour Permeability

BS 2782

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Tensile Strength

2

8.5g/m /day

The waterproofing system shall incorporate the priming and reflective coating materials recommended by the manufacturer of the membrane.

2

The waterproofing system shall be applied strictly in accordance with the instructions supplied by the manufacturer.

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END OF PART

QCS 2014

Section 14: Roofing Part 03: Metal and Plastic Roofing

Page 1

3

METAL AND PLASTIC ROOFING ................................................................. 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2

Scope References

3.2

FITTINGS AND ACCESSORIES ................................................................... 2

3.2.1 3.2.2

Fittings for Rigid Sheet Roofing Fixing Accessories

3.3

ALUMINIUM SHEET FLASHING AND APRONS .......................................... 3

3.3.1 3.3.2

Materials Description Installation of Aluminium Flashings and Aprons

3.4

CORRUGATED METAL SHEETS ................................................................. 3

3.4.1 3.4.2 3.4.3 3.4.4 3.4.5

Profiled Aluminium Sheets Hop-Dip Zinc Coated Corrugated Steel Sheets Installation of Corrugated and Troughed Roof Coverings Fixing Profiled Aluminium Sheets Fixing Galvanized Corrugated Sheets

3.5

CORRUGATED TRANSLUCENT SHEETS................................................... 6

3.5.1 3.5.2 3.5.3

Materials Description Submittals Fixing Corrugated Translucent Sheets

2 2

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2 2 3 3 3 4 4 5 6 6 6 6

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Page 2

3

METAL AND PLASTIC ROOFING

3.1

GENERAL

3.1.1

Scope

1

This Part specifies requirements for use of metal and plastic roofing systems for buildings and structures.

2

Related Sections are as follows: Thermal Insulation of buildings Carpentry, Joinery and Ironmongery

References

1

The following standards are referred to in this Part: BS 1210 ......................Wood Screws

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Section 15 Section 18

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BS 1474 ......................Wrought aluminium and aluminium alloys for general engineering purposes. Bars, extruded round tube and sections BS 1494 ......................Fixing accessories for building purposes

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BS 3083 ......................Hot-dip zinc coated and hot-dip aluminium/zinc coated corrugated steel sheets for general purposes

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BS 3416 ......................Bitumen based coatings for cold application, suitable for use in contact with potable water

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BS 4154 ......................Corrugated plastic translucent sheets made from thermo-setting polyester resins (glass fibre reinforced)

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BS 4868 ......................Profiled aluminium sheet for building BS EN 485 ..................Aluminium and aluminium alloys - Plate, sheet and strip

FITTINGS AND ACCESSORIES

3.2.1

Fittings for Rigid Sheet Roofing

1

Fittings are to match the profile of the specified sheet and shall be supplied by the same manufacturer.

3.2.2

Fixing Accessories

1

Screws for fixing aluminium roof edging, aprons, and the like are to be stainless steel to BS 1210, minimum 50 mm long.

2

Hook bolts and nuts shall comply with BS 1494, Part 1 and be 8 mm diameter cadmium or zinc coated steel with plastic sleeves or applied plastic coating, shaped to suit the sheets and roof members and complete with plastic washers.

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Section 14: Roofing Part 03: Metal and Plastic Roofing

Page 3

Seam bolts and nuts for aluminium sheets are to be aluminium and to galvanized sheets to be galvanized steel, 6 mm diameter and 40 mm long complete with plastic washers.

4

Filler pieces at ridges and eaves are to be approved pre-moulded cellular plastic or rubber bitumen units to fit exactly the contours of the corrugations.

5

Sealant strip are to be approved flexible expanded polyurethane foam strip impregnated with waxes and/or resins having an elastic recovery of 98% minimum and a density of not less 3 than 145 kg/m .

3.3

ALUMINIUM SHEET FLASHING AND APRONS

3.3.1

Materials Description

1

Aluminium sheet flashings, aprons, etc., are to be fabricated from 99.8 % aluminium sheet and strip to BS EN 485, material designated 1080A, 0.9 mm thick.

2

Aluminium roof edging is to be fabricated form materials 6063-TB or 6063-TF complying with BS 1474 to profiles to suit the verges and roof covering material.

3

Black bitumen coating solution shall comply with BS 3416, Type 1.

3.3.2

Installation of Aluminium Flashings and Aprons

1

Flashings, aprons, and the like, are to be formed from sheets not more than 1800 mm long and to be lapped a minimum of 75 mm at intersections.

2

After folding and dressing, two coats of black bitumen coating solution are to be applied to all areas, which will come into contact with materials containing cement. Repeated folding and dressing should be avoided to prevent work hardening.

3

The top edge of flashings are to be provided with a 13 mm turn-back to act as a waterstop and recessed a minimum of 25 mm into the wall. The flashing are to be fixed with 20 x 20 mm strips of aluminium folded into a wedge shape, covered with two coats of bitumen solution and driven into the full depth of the recess at 400 mm centres. Upon completion of fixing the recess are to be pointed in Class M6 cement mortar in accordance with Part 2 of Section 13, Masonry.

4

Materials containing steel, copper, brass or bronze should not be allowed to come into contact with aluminium.

3.4

CORRUGATED METAL SHEETS

3.4.1

Profiled Aluminium Sheets

1

Profiled aluminium sheets shall comply with BS 4868 and be manufactured from aluminium alloy to BS EN 485, material designation 3103-H8, with a minimum tensile strength of 2 175 N/mm . Unless otherwise specified, Profile S, with a minimum thickness of 0.9 mm shall be installed.

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QCS 2014

Section 14: Roofing Part 03: Metal and Plastic Roofing

Page 4

Hop-Dip Zinc Coated Corrugated Steel Sheets

1

Hop-Dip zinc coated corrugated steel sheets shall comply with BS 3083 and shall have a 2 sheet thickness of 0.9 mm and minimum 450 g/m zinc coating.

3.4.3

Installation of Corrugated and Troughed Roof Coverings

1

The sheeting is to be laid with the open joint of side laps away from the prevailing wind. The Contractor is to obtain the approval of the Engineer as to which end of the structure the laying is to commence before beginning sheeting work.

2

The eaves course are to be laid first and subsequent sheets laid in tiers up to the roof from eaves to ridge, aligning sheets on both slopes on double pitched roofs.

3

Corrugations or troughs are to be in line from eaves to ridge and eaves and verges are to maintain proper alignment.

4

Sheets are to be cut to clean, true lines with no distortion. All burrs, drilling swarf or dust and any other foreign matter to be removed before positioning sealing strips, filler pieces and washers.

5

Openings for outlets, vent pipes, etc., are to be cut to the minimum size necessary. Vent pipes and the like should always pass through the centre line of the crown and are to be offset below roof level if necessary.

6

Holes through the sheets are to be drilled 2 mm larger than the diameter of the bolt and always through the crown of the profile. No hole should be nearer than 40 mm to the end of the sheet. All fixings are to be of the specified type and size and be in the correct position true to line and secure.

7

Fittings are to be fixed, where possible, by the same bolts that secure the sheeting.

8

Filler pieces shall be installed between the corrugations or troughs and flat surfaces or supports at the end of sheet runs wherever necessary to ensure airtightness of the structure.

9

A movement joint shall be provided in all lengths over 45 m. The joint is to be formed by installing an approved proprietary movement joint cover in a suitably sized space between the sheet.

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3.4.2

QCS 2014

Section 14: Roofing Part 03: Metal and Plastic Roofing

Page 5

3.4.4

Fixing Profiled Aluminium Sheets

1

Corrugated or troughened sheets are to be laid to comply with the requirements of with Tables 3.1 and 3.2. Table 3.1 Minimum Laps for Roof Sheeting Side Lap

mm

Corrugations

more than 15

150



less than 15

230



vertical

100

1

less than 15

150

1

more than 15

230

1

vertical

100

1

150



230



Corrugated Galvanized

2

more than 15

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Sheet

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Troughed aluminium sheet

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Corrugated aluminium sheet

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Slope

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End Lap

Material

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less than 15

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Table 3.2 Maximum Permissible Dimensions for Roof Sheeting Maximum Rail Spacing (mm)

Maximum Unsupported Overhang (mm)

1350

1500

150

2200

2400

350

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Sheet Material

Maximum Purlin Spacing (mm)

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Corrugated aluminium

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Corrugated galvanized steel

The centre line of end laps to coincide as nearly as possible with the centre line of supports, or the back of angle purlins. All end laps to be fully supported.

4

Roofing sheets are to be fixed to metal purlins by hook bolts. Each bolt is to be fitted with a metal washer shaped to the profile of the sheet and placed on the outer face together with a plastic, or similar approved material, sealing washer, positioned between the metal washer and sheet so that the bolt hole is sealed when the bolt is tightened. The bolt should be tightened only sufficiently to seat the washer and so as to permit slight movement between the structural frame and the sheeting.

5

Each sheet is to be fixed at every purlin or rail by at least two bolts situated at the side laps or edges together with intermediate fastenings at maximum 375 mm centres.

6

In addition to purlin or rail fixings, side laps are to be secured by means of bolts or rivets passing through the crown of the profile at the following maximum centres:

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(a)

roofs more than 15 pitch

375 to 450 mm centres

(b)

roofs less than 15 pitch

300 to 375 mm centres

QCS 2014

(c)

Section 14: Roofing Part 03: Metal and Plastic Roofing vertical sheeting

Page 6

450 mm centres.

Ridge cappings are, where possible, to be secured to the roof by the same bolts that secure the sheeting or, if the ridge purlin in not sufficiently near the ridge to permit this, the capping should be secured to the sheeting on each side by seam bolts or rivets at maximum 450 mm centres. The lap of the capping along the ridge should not be less than 150 mm with the open joint away form the prevailing wind.

3.4.5

Fixing Galvanized Corrugated Sheets

1

Galvanised corrugated sheets are to be installed as described in Clause 3.4.3.

3.5

CORRUGATED TRANSLUCENT SHEETS

3.5.1

Materials Description

1

This Section covers pre-formed plastic panels or corrugated translucent sheets made from thermosetting polyester resins to comply with BS 4154 and are to match the profile of the adjoining metal sheets.

2

The colour of plastic panels shall be as designated in the Project Documentation unless otherwise approved by the Engineer.

3.5.2

Submittals

1

Shop drawings for plastic panels shall show details of construction and installation, including profiles, fastener types and flashing details.

2

Plastic panel samples, 750 mm square, shall be submitted for each colour or varying texture finish used.

3.5.3

Fixing Corrugated Translucent Sheets

1

The sheets are to be laid with the same minimum side and end laps as the adjoining sheets. Sealing strips be used where the end lap is less than 300 mm on roof pitches below 15.

2

Pre-moulded filler strips and clear mastic shall be used to seal laps.

3

Fixing accessories and holes are to be the same as used for the adjoining sheets.

4

Each sheet should be fixed at every purlin or rail by at least two bolts situated at the side laps and three intermediate fastenings for use with galvanized or aluminium corrugated profiles.

5

In addition to purlin or rail fixings, side laps are to be secured by means of seam bolts at maximum 300 mm centres. The use of self-tapping screws or blind rivets are not permitted.

6

Provide neoprene washers under bolt heads. If other fastenings are recommended by plastic sheet manufacturer, install in accordance with manufacturer’s recommendations.

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END OF PART

QCS 2014

Section 14: Roofing Part 04: Roof and Deck Insulation

Page 1

4

ROOF AND DECK INSULATION .................................................................. 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2 4.1.3 4.1.4

Scope References Submittals General Application

4.2

RIGID BOARD INSULATION......................................................................... 3

4.2.1

General Requirements

4.3

PROTECTION OF INVERTED ROOF SYSTEMS ......................................... 3

4.3.1

General Requirements

4.4

POLYSTYRENE BOARD INSULATION ........................................................ 3

4.4.1

General Requirements

4.5

CEMENT-FIBRE ROOF DECK ...................................................................... 4

4.5.1 4.5.2 4.5.3 4.5.4

General Description Cement-Fibre Roof Deck Planks Accessories Installations

4.6

INSULATING CONCRETE ROOF SCREEDS............................................... 5

4.6.1 4.6.2 4.6.3

General Description Materials Execution of Work

2 2 2 3

3 3 4 4 4 5

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QCS 2014

Section 14: Roofing Part 04: Roof and Deck Insulation

Page 2

4

ROOF AND DECK INSULATION

4.1

GENERAL

4.1.1

Scope

1

This Part specifies requirements for types of roofing and deck insulation.

2

Related Sections are as follows: General Membrane Roofing Metal and Plastic Roofing Roof tiles and Shingles

Section 1 Section 15

General Thermal Insulation of Buildings

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This Section Part 1 Part 2 Part 3 Part 5

References

1

The following standards are referred to in this Part:

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BS 3379 ......................Flexible polyurethane cellular materials for load bearing applications BS 3797 ......................Lightweight aggregates for concrete

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BS 5075 ......................Concrete admixtures

BS 1105 ......................Wood wool cement slabs up to 125 mm thick

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BS 3837 ......................Expanded polystyrene boards BS EN 490 ..................Concrete roofing tiles and fittings - Product specifications

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BS EN 491 ..................Concrete roofing tiles and fittings - Test methods EN 197-1 ....................Portland Cement Submittals

1

The contractor is to submit the following to the Engineer for approval before commencement of work in this section.

2

Manufacturers literature and samples of roofing, thermal insulation, vapor barrier, roof accessories, bitumen waterproof membranes, waterproofing materials, dampproof coursing and elastometric sealants, etc.

3

Primary roofing materials inclusive of insulation, barriers or membranes should be obtained from only one manufacturer if possible. Where secondary materials must be used, the primary manufacturer is to be provided with adequate literature and samples for concurrence that the secondary products are compatible for roofing warrantees. Concurrence will be provided by the Contractor in writing to the Engineer prior to commencement of work.

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4.1.3

QCS 2014

Section 14: Roofing Part 04: Roof and Deck Insulation

Page 3

General Application

1

Expanded extruded polystyrene boards shall comply with BS 3837, Grade EHD, Type A, extruded board with skins.

2

Spray applied polyurethane or isocyanurate foam insulation is to be protected from deterioration due to ultra violet light by a covering approved by the manufacturer of the foam.

3

Where spray applied foam is used as an integral part of the roof waterproofing system it must be specifically included in the manufacturer’s guarantee requirements.

4

Unless otherwise specified the insulation is to be at least equivalent to 50 mm thick material having an ultimate thermal conductivity of 0.032 W/mK at a mean temperature of 10C and a compressive resistance of not less than 150 kN/m2.

4.2

RIGID BOARD INSULATION

4.2.1

General Requirements

1

Rigid insulation boards are to be installed as a single layer to the thickness specified.

2

All joints between rigid insulation boards are to be tight and no gaps should exist where the board meets rooflights, edge details and services penetrating the roof structure. End joints are to be staggered.

3

On corrugated surfaces all long edges are to be supported by the crown of the corrugations.

4.3

PROTECTION OF INVERTED ROOF SYSTEMS

4.3.1

General Requirements

1

Insulating material having a water absorption in excess of 1.5% by volume in seven (7) days at 20 ºC are not to be used in inverted roof systems.

2

The insulation is to be covered by a layer of permeable filter membrane, laid loose and lapped 200 mm at all intersections before the paving slabs or solar reflective chipping is laid.

3

Paving slab protection is to be loose laid with 6 mm open joints on 100 x 100 x 6 mm inorganic spacers positioned at the corner junctions of the slabs. The paving slabs will have a minimum thickness of 40 mm on insulation boards of up to 50 mm and for every 10 mm increase in the insulation thickness the slab thickness should be increased by 5 mm.

4

Aggregate protection is to consist of a 50 mm minimum layer of chippings on insulation boards of up to 50 mm. The thickness of the aggregate layer to be increased to a depth equal to the thickness of insulation boards over 50 mm.

4.4

POLYSTYRENE BOARD INSULATION

4.4.1

General Requirements

1

Polystyrene board insulation shall conform to BS 3837, and shall include the following requirements:

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4.1.4

QCS 2014

Page 4

(a)

water absorption shall not be more than 0.1 % by weight

(b)

density shall not be less than 32 kg/m for Type VI

3

Standard polystyrene boards shall conform to the following requirements: (a)

nominal size shall be approximately 600 by 1200 mm minimum

(b)

they shall have a drainage channel on the bottom longitudinal edge of the board

(c)

they are to have a flat top surface where gravel ballast in used or ribbed bottom pavers are used

(d)

they are to have ribbed top surface where flat bottom paver is used

(e)

they are to be tapered for roof slope where top surface is level

(f)

the edges shall be square, except for drainage channels.

density

(ii)

compressive strength (28 days)

(iii)

bond strength to insulation1 MPa

(iv)

troweled finish with texture

25 MPa

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3

(i)

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(a) boards shall be top surfaced with 10 mm thick facing of Portland cement latex mortar having the following physical properties:

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(a)

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Mortar faced boards shall conform to the following requirements:

drainage channels on bottom longitudinal edges of board

(c)

nominal size shall be approximately 600 by 1200 mm minimum

(d)

they shall have tongue and grooved longitudinal edges

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Section 14: Roofing Part 04: Roof and Deck Insulation

CEMENT-FIBRE ROOF DECK

4.5.1

General Description

1

This Clause covers the furnishing and installation of cement-fibre roof deck planks.

4.5.2

Cement-Fibre Roof Deck Planks

1

Cement-Fibre planks shall be manufactured from treated wood fibres and Portland cement, bonded under pressure to BS 1105. The length and width of planks to be shown on plans will comply with manufacturer’s requirements to suit span and load. The long edges are to be tongue and grooved and the ends square. Zinc coated steel channels will be factory applied in the groove of the plank. A factory bonded layer of urethane foam insulation shall be applied to the top of the plank.

2

Examine planks before installation. Broken or cracked planks should not be used. Where exposed, repaint soiled planks with paint recommended by the plank manufacturer to match colour and texture of adjacent planks.

4.5.3

Accessories

1

Clips shall be as recommended by the cement-fiber plank manufacturer to suit the supporting members.

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QCS 2014

Section 14: Roofing Part 04: Roof and Deck Insulation

Page 5

Nails shall be galvanized cork type with integral 25 mm washer, of length to penetrate wood support not less than 25 mm.

4.5.4

Installations

1

Planks shall be cut to fit tight at perimeters, vertical surfaces, projections and openings. All edges and ends of planks and perimeter of openings greater than 200 mm are to be supported by framing members and bearing walls.

2

Planks are to be laid progressively with side joints (edges) tightly butted and with end joints in adjacent rows staggered.

3

Clips or nails are to be installed progressively as each plank is installed. Clips or nails are to be installed in accordance with the manufacturer's instructions.

4

Install a barrier, full depth of the plank, over the top of sound rated partitions and at the perimeter of exterior walls.

4.6

INSULATING CONCRETE ROOF SCREEDS

4.6.1

General Description

1

This section covers insulating concrete placed on a prepared structural deck.

2

Insulating concrete placed on steel deck forms are to have underside venting through slotted holes formed in the metal deck, combined with edge venting or topside venting through roof relief vents.

3

Insulating concrete placed over cast-in-place concrete or precast concrete substrates, is to be vented through the use of topside roof relief vents combined with edge venting.

4.6.2

Materials

1

Refer to Section 5, Concrete, for specifications relating to sand, cement, aggregates and water.

2

Portland cement shall conform to EN 197-1.

3

Concrete roofing tiles shall conform to BS EN 490 and BS EN 491.

4

Light weight aggregates shall conform to BS 3797.

5

Chipping shall be approved, clean, crushed white or pale grey, size 15 to 30 mm and shall comply with BS 3379.

6

Air entraining agent refer to BS 5075 Prt 2 and shall be a type as recommended by aggregate suppliers. Admixtures with chloride salts or pre-generated foam types are not acceptable.

7

Permeable filter membrane shall be to Clause 2.9.1.

8

Control joint filler shall be glass fibre or similar highly compressible material, which will compress to half of its thickness under a load of 170 KPa or less.

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QCS 2014

Section 14: Roofing Part 04: Roof and Deck Insulation

Page 6

Wire mesh reinforcing shall be used when roof deck slopes exceed 1:3 and for fire rated roof assemblies using metal decking. The wire mesh shall be 1 mm galvanized steel wire twisted to form 50 mm hexagons with 1.6 mm galvanised steel wire woven into mesh spaced 200 mm apart. Welded wire fabric of equivalent size may also be used an approval of the Engineer.

4.6.3

Execution of Work

1

The surface of the concrete base must be clean, firm and rough to ensure a good bond.

2

The base should be soaked with water for at least 12 hours and all surplus water removed before laying commences.

3

To obtain the required falls and thickness of screed, leveling battens are to be used, carefully fixed to line and level and fully bedded. There should be a minimum thickness of 40 mm of screed over the top of any conduit or duct.

4

Immediately prior to laying the screed, a thick brush coat of wet cement grout should be applied to the damp surface of the base concrete and be well scrubbed in. The brush coat must not be applied more than 10 minutes before it is covered with screed. Alternatively, the Engineer may required that surfaces which have been left for an excessive period of time before the screed is laid be treated with an approved bonding agent.

5

The screed is to consist of 1 part of cement to 5 parts of sand by weight. The mix shall only contain sufficient water that will allow full compaction and be evenly spread to a thickness approximately 10 mm greater than that required. The screed is to be thoroughly compacted by tamping and drawing off to the required level with a screed board.

6

The screed is to be laid in alternated bays, maximum 10 m², with plain butt joints to provide minimum falls of 1:80 and a minimum thickness of 50 mm. Movement and construction joints in the base should be carried through the screed.

7

The joints between bays and at junctions with all upstands are to be minimum 12 mm wide and be filled for the full depth of the joint with sealing strip or an approved polysulphide joint filler and sealing compounds.

8

A 75 x 75 mm triangular fillet is to be provided at the junction with all upstands.

9

The top surface is to be floated to smooth and even falls suitable for the waterproofing system to be employed and be free of low areas, lumps and projections. Care should be taken to avoid excessive trowelling which may cause crazing.

10

As soon as each bay is completed and has hardened sufficiently to prevent damage to its surface, it should be covered with polythene or similar sheets which should be adequately lapped and held down. The screed must not be allowed to dry out for a minimum period of seven (7) days and no traffic should be permitted on the surface during this time.

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END OF PART

QCS 2014

Section 14: Roofing Part 05: Roofing Tiles and Shingles

Page 1

5

ROOFING TILES AND SHINGLES ............................................................... 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2

Scope References

5.2

CLAY SHALE AND CONCRETE ROOFING TILES ...................................... 3

5.2.1 5.2.2 5.2.3

General Products Execution of Installation

5.3

ROOFING SHINGLES ................................................................................... 4

5.3.1 5.3.2 5.3.3

General Metal, asbestos-cement and Asphalt Shingles Shakes and Shingles of Other Materials

2 2

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QCS 2014

Section 14: Roofing Part 05: Roofing Tiles and Shingles

Page 2

5

ROOFING TILES AND SHINGLES

5.1

GENERAL

5.1.1

Scope

1

This Part specifies requirements for and the installation of roof tiles made of clay, shale and concrete, and additionally for shakes or shingles made of other materials.

2

Related Sections are as follows: General Membrane Roofing Metal and Plastic Roofing Roof and Deck Insulation

Section 1 Section 5 Section 13 Section 14 Section 15 Section 17 Section 18 Section 24

General Concrete Masonry Roofing Thermal Insulation of Buildings Metalwork Carpentry, Joinery and Ironmongery Finishes to Buildings

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This Section Part 1 Part 2 Part 3 Part 4

In general, roofing tile and shingle materials and their application shall conform to BS 5534, BS 8000 Part 6, BS EN 490, BS EN 491 and BS EN 539.

5.1.2

References

1

The following standards are referred to in this Section:

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BS 402 ........................Clay plain roofing tiles and fittings BS 680 ........................Roofing slates

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BS 747 ........................Roofing felts BS 1202 ......................Nails BS 1521 ......................Waterproof building papers BS 4016 ......................Building papers (breather type) BS 5534 ......................Code of Practice for slating and tiling BS 8000 ......................Workmanship on building sites BS EN 490 ..................Concrete roofing tiles and fittings - Product specifications BS EN 491 ..................Concrete roofing tiles and fittings - Test methods BS EN 538 ..................Clay roofing tiles for discontinuous laying flexural strength test BS EN 539 ..................Clay roofing tiles for discontinuous laying - determination of physical characteristics

QCS 2014

Section 14: Roofing Part 05: Roofing Tiles and Shingles

Page 3

5.2

CLAY SHALE AND CONCRETE ROOFING TILES

5.2.1

General

1

Roofing tiles made of clay, shale and concrete roofing tiles shall comply with (but are not limited to) the respective standards as follows: clay, shale roofing tiles: BS 402, BS 680, BS EN 538, BS EN 539, and BS 8000 Part 6

(b)

concrete roofing tiles: BS 680, BS EN 490 and 491, and BS 8000 Part 6.

Submittals of roofing materials to be used will be made by the Contractor in accordance with the relevant provisions of Section 1, General, shall include furnishing of the following: (a)

samples of each colour of each type of tile required in the Works; the tiles shall be of finished product quality and shape

(b)

shop drawings with details of any fabricated custom shapes and installation requirements.

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Product Delivery, Storage and Handling:

tiles and setting materials shall be delivered in manufacturers’ original, unopened containers clearly identifying manufacture and the contents

(b)

tiles shall not be stored in the flat position.

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(a)

The Contractor shall guarantee materials and workmanship to be free from defects and leaks for a period of two (2) years.

5.2.2

Products

1

Clay and shale roofing tiles shall be English, French, Greek, Roman or Spanish type unless otherwise specified in the Project Documentation or approved by the Engineer, and all tiles are to be hard burned, dense, fully vitrified, clay or shale, free from fire cracks or defects.

2

Concrete roof tiles will be of quality materials to BS EN 490 and BS EN 491.

3

Non-interlocking locking or interlocking tiles are acceptable, but should not be intermixed in use.

4

Nails brads, staples and spikes and any other fasteners used to secure tiles shall be corrosion-resistant nails or wire to BS 1202.

5

Felt underlay should be to tile manufacturer’s recommendations for related roof slope. Felt underlay shall be asphalt saturated organic felt, without perforations, nominal 66 kg/m2 to BS 747 unless otherwise shown on the drawings and shall comply to BS 4016, BS 1521 and BS 747.

5.2.3

Execution of Installation

1

Vent pipes and other projections through roofs and flashing materials are to be in place before laying tiles.

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QCS 2014

Section 14: Roofing Part 05: Roofing Tiles and Shingles

Page 4

2

Felt underlay shall be laid in single thickness, parallel to eaves with double thickness at hips and ridges. Horizontal joints shall be lapped 75 mm and vertical joints lapped 150 mm. Vertical joints shall be staggered. Felt shall be extended up 150 mm at abutting vertical walls, chimneys and parapets. Under the edges of built-up gutters, valleys, and metal flashings, the felt shall be lapped not less than 100mm.

3

Laying Tile tiles shall be laid free of horizontal obstructions which would impede shedding of surface water

(b)

courses shall be laid parallel with eaves

(c)

each tile shall be secured by at least two nails, of copper or stainless steel wire and shall be fastened where practicable

(d)

nails and wire fastenings in finished work shall be covered

(e)

tiles shall be laid with an end lap of at least 75 mm

(f)

fill laps of end bands, of tiles on ridges, and gable rakes with roofers plastic cement

(g)

roofers plastic cement may be used for levelling tiles and for pointing around eave bridge closures.

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(a)

Upon completion of the tiling, any cement splatter shall be removed from tile and adjacent surfaces.

5.3

ROOFING SHINGLES

5.3.1

General

1

Roofing shingles, as specified in this Section, are inclusive of all non-clay, shale or concrete tiles which are used in the same manner as roofing elements used in an overlapping system on sloped roofs.

5.3.2

Metal, asbestos-cement and Asphalt Shingles

1

Metal, asbestos-cement and asphalt shingles shall be installed in an approved manner as established by acceptable proprietary manufacturers and as detailed in the drawings

5.3.3

Shakes and Shingles of Other Materials

1

Other shake or shingle products of man-made plastic or compounds will require submittal of product specification and samples for testing prior to approval. Such products shall be installed in an approved manner as established by acceptable proprietary manufacturers and as detailed in the drawings.

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END OF PART

QCS 2014

Section 15: Insulation of Buildings Part 01: General

Page 1

GENERAL ............................................................................................................... 2

1.1 1.1.1 1.1.2

INTRODUCTION ..................................................................................................... 2 Scope 2 References 2

1.2 1.2.1 1.2.2 1.2.3

MATERIALS ............................................................................................................ 4 General Requirements 4 Submittals 4 Storage 5

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QCS 2014

Section 15: Insulation of Buildings Part 01: General

Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section covers the type, quality and application of exterior wall and roof insulation, damp proof courses, waterproof; and related joints, caulking and insulation.

2

Related Sections are as follows: This Section

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Section 1 ......... General Section 13 ....... Masonry Section 14 ....... Roofing Section 16 ...... Structural Metalwork Section 17 ....... Metalwork Section 24 ....... Finishes to Buildings Section 25 ....... Glass and Glazing

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Part 2 ............... Building Insulation Part 3 ............... Cold Stores

References

1

The following standards are referred to in this Section:

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BS 874........................Methods for determining thermal insulating properties

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BS 1142......................Fibre building boards BS 1202......................Nails

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BS 1210......................Wood screws

et it

BS 1449......................Steel plate, sheet and strip BS 2502......................Manufacture of sectional cold rooms (walk in type)

m

BS 2972......................Method of test for inorganic thermal insulating materials BS 3692......................ISO metric precision hexagon bolts, screws and nuts BS 3837......................Expanded polystyrene boards BS 3927...................... Rigid phenolic foam (PF) for thermal insulating in the form of slabs and profiled sections BS 3958......................Thermal insulation materials BS 4841......................Rigid polyurethane (PUR) and polyisocyanurate (PIR) foam for building applications BS 5250......................Code of practice for control of condensation in buildings BS 5617......................Urea-formaldehyde (UF) foam systems suitable for thermal insulation of cavity walls with masonry of concrete inner and outer leaves BS 5618......................Thermal insulation of cavity walls (with masonry of concrete inner and outer leaves) by filling with urea-formaldehyde (UF) foam systems BS 5803......................Thermal Insulation for use in pitched roof spaces in dwellings

QCS 2014

Section 15: Insulation of Buildings Part 01: General

Page 3

BS 6203......................Guide to fire characteristics and fire performance of expanded polystyrene materials (EPS and XPS) used in building applications BS 6676......................Thermal insulation of cavity walls using man-made mineral fibre batts (slabs) BS 7021......................Code of practice for thermal insulation of roofs externally by means of sprayed rigid polyurethane (PUR) or polyisocyanurate (PIR) foam BS 7456 .....................Code of practice for stabilization and thermal insulation of cavity walls (with masonry or concrete inner and outer leaves) by filling with polyurethane (PUR) foam systems BS 8208......................Assessment of stability of external cavity walls for filling with thermal insulants

.

BS 8216......................Code of practice for use of sprayed lightweight mineral coatings used for thermal insulation and sound adsorption in buildings

rw

.l. l

BS 8233......................Sound insulation and noise reduction for buildings. Code of practice

ta

BS EN 998-1 .............Specification for mortar for masonry: Part 1: Rendering and plastering mortar BS EN 3261................Unbacked flexible PVC flooring

qa

BS EN 13162:2012..... Thermal insulation products for buildings. Factory made mineral wool (MW) products. Specification

as

BS EN 13163..............Thermal insulation products for buildings. Factory made expanded polystyrene (EPS) products. Specification

se

BS EN 13164 .............Thermal insulation products for buildings. Factory made extruded polystyrene foam (XPS) products. Specification

ov

er

BS EN 13165..............Thermal insulation products for buildings. Factory made rigid polyurethane foam (PU) products. Specification BS EN 13166..............Thermal insulation products for buildings. Factory made phenolic foam (PF) products. Specification

et it

o

BS EN 13167:2012. ...Thermal insulation products for buildings. Factory made cellular glass (CG) products. Specification

m

BS EN 13168:2012.....Thermal insulation products for buildings. Factory made wood wool (WW) products. Specification BS EN 13169:2012.....Thermal insulation products for buildings. Factory made expanded perlite board (EPB) products. Specification BS EN 13170:2012.....Thermal insulation products for buildings. Factory made products of expanded cork (ICB). Specification BS EN 13171:2012.....Thermal insulation products for buildings. Factory made wood fibre (WF) products. Specification BS EN 13172..............Thermal insulation products. Evaluation of conformity BS EN 13467..............Thermal insulating products for building equipment and industrial installations. Determination of dimensions, squareness and linearity of preformed pipe insulation BS EN 14319-1 ..........Thermal insulating products for building equipment and industrial installations. In-situ formed dispensed rigid polyurethane (PUR) and polyisocyanurate foam (PIR) products

QCS 2014

Section 15: Insulation of Buildings Part 01: General

Page 4

BS EN 14320-1 ..........Thermal insulating products for building equipment and industrial installations. In-situ formed sprayed rigid polyurethane (PUR) and polyisocyanurate foam (PIR) products BS EN 14496..............Gypsum based adhesives for thermal/acoustic insulation composite panels and plasterboards. Definitions, requirements and test methods EN 1745:2002 ............Masonry and masonry products — Methods for determining design thermal values EN 13501-1 ................Fire classification of construction products and building elements — Part 1: Classification using test data from reaction to fire tests

.l. l

.

GSO EN 13950 Gypsum plasterboard thermal/acoustic insulation composite panels Definitions, requirements and test methods

rw

ISO 12575-1 ...............Thermal insulation. Exterior insulating systems for foundations Material specification systems

for

ta

ISO 12575-2 ...............Thermal insulation products. Exterior insulating foundations: Principal responsibilities of installers

qa

ISO 11925-2 ...............Reaction to fire tests -- Ignitability of products subjected to direct impingement of flame -- Part 2: Single-flame source test

MATERIALS

1.2.1

General Requirements

1

Types for insulation are: thermal /acoustic / fire / damp proof courses / waterproof

2

Thermal insulation materials shall meet requirements of BS 2972 for testing for inorganic thermal quality and expanded polystyrene materials shall meet fire requirements of BS 6203 or EN 13501-1 or ISO 11925-2.

3

Insulation material shall comply with any reference in paragraph 1.1.2, or approved by Qatar Standards.

4

Insulation materials shall be approved by Civil Defence Department

1.2.2

Submittals

1

Submittals shall comply with the relevant provisions of Section 1, General.

2

The Contractor shall submit to the Engineer the manufacturer’s literature and data for the following:

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1.2

(a)

insulation, each type used

(b)

adhesives, each type used

(c)

tape

QCS 2014

Section 15: Insulation of Buildings Part 01: General

Page 5

3

The Contractor shall submit to the Engineer details of all insulation materials to be installed. The details shall include, but not be limited to, the type, dimensions and thermal/acoustic/damp proof courses/waterproof insulating properties of the insulation. References to all applicable standards shall be included with the submission.

1.2.3

Storage

1

Materials shall be stored in accordance with the relevant provisions of Section 1, General.

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END OF PART

QCS 2014

Section 15: Insulation of Buildings Part 02: Building Insulation

Page 1

BUILDING INSULATION ......................................................................................... 2

2.1 2.1.1 2.1.2

GENERAL ............................................................................................................... 2 Scope 2 References 2

2.2 2.2.1

THERMAL INSULATION ......................................................................................... 4 Minimum Envelope Performance Requirements 4

2.3 2.3.1

ACOUSTICAL CONTROL ....................................................................................... 5 References 5

2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9

INSULATION MATERIAL TYPES ............................................................................ 6 General 6 External Thermal Insulation Composite System (ETICS) 6 Cavity Wall Insulation 6 Perimeter Insulation 6 Exterior Framing or Furring Insulation 7 Rigid Insulation 7 Masonry Fill Insulation 7 Adhesive 7 Tape 7

2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7

INSTALLATION ....................................................................................................... 7 Execution and Workmanship 7 Masonry Cavity Walls 8 Perimeter Insulation 8 Exterior Framing or Furring Blanket Insulation 8 Rigid Insulation 9 Masonry Fill Insulation 9 Insulation Behind Marble Cladding 9

2.6 2.6.1 2.6.2

PREFABRICATED WALL INSULATION................................................................ 10 General 10 Quality and Requirements 10

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QCS 2014

Section 15: Insulation of Buildings Part 02: Building Insulation

Page 2

2

BUILDING INSULATION

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the type, quality and application of exterior wall insulation.

2

Related Sections are as follows: This Section

References

1

The following standards are referred to in this Section:

.l. l

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ta

2.1.2

rw

Section 5 ......... Concrete Section 13 ....... Masonry Section 18 ....... Carpentry, Joinery and Ironmongery

.

Part 1 ............... General

BS 874........................Methods for determining thermal insulating properties BS 1202......................Nails

se

BS 1210......................Wood screws

as

BS 1142......................Fibre building boards

BS 3692......................Isometric precision hexagon bolts, screws, nuts

er

BS 3837......................Expanded polystyrene boards

ov

BS 3958......................Thermal insulation materials BS 4841......................Rigid urethane foam

o

BS 5250......................Code of practice for control of condensation in buildings

et it

BS 5617......................Urea-formaldehyde (UF) foam systems suitable for thermal insulation of cavity walls with masonry or concrete outer leaves

m

BS 5618......................Thermal insulation of cavity walls (with masonry or concrete outer leaves) by filling with urea-formaldehyde (UF) foam systems BS 5803......................Thermal insulation for use for use in pitched roof spaces in dwellings BS 6203......................Guide to fire characteristics and fire performance of expanded polystyrene materials (EPS and XPS) used in building applications BS 6676......................Thermal insulation of cavity walls using man-made mineral fibre batts (slabs) BS 7021......................Code of practice for thermal insulation of roofs externally by means of sprayed rigid polyurethane (PUR) or polyisocyanurate (PIR) foam BS 7456 .....................Code of practice for stabilization and thermal insulation of cavity walls (with masonry or concrete inner and outer leaves) by filling with polyurethane (PUR) foam systems BS 8208......................Assessment of stability of external cavity walls for filling with thermal insulants

QCS 2014

Section 15: Insulation of Buildings Part 02: Building Insulation

Page 3

BS 8216......................Code of practice for use of sprayed lightweight mineral coatings used for thermal insulation and sound absorption in buildings BS 8233......................Sound insulation and noise reduction for buildings. Code of practice BS EN 998-1 .............Specification for mortar for masonry: Part 1: Rendering and plastering mortar BS EN 13162:2012.....Thermal insulation products for buildings. Factory made mineral wool (MW) products. Specification BS EN 13163..............Thermal insulation products for buildings. Factory made expanded polystyrene (EPS) products. Specification

.l. l

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BS EN 13164 .............Thermal insulation products for buildings. Factory made extruded polystyrene foam (XPS) products. Specification

rw

BS EN 13165..............Thermal insulation products for buildings. Factory made rigid polyurethane foam (PU) products. Specification

ta

BS EN 13166..............Thermal insulation products for buildings. Factory made phenolic foam (PF) products. Specification

qa

BS EN 13167:2012. ...Thermal insulation products for buildings. Factory made cellular glass (CG) products. Specification

as

BS EN 13168:2012.....Thermal insulation products for buildings. Factory made wood wool (WW) products. Specification

se

BS EN 13169:2012.....Thermal insulation products for buildings. Factory made expanded perlite board (EPB) products. Specification

er

BS EN 13170:2012.....Thermal insulation products for buildings. Factory made products of expanded cork (ICB). Specification

ov

BS EN 13171:2012.....Thermal insulation products for buildings. Factory made wood fibre (WF) products. Specification BS EN 13172..............Thermal insulation products. Evaluation of conformity

et it

o

BS EN 13467..............Thermal insulating products for building equipment and industrial installations. Determination of dimensions, squareness and linearity of preformed pipe insulation

m

BS EN 14319-1 ..........Thermal insulating products for building equipment and industrial installations. In-situ formed dispensed rigid polyurethane (PUR) and polyisocyanurate foam (PIR) products BS EN 14320-1 ..........Thermal insulating products for building equipment and industrial installations. In-situ formed sprayed rigid polyurethane (PUR) and polyisocyanurate foam (PIR) products BS EN 14496..............Gypsum based adhesives for thermal/acoustic insulation composite panels and plasterboards. Definitions, requirements and test methods EN 1745:2002 ............Masonry and masonry products — Methods for determining design thermal values EN 13501-1 ................Fire classification of construction products and building elements — Part 1: Classification using test data from reaction to fire tests GSO EN 13950 ..........Gypsum plasterboard thermal/acoustic insulation composite panels Definitions, requirements and test methods

QCS 2014

Section 15: Insulation of Buildings Part 02: Building Insulation

Page 4

ISO 12575-1 ...............Thermal insulation. Exterior insulating systems for foundations Material specification ISO 12575-2 ...............Thermal insulation products. Exterior insulating foundations: Principal responsibilities of installers

systems

for

ISO 11925-2 ...............Reaction to fire tests -- Ignitability of products subjected to direct impingement of flame -- Part 2: Single-flame source test Health Technical Memorandum 08-01: Acoustics

THERMAL INSULATION

2.2.1

Minimum Envelope Performance Requirements

1

For all new air conditioned buildings, exterior building elements must have average thermal transmittance (also known as U Value) and Shading Coefficients (SC) that does not exceed the values specified and Light Transmittance greater than or equal to the values specified. External Walls, Roofs and Floors:

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(a)

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2.2

qa

Building elements forming the external walls and floors (where one side of the floor is exposed to ambient conditions) must have an average thermal transmittance (U Value) which does not exceed the following values: 2

U= 0.44W/m K

as

Roof

2

U=0.57W/m K

se

External Wall Floor

2

U=0.57W/m K

ov

er

If the floor is in contact with the ground, the insulations should only be applied to one meter (1m) in from the perimeter of the building.

If the total area of external walls that let in light is forty percent (40%) or less of the external wall area, then the glazing elements must meet the following performance criteria:

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2

Glazed Elements-Fenestration:

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(b)

o

Glazed elements with back insulated panels must be treated as walls (and therefore must meet the performance requirement for walls.)

3

4

2

Thermal Transmittance (Summer U Value)

U=2.1W/m K (max)

Shading Coefficient (SC)

0.4 (max)

Light Transmittance

0.25 (min)

If the total area of external walls that let in light is between forty percent (40%) and sixty percent (60%) of the external wall area, then the glazing elements must meet the following performance criteria: 2

Thermal Transmittance (Summer U Value)

U=1.9W/m k (max)

Shading Coefficient (SC)

0.32 (max)

Light Transmittance

0.1 (min)

If the total of external walls that let in light is sixty percent (60%) or greater of the external wall area, then the glazing elements must meet the following performance criteria.

QCS 2014

5

Page 5

2

Thermal Transmittance (Summer U Value)

U=1.9W/m K (max)

Shading Coefficient (SC)

0.25 (max)

Light Transmittance

0.1 (min)

For shop fronts and showrooms, other than those at ground floor level, glazing elements must meet the following performance criteria: 2

Thermal Transmittance (Summer U Value)

U=1.9W/m K (max)

Shading Coefficient (SC)

0.76 (max)

If the glazing portion of a roof is ten percent (10%) or less of the roof area, then the glazing elements must meet the following performance criteria:

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6

Section 15: Insulation of Buildings Part 02: Building Insulation

2

U=1.9W/m K (max)

Shading Coefficient (SC)

0.32 (max)

rw

Thermal Transmittance (Summer U Value)

qa

If the glazing portion of a roof is greater than ten percent (10%) of the roof area, then the glazing elements must meet the following performance criteria: 2

U=1.9W/m K (max)

Shading Coefficient (SC)

0.25 (max) 0.3 (min)

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Light Transmittance

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Thermal Transmittance (Summer U Value)

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7

0.4 (min)

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Light Transmittance

ACOUSTICAL CONTROL

2.3.1

References

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ov

2.3

et it

Building Type

m

Villas/Residential Buildings

Document Reference Building Regulations Approved Document E (revised 2003) (UK)

Healthcare Facilities

Health Technical Memorandum 08-01 (UK)

Educational facilities

Building Bulletin 93: Acoustic Design of Schools – A design Guide (UK)

Commercial Buildings

BS8233:1999 “Sound insulation and noise reduction for buildings-code of practice.” (UK)

Industrial

BS8233:1999 “Sound insulation and noise reduction for buildings-code of practice.” (UK)

Public

BS8233:1999 “Sound insulation and noise reduction for buildings-code of practice.” (UK)

*Residential buildings Accommodations.

include

Villas,

Apartments,

Worker

Accommodations

and

Student

**Educational Facilities include Nursery Schools, Primary Schools, Secondary Schools, Colleges and Universities.

QCS 2014

Section 15: Insulation of Buildings Part 02: Building Insulation

Page 6

INSULATION MATERIAL TYPES

2.4.1

General

1

Various types of insulation may be specified for varying conditions or wall construction. The BS, EN classification system is to be used for insulation material; or to any other reference mentioned in paragraph 2.1.2 , or approved by Qatar Standards.

2

The Contractor shall use only one type of insulation in any particular area where more than one type is optional unless approved other wise by the Engineer.

3

At least thermal insulation is to be used for exterior roofs and exterior walls of the building

4

Where insulation is used for exterior walls, roof surfaces, or below grade, the requirements for condensation control shall be to BS 5250 and BS 5803.

2.4.2

External Thermal Insulation Composite System (ETICS)

1

If specified the external thermal insulation composite system (ETICS) shall be bonded system and tested in accordance with ETAG-004 (European organization for technical approvals):-

2

The external thermal insulation system shall compose of the following components:-

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2.4

Adhesive layer

(b)

Extruded or expanded Polystyrene board

(c)

Insulation boards fasteners (Plastic or metal)

(d)

Cementitious adhesive protective mortar layer

(e)

Fibremesh reinforcement

(f)

Cementitious adhesive protective mortar layer

(g)

Decorative layer of acrylic or polymer modified cementitious mortar

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(a)

Cavity Wall Insulation

1

Mineral Fibre Board shall comply with the relevant provisions of BS 1142 and be faced with a vapour retarder having a perm rating of not more than 0.5.

2

Polyurethane or polyisocyanurate board shall comply with the relevant provisions of BS 4841 and be faced with a vapour retarder having a perm rating of not more than 0.5.

3

Polystyrene board shall comply with the relevant provisions of BS 3837.

4

Foam system insulation used in cavity walls shall be to BS 5617 and BS 5618.

5

Unless otherwise stated on the drawings cavity wall insulation shall be extruded polystyrene 3 board of minimum density 25 kg/m to the thickness detailed.

2.4.4

Perimeter Insulation

1

Polystyrene board where used for exterior perimeter insulation below ground and in contact with soil shall comply with the relevant provisions of BS 3837 and BS 8216.

2

Where sprayed lightweight mineral coatings are used, they shall be to BS 8216.

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2.4.3

QCS 2014

Section 15: Insulation of Buildings Part 02: Building Insulation

Page 7

Exterior Framing or Furring Insulation

1

On approval by the Engineer, batt or blanket type insulation can be used for exterior wall insulation provided that proper protection, as designated in the Project Documentation, is present.

2

Mineral fibre shall comply with the relevant provisions of BS 6676.

2.4.6

Rigid Insulation

1

Rigid insulation shall be applied to the inside face of exterior walls, spandrel beams, floors and where indicated in the Project Documentation.

2

Mineral fibre board shall comply with the relevant provisions of BS 6676 Part 1 and Part 2.

2.4.7

Masonry Fill Insulation

1

Vermiculite insulation shall comply with the relevant provisions of BS 8208.

2

Fasteners for masonry fill insulation shall be as follows:

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2.4.5

staples or nails complying with the relevant provisions of BS 1202, zinc-coated, size and type best suited for purpose.

(b)

screws complying with the relevant provisions of BS 1210 and BS 3692, with washer not less than 50 mm in diameter.

(c)

steel impaling pins with heads not less than 50 mm in diameter with adhesive for anchorage to substrata; the impaling pins shall be of sufficient length to extend beyond the insulation and retail cap washer when a washer is placed on the pin.

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(a)

Adhesive

1

Adhesives shall be as recommended by the manufacturer of the insulation.

2.4.9

Tape

1

Tape used to seal cuts, tears or unlapped joints of insulation shall have pressure sensitive adhesive on one face.

2

The perm rating of the tape shall not be more than 0.50.

2.5

INSTALLATION

2.5.1

Execution and Workmanship

1

Insulation shall be installed with the vapour barrier facing the heated side, unless specified otherwise.

2

Rigid insulating units shall be installed with joints close and flush, in regular courses and with cross-joints broken.

3

Batt or blanket insulation shall be installed with tight joints and filling framing void completely. Seal cuts, tears, and unlapped joints with tape.

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2.4.8

QCS 2014

Section 15: Insulation of Buildings Part 02: Building Insulation

Page 8

Insulation shall be fitted tight against adjoining construction and penetrations, unless specified otherwise.

2.5.2

Masonry Cavity Walls

1

Insulation shall be mounted on exterior faces of inner leaves of masonry cavity walls and brick faced concrete walls. Fill joints with the same material used for bonding.

2

Polystyrene board shall be bonded to surfaces with adhesive or Portland cement mortar mixed and applied in accordance with recommendations of insulation manufacturer.

3

Mineral fibreboard and polyurethane shall be bonded to surfaces with adhesive as recommended by insulation manufacturer.

2.5.3

Perimeter Insulation

1

When applying vertical perimeter insulation, the contractor shall:

.l. l

rw

fill joints of insulation with the same material as used for bonding

(b)

bond polystyrene board to surfaces with adhesive or Portland cement mortar mixed and applied in accordance with recommendations of the insulation manufacturer.

qa

ta

(a)

When applying horizontal perimeter insulation under concrete floor slabs the Contractor shall: lay insulation boards and blocks horizontally on level, compacted and drained fill

(b)

extend insulation from foundation walls towards the centre of the building.

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(a)

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2

.

4

Exterior Framing or Furring Blanket Insulation

1

The insulation shall be packed around door frames and windows and in building expansion joints, door soffits and other voids. Open voids are not permitted. The insulation shall be held in place with pressure sensitive tape.

2

Vapour retarder flanges shall be lapped together over the face of the framing for a continuous surface. Seal all penetrations through the insulation.

3

The blanket insulation shall be fastened between metal studs or framing and exterior wall furring by continuous pressure sensitive tape along flanged edges.

4

The blanket insulation between wood studs or framing shall be fastened with nails or staples through the flanged edges on the face of the stud. Fastenings shall be spaced the not more than 150 mm apart.

5

For roof rafter insulation or floor joist insulation, mineral fibre blankets shall be placed between the framing to provide not less than a two 50 mm space between the insulation and the roof sheathing or sub-floor.

6

Ceiling insulation and soffit insulation shall be as follows:

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2.5.4

(a)

at wood framing, blanket insulation shall be fastened between the wood framing or joist with nails or staples through flanged edges of insulation.

QCS 2014

Section 15: Insulation of Buildings Part 02: Building Insulation

Page 9

(b)

at metal framing or ceiling suspension systems, blanket insulation shall be installed above suspended ceilings or metal framing at right angles to the main runners or framing; the insulation shall be taped tightly together so no gaps occur and metal the framing members are covered by insulation.

(c)

in areas where suspended ceilings adjoin areas without suspended ceilings, either blanket, batt, or mineral fibreboard insulation shall be installed; the insulation shall extend from the suspended ceiling to underside of deck or slab above; the insulation shall be secured in place to prevent collapse or separation of the insulation and maintain it in a vertical position; blanket or batt insulation shall be secured to the structure above with continuous cleats.

Rigid Insulation

1

Rigid insulation shall be securely fixed to the interior face of exterior walls of solid masonry, or to concrete walls, beams, beam soffits, underside of floors, and to the face of studs where shown on the Project Drawings for interior walls unless otherwise approved by the Engineer.

2

The insulation shall be bonded to solid vertical surfaces with adhesive as recommended by insulation manufacturer. Joints shall be filled with adhesive cement.

3

Impaling pins shall be used for attachment of the insulation to the underside of horizontal surfaces. Fastenings shall be spaced as necessary to hold insulation in place and prevent sagging.

4

Insulation board is to be fastened at walls or underside of ceilings with screws, nails or staples. Fastenings shall be spaced not more than 25 mm apart and there shall be a fastening in each corner. The fasteners shall be staggered at the joints between boards.

5

Floor insulation shall be as follows:

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2.5.5

insulation shall be bond to concrete floors in attics by coating surfaces with hot asphalt applied at rate of not less than 35 kg per 10 m2, and firmly bed the insulation.

(b)

when applied in more than one layer, bed succeeding layers in hot asphalt applied at the rate to equal a total of not less than 35 kg per 10 m2 when completed.

et it

insulation may be installed with non-flammable adhesive in accordance with the manufacturer's instructions when a separate vapour barrier is used.

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(a)

2.5.6

Masonry Fill Insulation

1

Fill insulation shall be poured into cavity voids of masonry units from the tops of walls, or from a sill where windows or other openings occur.

2

The fill insulation shall be poured in lifts of not more than 6 metres.

2.5.7

Insulation Behind Marble Cladding

1

Insulation to external walls is to be 60, 70 or 80 mm thick, as shown on the Project Drawings; resin bonded glass fibre slabs shall be approximate 600 x 1250 mm size

2

The wall insulation is to be mounted on the outside face of the external concrete walls, behind the marble cladding panels. After ensuring that the surface is even and free from dirt, grease, oil, concrete nibs etc an approved primer is to be applied.

QCS 2014

Section 15: Insulation of Buildings Part 02: Building Insulation

Page 10

The insulation slabs are to be fixed with an approved adhesive in accordance with the manufacturer’s instructions. Both sides of the insulation are to be covered building paper. The external face of the insulation is to be finished mat black.

2.6

PREFABRICATED WALL INSULATION

2.6.1

General

1

This Clause addresses the use of insulation in prefabricated wall systems.

2.6.2

Quality and Requirements

1

Insulation and related vapour barriers or weather proofing are to be as shown on the Project Drawings and as specified in the manufacturer’s literature, shop drawings and any other relevant supporting documentation.

2

Manufacturer’s literature, shop drawings, supporting documentation and certification that necessary thermal requirements will be met shall be submitted to the Engineer for approval prior to delivery.

3

Thermal requirements will at minimum meet specifications as stated in this Part 2 of this Section for standard wall construction unless stated otherwise in the Project Documentation.

4

Curtain wall or glass clad wall systems are also to meet the thermal requirements of this Section. Refer to Section 25 for additional requirements.

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END OF PART

QCS 2014

Section 15: Thermal Insulation of Buildings Part 03: Cold Stores

Page 1

3

COLD STORES ............................................................................................. 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2 3.1.3

Scope References Submittals

3.2

WALK-IN REFRIGERATOR OR FREEZER CONSTRUCTION .................... 2

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5

General Size Doors Floor Finish Metal Finishing

3.3

WALL PANEL CONSTRUCTION .................................................................. 3

3.3.1 3.3.2 3.3.3 3.3.4

General Panel edges Insulation Door Panel and Door

3.4

REFRIGERATION EQUIPMENT ................................................................... 5

3.4.1

General Requirements

3.5

INSTALLATION ............................................................................................. 5

3.5.1 3.5.2

General Requirements Start-Up, and Performance Tests and Instructions

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2 2 2 2 3 3 3 3 3 3 3 4 5 5 5

QCS 2014

Section 15: Thermal Insulation of Buildings Part 03: Cold Stores

Page 2

3

COLD STORES

3.1

GENERAL

3.1.1

Scope

1

This Part describes requirements specific to insulation and construction of Walk-in refrigerators and freezers which can be used for dietetics, autopsy and laboratory uses.

2

Related Sections are as follows:

3.1.2

References

1

The following standards are referred to in this Section:

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Masonry Air Conditioning, Refrigeration and Ventilation Finishes to Buildings

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Section 13 Section 22 Section 24

as

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BS 874 ........................Methods for determining thermal insulating properties BS 1449 ......................Steel plate, sheet and strip BS 2502 ......................Manufacture of sectional cold rooms (walk in type) BS EN 3261 ................Unbacked flexible PVC flooring BS 6319 ......................Testing of resin and polymer/cement compositions for use in construction Submittals

1

The Contractor is to furnish the following prior to commencement of the works: manufacturer's literature and data: walk-in units, including assembly instructions

(ii)

condensing units, with mounting rack where required

(iii)

unit coolers

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temperature controls and alarms

(v)

temperature recorders for mortuary refrigerators

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(vi)

mortuary walk-in ventilation accessories

(vii)

diagrams and details of piping, wiring and controls

(b)

operating test data

(c)

manufacturer’s standard maintenance and operating manuals.

3.2

WALK-IN REFRIGERATOR OR FREEZER CONSTRUCTION

3.2.1

General

1

Walk-In refrigerators/freezers shall be prefabricated, sectional, all-metal clad, modular and designed for easy and accurate assembly and shall comply with the relevant provisions of BS 2502

QCS 2014

Section 15: Thermal Insulation of Buildings Part 03: Cold Stores

Page 3

Size

1

Room dimensions shall be as shown on drawings with a minimum overall height of 2500 mm, unless shown otherwise.

3.2.3

Doors

1

Doors shall be 1220 mm wide by 1980 mm high, except doors for freezers with floor area 2 less than 14 m may be 920 mm (nominal) wide.

3.2.4

Floor Finish

1

Floor finish shall be seamless modified epoxy polyurethane system with the following properties and conforming to BS EN 3261 Part 1.

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> 95 MPA > 20 MPA > 10 MPA O -40 to 120 C Resist

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Compressive Strength, BS 6319 Flexural Strength, BS6319 Tensile Strength, BS6319 Service Temperature Thermal shock resistant

.

3.2.2

Metal Finishing

1

Inside facing of walls and ceiling, and outside facing of exposed walls shall be stainless steel, to BS 1449.

3.3

WALL PANEL CONSTRUCTION

3.3.1

General

1

Wall panels shall:

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3.2.5

be 100 mm thick with precisely formed interior and exterior metal pans

(b)

be filled with foamed-in-place urethane foam with an overall heat transfer coefficient (U) of 0.03

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be interchangeable

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(c)

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(a)

(d)

be available in nominal 300, 600, 900 and 1200 mm widths

(e)

be without wood or metal structural members

(f)

have quick-lock panel fasteners.

3.3.2

Panel edges

1

Panel edges shall be foamed-in-place, tongue-and-grooved urethane to assure tight joints.

2

There shall be gaskets on the interior and exterior of each panel along every tongue to provide a gasketed seal at each panel joint.

3.3.3

Insulation

1

Insulation shall be "pour-type" urethane, foamed-in-place with an expanding agent with a coefficient of thermal conductivity (k) of not more than 0.12.

QCS 2014

Section 15: Thermal Insulation of Buildings Part 03: Cold Stores

Page 4

The insulation shall be 97% closed cell with a flame spread rating of 25 or less, when tested in accordance with BS 2502.

3

Fibreglass, polystyrene or similar materials are not acceptable as insulation.

3.3.4

Door Panel and Door

1

There shall be a channel thermal breaker type reinforcing steel frame around the entire perimeter of the door opening.

2

The door is to be an in-fitting flush-mounted type with dual flexible blade wiper gasket on the bottom and a replaceable magnetic gasket on the top edge and along both sides.

3

The door shall incorporate a heated, double glass view window.

4

Door construction shall include an aluminium diamond plate on the inside of the door panel and shall be hung with a minimum of three hinges.

5

A hydraulic exterior door closer is to be incorporated to prevent slamming and assure secure closing.

6

For doors with a width of 1220 mm or wider, the door hinges shall be the self-closing cam-lift type hinges. They shall have a chrome plated or polished aluminium finish.

7

The doors shall be lockable but with an inside safety release mechanism to prevent anyone from being locked inside.

8

The door shall incorporate a concealed, energy use selective, anti-sweat heater wire circuit which will provide sufficient heat to prevent condensation and frost formation at the door jambs and exterior edges of the door on all sides.

9

A two way toggle switch outside the door and inside the unit shall be provided with a pilot light and a top mounted junction box. This switch is to operate all lights in the walk-in refrigerator/freezer. Fixtures shall be vapour proof incandescent

10

The door shall incorporate a 50 mm minimum diameter, dial type, flush mounted thermometer.

11

All freezers operating at -17 C or lower shall incorporate a two-way type port to allow for an increase or decrease of air pressure on the interior of the freezer in order to equalise with air pressure on the exterior. The ports shall be automatically controlled, UL approved, anti-sweat heaters. The complete device is to be provided and be listed assembled and ready for connection. The port shall be installed in a wall panel away from the direct air stream flowing from the coils.

12

Wherever compartment dimensions exceed clear-span ability of ceiling panels, an I-beam support on the exterior of the ceiling or other designated support system shall be provided. Beams or posts within compartments are not acceptable unless otherwise approved by the Engineer.

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QCS 2014

Section 15: Thermal Insulation of Buildings Part 03: Cold Stores

Page 5

REFRIGERATION EQUIPMENT

3.4.1

General Requirements

1

Mechanical equipment as needed for condensing units or unit coolers will be incorporated as designated and installed in accordance with the respective manufacturer’s specification as designated or as approved by the Engineer.

3.5

INSTALLATION

3.5.1

General Requirements

1

The Contractor shall assemble walk-in units and install refrigeration equipment as described in the respective manufacturer's instructions. All panel joints shall be made tight and all panel penetrations shall be sealed to prevent condensation or frosting.

2

Unit coolers shall be suspended below the ceiling sufficiently to allow cleaning the top of the unit cooler (890 mm minimum).

3

Penetrations for lights and other devices neatly drilled.

4

Piping, pipe insulation and refrigerant shall be provided in accordance with Section 22, Air Conditioning, Refrigeration and Ventilation.

5

Installation of controls shall be as specified by respective manufacturer’s.

3.5.2

Start-Up, and Performance Tests and Instructions

1

Testing shall be performed in accordance with manufacturer’s specifications. Each system shall be operated for eight hours and the conditions recorded hourly.

2

The Contractor shall submit the following information:

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compressor nameplate data: make, model, horsepower, RPM, refrigerant and charge in grams.

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(b)

station, building name and system identification, Contractor, date and time.

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(a)

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3.4

(c)

compressor operation: approximate percentage running time, pressure gauge readings, actual amps (starting and running), condenser water temperature in and out, or condenser entering air temperature.

(d)

room temperatures

(e)

defrost and drain functions of unit coolers.

The Contractor shall demonstrate alarm functions. END OF PART

QCS 2014

Section 16: Structural Steelworks Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2 1.1.3

Scope References System Description

1.2

DEFINITIONS ................................................................................................ 2

1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10 1.2.11 1.2.12 1.2.13 1.2.14 1.2.15 1.2.16 1.2.17 1.2.18

General Connection Design Design Calculations Design Drawings Erection Drawings Fabrication Data Fabrication Drawings Fittings Foundation Plan Drawings Shop Drawings Inspection Authority Ordinary Bolts Production Test Plate Quality Assurance Fillet Weld Full Penetration Weld Partial Penetration Weld Full Strength Weld

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QCS 2014

Section 16: Structural Steelworks Part 01: General

Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies the requirements associated with all aspects of structural steelwork including materials, drawings, workmanship and protective treatment.

2

Related Sections and parts are as follows: All Parts

References

1

The following standards are referred to in this Part:

.

1.1.2

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This Section

BS 5950 ......................Structural use of steelwork in building

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Eurocode 3: Part 1.1 (DD ENV1993-l.l), General rules and rules for buildings System Description

1

This Section deals with structural steelwork designed in accordance with the following:

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BS 5950: Part 1,Code of practice for design in simple and continuous construction: hot rolled sections

(b)

Eurocode 3: Part 1.1 (DD ENV1993-l.l), General rules and rules for buildings, where the references to BS 5950 in the National Application Document are taken into account.

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DEFINITIONS

1.2.1

General

1

Terms which are defined in this section are treated as Proper Nouns throughout the text of the Specification. The following definitions apply for the purposes of this Specification:

1.2.2

Connection Design

1

The design of bolts, welds, cleats, plates and fittings required to provide an adequate load path between the end of a member and the component it connects to.

1.2.3

Design Calculations

1

Calculations, prepared by the Engineer, showing the design and analysis of the structure, including computer data sheets.

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QCS 2014

Section 16: Structural Steelworks Part 01: General

Page 3

Design Drawings

1

Fully dimensioned drawings prepared by the Engineer showing all members with their size and material grades, the forces to be developed in their connections, any cambers and eccentricities and other information necessary for the design of the connections and completion of Fabrication and Erection Drawings.

1.2.5

Erection Drawings

1

Drawings, prepared when necessary by the Contractor, showing details to amplify the information given in the Contractor's erection method statement and showing details of any temporary steelwork (see Part 8 of this Section).

1.2.6

Fabrication Data

1

Numerical control tapes, computer discs, data bases or other electronic means of communication for automatic methods of fabrication.

1.2.7

Fabrication Drawings

1

Drawings, prepared by the Contractor, showing all necessary information required to fabricate the structural steelwork.

1.2.8

Fittings

1

Plates, flats or rolled sections which are welded or bolted to structural steel components.

1.2.9

Foundation Plan Drawings

1

Drawings, prepared by the Contractor or the Engineer, indicating location of column bases and details of foundation connections to the steelwork.

1.2.10

Shop Drawings

1

Drawings, prepared by the Contractor, showing plans, cross sections and elevations, main dimensions and the erection marks of components.

1.2.11

Inspection Authority

1

A qualified independent body or association which verifies compliance with the Project Documentation.

1.2.12

Ordinary Bolts

1

A bolt used in a non-preloaded bolt assembly which is designed to carry forces in shear, bearing or tension.

1.2.13

Production Test Plate

1

A plate used for testing purposes, which is made of the same material and using the same procedures as the joint in a component.

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1.2.4

QCS 2014

Section 16: Structural Steelworks Part 01: General

Page 4

Quality Assurance

1

Activities concerned with the provision of systems, equipment and personnel necessary to achieve the required level of quality.

1.2.15

Fillet Weld

1

A weld, other than a butt or edge weld, which is approximately triangular in transverse cross section and which is generally made without preparation of the parent material.

1.2.16

Full Penetration Weld

1

A weld between elements which may be in-line, in the form of a tee, or a corner in which the weld metal achieves full penetration throughout the joint thickness.

1.2.17

Partial Penetration Weld

1

A weld formed using a technique which ensures a specified penetration which is less than the depth of the joint.

1.2.18

Full Strength Weld

1

Any of the above welds designed to develop the full strength of the element which it connects.

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1.2.14

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END OF PART

QCS 2014

Section 16: Structural Steelworks Part 10: Protective Treatment

Page 1

10

PROTECTIVE TREATMENT ......................................................................... 2

10.1

GENERAL ...................................................................................................... 2

10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.1.7

Scope References Method Statement Working Conditions Storage of Materials Application Procedures Handling and Storage

10.2

SURFACE PREPARATION ........................................................................... 3

10.2.1 10.2.2 10.2.3 10.2.4

General Wire Brushing Blast Cleaning Surface Defects

10.3

SPRAYED METAL COATINGS ..................................................................... 3

10.3.1 10.3.2 10.3.3 10.3.4 10.3.5

Method Storage and Handling Repair of Extensively Damaged Areas Repair of Minimally Damaged Areas Sealing Before Painting

10.4

GALVANIZING ............................................................................................... 4

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10.4.1 Procedures 10.4.2 Touch-up of Galvanized Surfaces 10.4.3 Vent Holes

3 3 3 3 3 3 3 4 4 4 4 4

SURFACE COATINGS (PAINT) .................................................................... 4

10.5.1 10.5.2 10.5.3 10.5.4 10.5.5 10.5.6 10.5.7 10.5.8 10.5.9

Surface Condition Prior to Painting Surfaces to be Embedded in Concrete Coatings Application Life Multiple Coats Stripe Coats Storage and Handling Painting on Site Painting of Site Fixed Bolts and Welding

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QCS 2014

Section 16: Structural Steelworks Part 10: Protective Treatment

Page 2

10

PROTECTIVE TREATMENT

10.1

GENERAL

10.1.1

Scope

1

This Part specifies the requirements for protective treatment for structural steelwork.

2

Related Sections and Parts are as follows: This Section Part 2

Materials

References

1

The following standards are referred to in this Part:

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10.1.2

BS 729 ........................Hot dip galvanized coatings on iron and steel articles.

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BS 5493 ......................Code of practice for protective coating of iron and steel structures against

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corrosion.

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BS 7079 ......................Preparation of steel substrates before application of paints and related products. coatings

–Thermal

spraying-zinc

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BS EN 22063 ..............Metallic and other inorganic aluminium and their alloys.

Method Statement

1

The Contractor shall prepare a written method statement giving sequential details of the surface preparation and protective treatment procedure (including touching-in procedures) to be used in achieving the Employer's specification.

10.1.4

Working Conditions

1

Work shall he carried out in accordance with the recommendations given in BS 5493.

10.1.5

Storage of Materials

1

Protective treatment materials shall he stored in a clean, dry area which is protected from extreme temperatures, and used in order of delivery, in accordance with the manufacturer's recommendations and within the advised shelf life.

10.1.6

Application Procedures

1

Materials shall be prepared, and coatings applied to surfaces, in accordance with the manufacturer's recommendations.

10.1.7

Handling and Storage

1

The procedures for handling and storage shall be so arranged that the protected surface is unlikely to be damaged.

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QCS 2014

Section 16: Structural Steelworks Part 10: Protective Treatment

Page 3

SURFACE PREPARATION

10.2.1

General

1

Unless it has been specifically approved by the Engineer all steelwork surfaces which are to be painted shall be blast cleaned.

10.2.2

Wire Brushing

1

Surfaces which are not to be blast cleaned, but are to be coated, shall be wire brushed to remove loose mill scale, and cleaned to remove dust, oil and grease.

10.2.3

Blast Cleaning

1

The standard of blast cleaning specified shall be in accordance with BS 7079 Part Al.

2

The methods used shall be capable of cleaning all surfaces of the component. The surface roughness shall be compatible with that recommended for the coating to be applied but shall not be to a lesser quality than Sa 2 as defined in BS 7079

3

The cleanliness levels specified shall be those existing at the time of the application of coating.

4

When abrasives are recycled in the blast cleaning system, the equipment shall be fitted with a dust removal system to remove fines and contaminants.

10.2.4

Surface Defects

1

Surface defects revealed during surface preparation shall be dealt with in accordance with Clause 2.2.1-2 and 2.2.1-3 of this Section.

10.3

SPRAYED METAL COATINGS

10.3.1

Method

1

Sprayed metal coatings may consist of either zinc or aluminium applied to the surface as a molten dispersed spray in accordance with BS EN 22063 to a level given in the Protective Treatment Specification.

10.3.2

Storage and Handling

1

Storage and handling procedures shall be so arranged that the sprayed metal surface is unlikely to be damaged.

10.3.3

Repair of Extensively Damaged Areas

1

The area shall be cleaned using a needle gun or abrasive papers or cloths. After washing down and drying, the area shall be resprayed overlapping the undamaged area by 20mm.

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10.2

QCS 2014

Section 16: Structural Steelworks Part 10: Protective Treatment

Page 4

Repair of Minimally Damaged Areas

1

An area less than 10 cm2 may be repaired after cleaning, as described in Clause 10.4.3 of this Part, by applying a paint which is compatible and has similar properties to the metal spray.

10.3.5

Sealing Before Painting

1

Sprayed metal coating shall be sealed before the application of paint coats in accordance with BS 5493 Table 4C Part 2.

10.4

GALVANIZING

10.4.1

Procedures

1

Galvanizing shall be performed in accordance with BS 729.

10.4.2

Touch-up of Galvanized Surfaces

1

Small areas which are within 10mm of intact galvanized coating may be touched up in accordance with Appendix D of BS 729.

2

Preparation for touching up is to be as required by the manufacturer of the touch-up product.

10.4.3

Vent Holes

1

If so required by the Engineer, vent holes in hollow members, necessary during the galvanizing process, shall be sealed after galvanizing with a plug of approved material.

10.5

SURFACE COATINGS (PAINT)

10.5.1

Surface Condition Prior to Painting

1

Steelwork shall be dry and cleaned to the surface cleanliness specified in Clause 10.2 of this Part.

10.5.2

Surfaces to be Embedded in Concrete

1

Steel surfaces to be embedded in concrete shall be left unpainted and need not be blast cleaned unless required by the Project Documentation.

10.5.3

Coatings

1

Where steelwork is to be finished with a paint coating system it shall be carried out in accordance with the requirements of BS 5493 and to the requirements of the Project Documentation.

10.5.4

Application Life

1

All paint products shall be used within the manufacturer's recommended pot life.

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10.3.4

QCS 2014

Section 16: Structural Steelworks Part 10: Protective Treatment

Page 5

10.5.5

Multiple Coats

1

Where two or more coats of a product are to be applied, a different colour shade shall be used for each coat.

10.5.6

Stripe Coats

1

Additional stripe coats of primer or undercoat shall be applied in the following circumstances: welded surfaces where a weld-through primer has been used

(b)

steelwork which will be exposed externally in the finished works

(c)

all edges and corners

(d)

seal gaps between adjacent components such as shop and site bolted connections.

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Storage and Handling

1

Storage and handling procedures shall ensure that damage to the protective system is minimised.

10.5.8

Painting on Site

1

Work shall not proceed when the steel surfaces are wet or the ambient temperature, or dew point, is below that recommended by the paint manufacturers. (See Clause 10.1.4 of this Part).

10.5.9

Painting of Site Fixed Bolts and Welding

1

All protruding portions of bolt assemblies and site weld surfaces shall be cleaned to remove traces of oil, dust, welding flux etc. to the levels specified in 10.5.1.

2

The paint system specified in the Project Documentation shall be applied to ensure similar properties and compatibility with the surface treatment system being used on the surrounding surfaces.

3

Bolt assemblies which are supplied with a protective treatment need not be painted except when the Employer's specification requires it.

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END OF PART

QCS 2014

Section 16: Structural Steelworks Part 02: Materials

Page 1

2

MATERIALS .................................................................................................. 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6

Scope References Material Qualities Material Testing Test Certificates Dimensions and Tolerances

2.2

SURFACE CONDITION ................................................................................. 4

2.2.1

General

2.3

SUBSTITUTION OF MATERIAL OR FORM .................................................. 5

2.3.1

General

2.4

WELDING CONSUMABLES ......................................................................... 5

2.4.1 2.4.2

Standards Storage

2.5

STRUCTURAL FASTENERS ........................................................................ 5

2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7

Ordinary Bolt Assemblies High Strength Friction Grip (HSFG) Bolt Assemblies Foundation Bolts. Cup and Countersunk Bolts Washers Lock Nuts Fastener Coatings

2.6

SHEAR STUDS ............................................................................................. 6

2.6.1

General

2.7

PROTECTIVE TREATMENT MATERIALS.................................................... 6

2.7.1 2.7.2 2.7.3 2.7.4 2.7.5

Metallic Blast Cleaning Abrasives Surface Coatings Sherardized Coatings Galvanizing Materials Proprietary Items

2 2 3 3 3 3

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QCS 2014

Section 16: Structural Steelworks Part 02: Materials

Page 2

MATERIALS

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the materials requirements for structural steelwork.

2

Related Sections and parts are as follows: Bolting

Section 1

General

2.1.2

References

1

The following standards are referred to in this Part:

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2

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BS 4 ............................Structural steel sections, Part 1 1993, Hot-rolled sections.

qa

BS 639 ........................Covered carbon and carbon manganese steel electrodes for manual metal-arc welding BS 729 ........................Hot dip galvanised coatings on iron and steel articles.

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BS 2901 ......................Filler rods and wires for gas-shielded arc welding.

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BS 2989 ......................Continuously hot-dip zinc coated and iron-zinc alloy coated steel flat products.

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BS 3692 ......................ISO metric precision hexagon bolts, screw and nuts.

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BS 4165 ......................Electrode wires and fluxes for the submerged arc welding of carbon steel and medium-tensile steel. BS 4190 .....................ISO metric black hexagon bolts, screw and nuts.

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BS 4320 ......................Metal washers for general engineering purposes.

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BS 4395 ......................High strength friction grip bolts and associated nuts and washers for structural engineering.

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BS 4929 ......................Steel hexagon prevailing-torque type nuts BS 4933 ......................ISO metric black cup and countersunk head bolts and screws with hexagon nuts. BS 4848 ......................Hot rolled structural steel sections BS 4921 ......................Sherardized coatings on iron and steel BS 5950 ......................Structural use of steel work in building BS 6363 ......................Welded cold formed steel structural hollow sections BS 7079 ......................Preparation of steel substrates before application of paints and related products. BS 5135 ......................Process of arc welding of carbon and carbon manganese steels BS 7084 ......................Carbon and carbon-manganese steel tubular cored welding electrodes BS 7419 ......................Holding down bolts BS EN 10025 ..............Hot rolled products of non-alloy structural steels-Technical delivery conditions.

QCS 2014

Section 16: Structural Steelworks Part 02: Materials

Page 3

BS EN 10029 ..............Tolerances on dimensions, shape and mass for hot rolled steel plates 3mm thick or above. BS EN 10034 ..............Structural steel I and H sections-Tolerances on shape and dimensions. BS EN 10051 ..............Continuously hot-rolled uncoated plate, sheet and strip of non-alloy and alloy steels-Tolerances on dimensions and shape BS EN 10147 ..............Continuously hot-dip zinc coated structural steel sheet and stripTechnical delivery conditions. BS EN 10163 ..............Delivery requirements for surface conditions of hot rolled steel plates wide flats and sections. BS EN 10210 ..............Hot finished structural hollow sections of non-alloy and fine grains structural steels.

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BS EN 102101 ............Technical delivery conditions

EN 10051 ................... Specification for continuously hot-rolled uncoated plate, sheet and strip of non-alloy steels. Tolerances on dimension and shape

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EN 10113 ...................Hot rolled products in weldable fine grain structural steels.

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EN 10155 ...................Structural steels with improved atmospheric corrosion resistance. Technical delivery conditions. Material Qualities

1

Material shall be steel in rolled sections, structural hollow sections, plates and bars and shall comply with the appropriate standard shown in Table 2.1.

2

The steel designations used in this publication are those given in BS 5950.

2.1.4

Material Testing

1

All steel shall have been specifically tested in accordance with the appropriate material quality standard shown in Table 2.1.

2.1.5

Test Certificates

1

The Contractor shall obtain the manufacturer's test certificates and submit them to the Engineer for review.

2.1.6

Dimensions and Tolerances

1

Dimensions and Tolerances shall comply with the appropriate standard shown in Table 2.1.

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2.1.3

QCS 2014

Section 16: Structural Steelworks Part 02: Materials

Page 4

Table 2.1 Material and Dimension Standards Dimensions

Dimension Tolerances

U.B. and U.C.

BS 4 : Part 1

BS EN 10034

Joists

BS 4 : Part 1

BS 4 : Part 1

BS 4 : Part 1

BS 4 : Part 1

Angles

BS 4848 : Part 4

BS 4848 : Part 4

Plate and Flats

Not Applicable

BS EN 10029

1

Channels

BS EN 10025

Structural Hollow Sections

2

BS EN 10210-I

BS 4848 : Part 2

BS 4848 : Part 2

BS 6363

BS 6363

BS 6363

Cold Formed Galvanised Open Sections and Strip

Not Applicable

BS 2989

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BS EN 10147

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Hollow Sections

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Hot Finished

Notes:

Material quality requirements for Fine Grain Steels are given in EN 10113 Material quality requirements for Weather resistant grades are given in EN 10155. BS EN 10210-1 contains material quality requirements for Non-alloy and Fine Grain Steels. Tolerances for plates cut from wide strip produced on continuous mills are given in BS EN 10051.

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Material Quality

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SURFACE CONDITION

2.2.1

General

1

Steel surfaces when used shall not be more heavily pitted or rusted than Grade C of BS 7079 Part Al.

2

Surface defects in hot rolled sections, plates and wide flats revealed during surface preparation which are not in accordance with the requirements of BS EN 10163 shall be rectified accordingly.

3

Surface defects in hot rolled hollow sections revealed during surface preparation which are not in accordance with the requirements of BS EN 10210-1 shall be rectified accordingly.

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QCS 2014

Section 16: Structural Steelworks Part 02: Materials

Page 5

SUBSTITUTION OF MATERIAL OR FORM

2.3.1

General

1

Material quality or section form of components may, with the agreement of the Engineer be substituted where it can be demonstrated that the structural properties are not less suitable than the designed component.

2.4

WELDING CONSUMABLES

2.4.1

Standards

1

Consumables for use in metal arc welding shall comply with BS 639, BS 2901, Part 1, BS 4165 or BS 7084 as appropriate.

2.4.2

Storage

1

Consumables to be stored in the Contractor's works and on the Site, shall be kept in a controlled atmosphere, in accordance with BS 5135. Any drying or baking of consumables before issue shall be carried out in accordance with the manufacturer's recommendations.

2.5

STRUCTURAL FASTENERS

2.5.1

Ordinary Bolt Assemblies

1

Shop and site bolts and nuts shall be to one the following grades:

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2.3

Grade 4.6 in accordance with BS 4190

(b)

Grade 8.8 or 10.9 in accordance with BS 3692.

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Dimensions, tolerance and threaded length to BS 4190.

3

Refer to Clause 6.2.1 of this Section for bolt/nut combinations.

2.5.2

High Strength Friction Grip (HSFG) Bolt Assemblies

1

HSFG bolt assemblies shall be in accordance with BS 4395.

2

Refer to Clause 6.4.1 of this Section for bolt/nut combinations.

2.5.3

Foundation Bolts.

1

Holding down bolts shall be in accordance with BS 7419.

2.5.4

Cup and Countersunk Bolts

1

Cup and countersunk bolts shall be in accordance with BS 4933.

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Section 16: Structural Steelworks Part 02: Materials

Page 6

Washers

1

Metal washers shall be made in accordance with BS 4320 Section 2. Unless otherwise specified, black steel washers to Form E shall be used.

2

Refer to Clause 3.4.6 for washers for holding down bolts.

2.5.6

Lock Nuts

1

Lock nuts shall be in accordance with BS 4929: Part 1.

2.5.7

Fastener Coatings

1

Where specific coatings are required, they shall be provided by the fastener manufacturer.

2.6

SHEAR STUDS

2.6.1

General

1

Proprietary studs used in composite construction shall be the headed type with the following properties after being formed:

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2.5.5

minimum yield strength - 350 N/mm2

(b)

minimum ultimate tensile strength -450 N/mm2

(c)

elongation of 15% on a gauge length of 5.65 A, where A is the area of the test specimen.

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(a)

PROTECTIVE TREATMENT MATERIALS

2.7.1

Metallic Blast Cleaning Abrasives

1

Chilled iron grit shall be in accordance with BS 7079 Part E2, and cast steel grit shall be in accordance with BS 7079 Part E3.

2.7.2

Surface Coatings

1

Paint materials and other coatings supplied shall be in accordance with the appropriate British Standard or European Standard for the materials.

2.7.3

Sherardized Coatings

1

Sherardized coatings shall be in accordance with BS 4921.

2.7.4

Galvanizing Materials

1

The composition of zinc in galvanizing baths shall be in accordance with BS 729.

2.7.5

Proprietary Items

1

All proprietary items shall be used in accordance with the manufacturer's recommendations and instructions.

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2.7

END OF PART

QCS 2014

Section 16: Structural Steelworks Part 03: Drawings

Page 1

3

DRAWINGS ................................................................................................... 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2 3.1.3

Scope References General Requirements

3.2

GENERAL ARRANGEMENT DRAWINGS .................................................... 2

3.2.1 3.2.2

Marking System General Arrangement Drawings (Marking Plans)

3.3

FOUNDATION PLAN DRAWINGS ................................................................ 3

3.3.1

General Requirements

3.4

FABRICATION DRAWINGS .......................................................................... 3

3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10

Fabrication Shop Drawings Attachments to Facilitate Erection Welding Packings, Clearances and Camber Hole Sizes Holding Down Bolt Covers Connections to allow Movement Machining Note Drilling Note HSFG Faying Surfaces

3.5

ERECTION DRAWINGS ............................................................................... 4

3.5.1 3.5.2

Erection Method Statement Temporary Steelwork

3.6

DRAWING ACCEPTANCE ............................................................................ 5

3.6.1 3.6.2 3.6.3

Acceptance by the Engineer Meaning of Acceptance Acceptance Classification

3.7

AS ERECTED DRAWINGS ........................................................................... 5

3.7.1

General Requirements

2 2 2

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QCS 2014

Section 16: Structural Steelworks Part 03: Drawings

Page 2

DRAWINGS

3.1

GENERAL

3.1.1

Scope

1

This Part specifies the requirements for drawings associated with structural steelwork.

2

Related Parts and Sections are as follows: Welding Bolting Accuracy of Fabrication Erection Accuracy of Erected Steelwork

Section 1

General

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This Section Part 5 Part 6 Part 7 Part 8 Part 9

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3

References

1

The following standards are referred to in this Part:

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BS 499 ........................Welding terms and symbols

BS 1192 ......................Construction and drawing practice

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BS 4640 ......................Classification of metal working machine tools by types General Requirements

1

All design, fabrication and erection drawings shall be made in accordance with BS 1192 Parts 1 and 2.

2

All welding symbols shall conform to BS 499 Part 2.

3.2

GENERAL ARRANGEMENT DRAWINGS

3.2.1

Marking System

1

Every component which is to be individually assembled or erected shall be allocated an erection mark.

2

Members which are identical in all respects may have the same erection mark.

3.2.2

General Arrangement Drawings (Marking Plans)

1

Drawings shall be prepared by the Contractor showing plans and elevations at a scale such that the erection marks for all members can be shown on them. Preferred scales are 1:100 or larger.

2

The drawings shall show the grid locations as indicated on the design drawings, main dimensions, member levels and centre lines. Details at an enlarged scale should also be made if these are necessary to show the assembly of members.

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3.1.3

QCS 2014

Section 16: Structural Steelworks Part 03: Drawings

Page 3

FOUNDATION PLAN DRAWINGS

3.3.1

General Requirements

1

Foundation Plan Drawings shall show the base location, position and orientation of columns, the marks of all columns, any other members in direct contact with the foundations, their base location and level, and the datum level.

2

The drawings shall show complete details of fixing steel or bolts to the foundations, method of adjustment and packing space.

3.4

FABRICATION DRAWINGS

3.4.1

Fabrication Shop Drawings

1

Fabrication Drawings shall show all necessary details and dimensions to enable fabrication of components to proceed.

3.4.2

Attachments to Facilitate Erection

1

The Fabrication Drawings shall show details of holes and fittings necessary to provide for lifting and erection of components (see Clause 8.2.1 of this Section).

2

Unless specifically agreed otherwise, such holes and fittings may remain on the permanent structure. Account shall be taken of Clause 5.4.5 of this Section when detailing the welding of temporary attachments.

3.4.3

Welding

1

Any requirements for edge preparations for welds shall be indicated on the Fabrication Drawings. Welding inspection requirements which differ from those specified in Clause 5.5.5 of this Section shall be indicated on the drawings.

3.4.4

Packings, Clearances and Camber

1

When preparing Fabrication Drawings, the Contractor shall make provision for the following:

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3.3

(a)

packings which may be necessary to ensure proper fit-up of joints (see Clauses 6.3.1 and 6.5.1 of this Section)

(b)

the need for clearances between the fabricated components so that the permitted deviations in fabrication and erection are not exceeded (see Parts 7 and 9 of this Section)

(c)

the Engineer's requirements for pre-set or cambers.

3.4.5

Hole Sizes

1

Holes shall be shown on the Fabrication Drawings to the following sizes: (a)

for ordinary bolts and HSFG bolts: (i)

not exceeding 24mm diameter - 2 mm greater than the bolt diameter

(ii)

greater than 24mm diameter - 3 mm greater than the bolt diameter

QCS 2014

(b)

Section 16: Structural Steelworks Part 03: Drawings For holding down bolts: (i)

(c)

Page 4

6mm greater than the bolt diameter, but with sufficient clearance to ensure that a bolt, whose adjustment may cause it to be out of perpendicular, can be accommodated through the base plate (see Table 9.1 Item 3 of this Section).

For fitted bolts: (i)

in accordance with Clause 6.2.8 of this Section.

Holding Down Bolt Covers

1

Holding down bolt details shall include provision of loose cover plates or washers with holes 3 mm greater than the holding down bolts.

3.4.7

Connections to allow Movement

1

Where the connection is designed to allow movement, the bolt assembly used shall remain secure without impeding the movement.

3.4.8

Machining Note

1

Any machining requirements shall be clearly noted on the Fabrication Drawings.

3.4.9

Drilling Note

1

The Fabrication Drawings shall indicate those locations where holes shall be drilled in accordance with the situations noted below (see also Clause 4.7.3 of this Section):

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3.4.6

in non-slip connections for HSFG bolts

(b)

at locations where plastic hinges are assumed in the design analysis

(c)

in elements of rigid connections where yield lines are assumed;

(d)

where repetition of loading makes fatigue critical to the member design

(e)

where the design code of practice does not permit punched holes.

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(a)

HSFG Faying Surfaces

1

When considering the coefficient of friction to use in the design of high strength friction grip bolted connections, the following values are to be used:

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(a)

unless the Engineer advises otherwise, untreated surfaces which are in accordance with BS 4604 may be considered as having a slip factor of 0.45; masking shall be used to keep the surfaces free of protective treatments.

(b)

surfaces which have been machined, or given any type of treatment, shall have the slip factor determined by tests carried out in accordance with BS4604 Part1.

3.5

ERECTION DRAWINGS

3.5.1

Erection Method Statement

1

When necessary to amplify the information given in his erection method statement, the Contractor shall prepare Erection Drawings.

QCS 2014

Section 16: Structural Steelworks Part 03: Drawings

Page 5

Temporary Steelwork

1

Details and arrangements of temporary steelwork necessary for erection purposes shall be shown on the Erection Drawings.

3.6

DRAWING ACCEPTANCE

3.6.1

Acceptance by the Engineer

1

Drawings made by the Contractor shall be submitted to the Engineer for acceptance in the period designated by the Employer.

3.6.2

Meaning of Acceptance

1

Acceptance by the Engineer of drawings prepared by the Contractor means that the Contractor has correctly interpreted the design requirements and that the Engineer accepts the Connection Design.

2

Acceptance does not relieve the Contractor of the responsibility for accuracy of his calculations, detail dimensions on the drawings, nor the general fit-up of parts to be assembled on site.

3.6.3

Acceptance Classification

1

The designations given in Table 3.1 shall be used by the Engineer when accepting drawings:

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Table 3.1 Acceptance Classification of Drawings

Drawing is accepted and may be released for construction

Accepted subject to comments

Drawing must be amended in line with the comments, and re -submitted for acceptance. Drawing must be amended in the way indicated and re-submitted for acceptance.

Not Accepted

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Meaning

Accepted or Reviewed or Approved or No Comment

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3.7

AS ERECTED DRAWINGS

3.7.1

General Requirements

1

On completion of the contract, the Contractor shall provide the Engineer with one set of paper prints of "As Erected" drawings comprising: (a)

general Arrangement Drawings

(b)

fabrication Drawings

(c)

drawings made after fabrication showing revisions

(d)

the fabrication drawing register. END OF PART

QCS 2014

Section 16: Structural Steelworks Part 04: Fabrication

Page 1

FABRICATION ........................................................................................................ 2

4.1 4.1.1

GENERAL ............................................................................................................... 2 Scope 2

4.2 4.2.1 4.2.2 4.2.3

IDENTIFICATION .................................................................................................... 2 Traceability of Steel 2 Material Grade Identification 2 Marking Steelwork 2

4.3 4.3.1

HANDLING .............................................................................................................. 2 General Requirements 2

4.4 4.4.1 4.4.2 4.4.3

CUTTING AND SHAPING ....................................................................................... 3 Cutting Operations 3 Flame-cut Edges 3 Columns 3

4.5 4.5.1

MACHINING ............................................................................................................ 3 Thickness of Machined Parts 3

4.6 4.6.1 4.6.2

DRESSING .............................................................................................................. 3 Removal of Burrs 3 Dressing of Edges 3

4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5

HOLING................................................................................................................... 3 Matching 3 Drilling Through More Than One Thickness 4 Punching Full Size 4 Punching and Reaming 4 Slotted Holes 4

4.8 4.8.1

ASSEMBLY ............................................................................................................. 4 General Requirements 4

4.9 4.9.1

CURVING AND STRAIGHTENING ......................................................................... 5 General Requirements 5

4.10 4.10.1

INSPECTION........................................................................................................... 5 General Requirements 5

4.11 4.11.1 4.11.2

STORAGE ............................................................................................................... 5 Stacking 5 Visible Markings 5

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4

QCS 2014

Section 16: Structural Steelworks Part 04: Fabrication

Page 2

4

FABRICATION

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the general requirements for the fabrication of structural steelwork components.

2

Related Sections and Parts are as follows: This Section Part 2 Part 6 Part 7 Part 9

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Materials Bolting Accuracy of Fabrication Accuracy of Erected Steelwork

IDENTIFICATION

4.2.1

Traceability of Steel

1

All steel to be used in the Works shall have a test certificate (see Clause 2.1.5 of this Section).

4.2.2

Material Grade Identification

1

The material grades of all steel shall be identifiable except for design grades 43A and 43B, and in the case of structural hollow sections, 43D.

4.2.3

Marking Steelwork

1

Individual pieces shall be capable of positive identification at all stages of fabrication.

2

Completed components shall be marked with a durable and distinguish erection mark in such a way as not to damage the material. Hard stamping may be used, except where otherwise specified by the Engineer.

3

Where areas of steelwork are indicated on the drawings as being unmarked, they shall be left free of all markings and hard stamping.

4.3

HANDLING

4.3.1

General Requirements

1

Steelwork shall be bundled, packed, handled and transported in a safe manner so that permanent distortion does not occur and surface damage is minimised.

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QCS 2014

Section 16: Structural Steelworks Part 04: Fabrication

Page 3

CUTTING AND SHAPING

4.4.1

Cutting Operations

1

Cutting and shaping of steel may be carried out by shearing, cropping, sawing, nibbling, laser cutting or machine flame cutting, except that where machine flame cutting is impractical, hand flame cutting may be used.

4.4.2

Flame-cut Edges

1

Flame-cut edges which are free from significant irregularities shall be accepted without further treatment except for the removal of dross, otherwise cut edges shall be dressed to remove irregularities.

4.4.3

Columns

1

Columns with ends not in direct bearing or intended to be erected on packs or shims, shall be fabricated to the accuracy given in Item 2 of Table 7.1 of this Section.

2

Columns intended to be in direct bearing shall be fabricated to the accuracy given Item 3 of Table 7.1 of this Section..

3

Column sections which are one metre and over in width or depth and are intended to be in direct bearing, shall be specially prepared at the butting ends so that the erection tolerances in Items 4 and 5 of Table 9.2 of this Section can be achieved.

4.5

MACHINING

4.5.1

Thickness of Machined Parts

1

The thickness of elements shown on the drawings as requiring machining shall mean the minimum thickness after the machining operations.

4.6

DRESSING

4.6.1

Removal of Burrs

1

Cut edges shall be dressed to remove dross, burrs, and irregularities. Holes shall be dressed as required to remove burrs and protruding edges.

4.6.2

Dressing of Edges

1

Sharp edges shall be dressed, but a 90 rolled, cut, sheared or machined edge is acceptable without further treatment.

4.7

HOLING

4.7.1

Matching

1

All matching holes for fasteners or pins shall register with each other so that fasteners can be inserted without undue force through the assembled members in a direction at right angles to the faces in contact. Drifts may be used but holes shall not be distorted.

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4.4

QCS 2014

Section 16: Structural Steelworks Part 04: Fabrication

Page 4

4.7.2

Drilling Through More Than One Thickness

1

Drilling shall be permitted through more than one thickness where the separate parts are tightly clamped together before drilling. The parts shall be separated after drilling and any burrs removed.

4.7.3

Punching Full Size

1

Full size punching of holes shall be permitted when: the tolerance on distortion of the punched hole does not exceed that shown in Item 3 of Table 7.2 of this Section.

(b)

the holes are free of burrs which would prevent solid seating of the parts when tightened

(c)

the thickness of the material is not greater than the hole diameter

(d)

the maximum thickness for all steel grades used from the standards listed in Table 2.1 of this Section is:

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2 mm for sub-grade A

(ii)

l6 mm for sub-grade B

(iii)

20 mm for sub-grade C or higher sub-grade; in spliced connections when the holes in mating surfaces are punched in the same direction.

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(i)

Punching and Reaming

1

Punching is permitted without the conditions in Clause 4.7.3 of this Part, provided that the holes are punched at least 2 mm less in diameter than the required size and the hole is reamed to the full diameter after assembly.

4.7.5

Slotted Holes

1

Slotted holes shall be made by one of the following methods:

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(c)

machine operated flame cutting.

punched in one operation formed by drilling two holes and completed by cutting

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4.8

ASSEMBLY

4.8.1

General Requirements

1

All components shall be assembled within tolerances specified in Section 7 of this Section and in a manner such that they are not bent, twisted or otherwise damaged.

2

Drifting of holes to align the components shall be permitted, but must not cause damage or distortion to the final assembly (see Clause 6.3.2).

QCS 2014

Section 16: Structural Steelworks Part 04: Fabrication

Page 5

4.9

CURVING AND STRAIGHTENING

4.9.1

General Requirements

1

Curving or straightening components during fabrication, shall be performed by one of the following methods: mechanical means, taking care to minimise indentations, or change of crosssection

(b)

the local application of heat, ensuring that the temperature of the metal is carefully controlled, and does not exceed 650oC

(c)

the induction bending process where the procedure used includes careful temperature control; after curving or straightening, welds within the area of curving or straightening shall be visually inspected. Welds which are to be subject to non destructive examination shall have these tests carried out after curving or straightening.

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INSPECTION

4.10.1

General Requirements

1

Sufficient components shall be checked for dimensional accuracy and conformity to drawing, to prove that the manufacturing process is working satisfactorily.

4.11

STORAGE

4.11.1

Stacking

1

Fabricated components which are stored prior to being transported or erected shall be stacked clear of the ground, and arranged if possible so that water cannot accumulate. They shall be kept clean and supported in such a manner as to avoid permanent distortion.

4.11.2

Visible Markings

1

Individual components shall be stacked and marked in such a way as to ensure that they can be identified.

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4.10

END OF PART

QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 1

5

WELDING ...................................................................................................... 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2 5.1.3

Scope References System Description

5.2

WELDER QUALIFICATION ........................................................................... 2

5.2.1 5.2.2

Testing Certification

5.3

WELDING PROCEDURES ............................................................................ 3

5.3.1 5.3.2 5.3.3

Preparation of Procedures Approval of Procedures and Procedure Tests Availability of Welding Procedure Sheets

5.4

ASSEMBLY ................................................................................................... 3

5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7

Fit-up Jigs Tack Welds Distortion Control Fabrication or Erection Attachments Extension Pieces Production Test Plates

5.5

NON-DESTRUCTIVE TESTING OF WELDS ................................................ 4

5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6

Record of Testing Visual Inspection of Welds Surface Flaw Detection Ultrasonic Examination Scope of Inspection Acceptance Criteria and Corrective Action

5.6

SHEAR STUD WELDING .............................................................................. 5

5.6.1 5.6.2 5.6.3 5.6.4

Method Trial Welding Tests and Inspection Defective Studs

2 2 2

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QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 2

5

WELDING

5.1

GENERAL

5.1.1

Scope

1

This Part specifies the requirements for welding associated with structural steelwork.

5.1.2

References

1

The following standards are referred to in this Part: BS 3923 ......................Methods for ultrasonic examination of welds

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BS 4570 ......................Fusion welding of steel castings

BS 4872 ......................Approval testing of welders when welding procedure approval is not required BS 5135 ......................Process of arc welding of carbon and carbon manganese steels

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BS 5289 ......................Code of practice for visual inspection of fusion welded points

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BS 6072 ......................Method for magnetic particle flaw detection BS 6443 ......................Penetrant flaw detection

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BS EN 287 ..................Approval testing of welders for fusion welding

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BS EN 288 ..................Approval of welding procedures for metallic materials System Description

1

Welding shall be a metal arc process in accordance with BS 5135 and BS 4570, as appropriate, together with other clauses contained in this section, unless otherwise specifically permitted by the Engineer.

2

Welding consumables used shall be chosen to ensure that the mechanical properties of the weld metal are not less than those required for the parent metal.

3

Joints shall be prepared in accordance with BS 5135. Precautions shall be taken to ensure cleanliness of the connection prior to welding.

5.2

WELDER QUALIFICATION

5.2.1

Testing

1

Welders shall be tested to meet the requirements of BS EN 287 Part 1 but, in the case of welders engaged on fillet welding only, BS 4872 Part 1 is an acceptable alternative.

2

As an alternative, when permitted by the Employer, welders may be tested to meet the requirements of the American Society of Mechanical Engineers, ASME IX, or the American Welding Society, AWS Dl.1.

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5.1.3

QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 3

Certification

1

Welder testing shall be witnessed and certificates endorsed by an independent Inspection Authority.

2

The certification shall remain valid providing it complies with the conditions for re-approval of certification specified in BS EN 287 Part 1.

5.3

WELDING PROCEDURES

5.3.1

Preparation of Procedures

1

Approved written welding procedures shall be available in accordance with BS 5135, and tested in accordance with BS EN 288 Part 3 by the Contractor.

5.3.2

Approval of Procedures and Procedure Tests

1

Procedures and tests shall be approved by an independent Inspection Authority.

5.3.3

Availability of Welding Procedure Sheets

1

Welding Procedure sheets shall be made available to the welder prior to the commencement of the work and shall be available to the Engineer and Inspection Authority on request.

5.4

ASSEMBLY

5.4.1

Fit-up

1

Joints shall be fitted up to the dimensional accuracy required by the welding procedure, depending on the process to be used, to ensure that the quality in Table 5.2 is achieved.

5.4.2

Jigs

1

Fabrications assembled in jigs may be completely welded in the jig, or may be removed from the jig after tack welding.

5.4.3

Tack Welds

1

Tack welds shall be made using the same procedures as for the root runs of main welds. The length of the tack shall be the lesser of 4 times the thickness of the thicker part or 50 mm, unless demonstrated by a weld procedure qualification.

2

Tack welds which are not defective may be incorporated into main welds provided that the welder is qualified as in Clause 5.2 of this Part. However, where joints are welded using an automatic or mechanised process, the suitability of the tack weld used for incorporation into automatic processes shall be demonstrated in the weld procedure qualification.

3

Where tack welds are made in circumstances other than those identified above, they must be removed.

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5.2.2

QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 4

Distortion Control

1

The sequence of welding a joint or a sequence of joints shall be such that distortion is minimised (see Part 7 of this Section).

5.4.5

Fabrication or Erection Attachments

1

Welding of attachments required for fabrication or erection purposes shall be made in accordance with the requirements for a permanent weld.

2

When removal is necessary, they shall be flame cut or gouged at a point not less than 3 mm from the surface of the parent material. The residual material shall be ground flush and the affected area visually inspected. When thicknesses are greater than 20 mm it shall also be checked by magnetic particle inspection. Acceptance criteria are as set out in Table 5.2. Attachments shall not be removed by hammering. (See Clause 3.4.2 of this Section).

5.4.6

Extension Pieces

1

Where the profile of a weld is maintained to the free end of a run by the use of extension pieces they shall be of material of a similar composition, but not necessarily the same grade, as the component. They shall be arranged so as to provide continuity of preparation and shall be removed after completion of the weld and the surface ground smooth.

5.4.7

Production Test Plates

1

Where production test plates are required for testing purposes, they shall be clamped in line with the joint. The grade of material and rolling direction shall match the parent plate, but need not be cut from the same plates or cast.

5.5

NON-DESTRUCTIVE TESTING OF WELDS

5.5.1

Record of Testing

1

The test results shall be recorded and be available for inspection by the Engineer.

5.5.2

Visual Inspection of Welds

1

Visual inspection shall be made in accordance with guidance given in BS 5289 over the full length of the weld and before NDT inspection is performed (see Tables 5.1 and 5.2). Any welds which will be rendered inaccessible by subsequent work shall be examined in accordance with Tables 5.1 and 5.2 prior to the loss of access.

2

A suitably qualified person for visual inspection of welds may be a welding inspector or a welder who can provide evidence of having been trained and assessed for competence in visual inspection of the relevant types of welds.

5.5.3

Surface Flaw Detection

1

Where a closer examination of a weld surface is required in accordance with Table 5.1, magnetic particle inspection (MPI) shall be used in accordance with the recommendations given in BS 6072.

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5.4.4

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Section 16: Structural Steelworks Part 05: Fabrication

Page 5

If magnetic particle inspection equipment is not available, dye penetrant inspection (DPI) may be used in accordance with the recommendations given in BS 6443.

3

Final surface flaw detection of a welded joint shall be carried out not less than 16 hours from the time of completion of the weld to be inspected, or not less than 40 hours in the case of welds to Design Grade 55 material. The Contractor shall note that where a welding procedure requires an inspection after initial weld runs before further welding is performed, such inspections may be carried out when the weld metal has cooled to ambient temperature.

4

A suitably qualified person for surface flaw detection of welds may be a welding inspector or a welder who holds a current certificate of competence in surface flaw detection of the relevant types of work, from a nationally recognised authority.

5.5.4

Ultrasonic Examination

1

Where ultrasonic examination is required in accordance with Tables 5.1 and 5.2, it shall be made in accordance with BS 3923 Part 1, Level 2B. Examination shall be carried out not less than 16 hours from the time of completion of the weld to be inspected, or not less than 40 hours in the case of butt welds thicker than 40 mm or any welds to Design Grade 55 material.

2

Operators carrying out final ultrasonic examination of the weld shall hold a current certificate of competence from a nationally recognised authority.

5.5.5

Scope of Inspection

1

The scope of inspection shall be in accordance with Table 5.1.

5.5.6

Acceptance Criteria and Corrective Action

1

Acceptance criteria, corrective action and re-testing shall be in accordance with Table 5.2 for components subject to static loading.

2

The acceptance criteria shown in Table 5.2 are not intended to apply to bridges, offshore structures, or other dynamically loaded structures.

5.6

SHEAR STUD WELDING

5.6.1

Method

1

Shear studs shall be welded in accordance with the manufacturer's recommendations for materials, procedures and equipment.

5.6.2

Trial Welding

1

When specified by the Engineer and before production welding of studs commences, procedure trials shall be carried out. The trials shall be made on samples of material and studs representative of those to be used in the work. The samples of materials and studs shall be agreed with the Engineer.

2

Where primers are to be applied to the work prior to the welding of studs they shall be applied to the sample material before the procedure trials are made.

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QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 6

Tests and Inspection

1

All studs are to be visually inspected. They shall show a full 360 collar.

2

At locations agreed with the Engineer a minimum of 5% of studs which have satisfied the visual inspection shall have a bend test. The bend test shall be made by striking the head of the stud with a 6kg hammer until it is displaced laterally a distance of about one quarter of the height of the stud. The stud weld shall not show any signs of cracking or lack of fusion.

3

Studs subjected to the bend test shall not be straightened.

5.6.4

Defective Studs

1

Studs with defective welding shall be removed in the manner described in Clause 5.4.5 of this Part, and replaced and re-tested as in Clause 5.6.3 of this Part.

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5.6.3

QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 7

Table 5.1 Welds - Scope of Inspection The requirements of this table shall not preclude the use of Non- Destructive Testing outside the limits shown should the results of visual inspection or NDT indicate that a lapse in quality may have occurred in specific joints PART A.

VISUAL INSPECTION Prior to Non -Destructive Testing all welds to be visually inspected by a suitably qualified person (See Clause 5.5.2 of this Part) THICKNESS WHEN NON-DESTRUCTIVE TESTING BECOMES MANDATORY (all dimensions in mm)

Weld Type

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PART B.

Butt (full, partial penetration and with reinforcing fillets) In-line Single sided

Double sided and single sided plus backing

Single sided

Corner

Double sided and single sided plus backing

All

t max  10

1max  12

1max  20

1max ≤ 20

1max ≤ 20

t max  10

1max  10

1max ≤ 15

1max ≤ 15

1max ≤ 15

43/50

t max ≤ 10

1max ≤ 12

1max ≤ 12

1max  30

1max ≤ 30

55

t max ≤ 10

1max ≤ 10

1max ≤ 10

1max ≤ 20

1max ≤ 20

43/50

U/S

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55

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MPI

o

Design Grade

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as

Examples

ta

Procedures

Tee and Cruciform

qa

Joint Type

Notation

MPI - Magnetic Particle Inspection (see Clause 5.5.3 of this Part) U/S - Ultrasonic Examination (see Clause 5.5.4 of this Part) 

- Less than



- Less than or equal to

QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 8

Table 5.1 (Continued) Welds - Scope of Inspection PART B. (Cont.)

THICKNESS WHEN NON-DESTRUCTIVE TESTING BECOMES MANDATORY (all dimensions in mm)

Weld Type

Fillet

Joint Type

Lap

Tee and Cruciform

Procedures

All

All

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Examples

t max ≤ 15 Not Mandatory

55

Not Mandatory

Notation

se

43/50

qa

55

as

t max ≤ 20

t max ≤ 20 t max ≤ 15 t max ≤ 20 t max ≤ 15

MPI - Magnetic Particle Inspection (see Clause 5.5.3 of this Part)

er

U/S - Ultrasonic Examination (see Clause 5.5.4 of this Part)

ov

 - Less than

o

 - Less than or equal to

et it

U/S

43/50

m

MPI

ta

Design Grade

QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 9

Table 5.1 (Continued) Welds - Scope of Inspection PART C

FREQUENCY OF TESTING OF JOINTS IDENTIFIED IN PART B

Connection Zones

Shop Welds

First 5 identified joints of each type having same basic dimensions, material grades and weld geometry and welded to the same procedures . Thereafter 1 in 5 joints of each type ( if the first 5 have complied with Table 5.2 ) All identified joints Traverse butts in web and flange plates before assembly

As for shop welds in Connection Zones

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Member Zones

.

Site Welds

Built up

Transverse fillet welds at ends of cover plates

Members

qa

e.g. for fixing purlins side rails, buckling stiffeners etc.

0.5 m in each 10 m or part thereof 1 in 20 Attachments

as

Secondary Attachment Welds

ta

Longitudinal welds

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Note :- Where only partial inspection is required the joints for testing shall be selected on a random basis, but ensuring that sampling covers the following variables as widely as possible : Joint Type , Material Grade and Welding Equipment .

Notation

MPI - Magnetic Particle Inspection (see Clause 5.5.3 of this Part) U/S - Ultrasonic Examination (see Clause 5.5.4 of this Part) 

- Less than



- Less than or equal to

QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 10

Table 5.2 Weld Quality Acceptance Criteria and Corrective Actions

PARAMETER

WELD TYPE

PARTICULAR CONDITIONS

REMEDIAL ACTION FOR NONCONFORMING WELDS (see Note 2)

ACCEPTANCE REQUIREMENTS (all dimensions in mm) (see Note 1 and 5 )

Fig

WELD GEOMETRY All

As specified on drawings

Repair

Weld Type

All

As specified on drawings

Refer to Engineer

Length

All

 As specified on drawings

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PROFILE

.

Location

Butt

tb  As drawing (Av.50)

Thickness

Fillet

tf  As drawing (Av.50)

ta

Throat

Repair

b,c

Repair

a

Repair or grind and MPI after grinding

Fillet

1f  As drawing

a

Repair

Toe Angle

All

  90

a

Grind and MPI after grinding

Cap/Root Bead (Height or concavity)

Butt

Butt Joint

-1  Cb  4

b

Repair or grind

Misalignment

Butt

Butt Joint

m  As drawing + 0.25t

d

Refer to engineer

se

er

ov

 As drawing + 3 m  As drawing + 0.50t

Joint

and  As drawing + 6

o

Cruciform

e

m

Notes:-

et it

All

as

Leg Length

qa

 As drawing + 5

1. Where there are two limits for one dimension both shall apply All limits are peak values unless indicated as average 2. Where a repair is necessary an approved procedure must be used. If on increasing the scope of inspection, further non-conformances are found, the scope shall be increased to 100% for the joint type in question. 3. May be accepted up to the limits for slag lines if the joint is subjected to longitudinal shear only. 4. All welds to the same procedure. 5. Abbreviations: Av. 100 or Av.50 indicates the average value over 100mm or 50mm length 

Equal or greater than



Equal or less than



Sum of

QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 11

Table 5.2 (Continued) Weld Quality Acceptance Criteria and Corrective Actions PARAMETER

WELD TYPE

PARTICULAR CONDITIONS

REMEDIAL ACTION FOR NONCONFORMING WELDS (see Note 2)

ACCEPTANCE REQUIREMENTS (all dimensions in mm) (see Note 1 and 5 )

Single Sided

U1+ U2  0.1t (Av.100)

D,e

And  2

D,e

Transverse Weld

U1+ U2  0.05t (Av.100)

D,e

And  1

D,e

Longitudinal Weld

rp  As drawing+0.1t(Av.100)

(lack of)

and

Butt

and

if root is inaccessible

f f

d  10 in 100 (length)

f

Not Permitted

Repair

Repair and increase MPI to 100% (Note 4)

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o

All

c

d  20 in 100 (length)

ov

er

Transverse Weld

Notes:-

3

se

Longitudinal Weld

Repair and double scope of Ultrasonic inspection

As drawing +2

d 

All Welds

All

Lack of Fusion and Cracks



as

Porosity

c

 As drawing +3

rp  As drawing+0.05t(Av.100)

Transverse Weld

Repair

.

Longitudinal Weld

ta

Root Penetration

DISCONTINUITIES

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All

SURFACE

qa

Undercut

Fig

m

6. Where there are two limits for one dimension both shall apply All limits are peak values unless indicated as average 7. Where a repair is necessary an approved procedure must be used. If on increasing the scope of inspection, further non-conformances are found, the scope shall be increased to 100% for the joint type in question. 8. May be accepted up to the limits for slag lines if the joint is subjected to longitudinal shear only. 9. All welds to the same procedure. 10. Abbreviations: Av. 100 or Av.50 indicates the average value over 100mm or 50mm length 

Equal or greater than



Equal or less than



Sum of

QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 12

Table 5.2 (Continued) Weld Quality Acceptance Criteria and Corrective Actions PARAMETER

WELD

PARTICULAR CONDITIONS

TYPE

REMEDIAL ACTION FOR NONCONFORMING WELDS (see Note 2)

ACCEPTANCE REQUIREMENTS (all dimensions in mm) (see Note 1 and 5 )

All Welds

1`  10 )

g

1  6t in 200 (length)

g

Transverse Weld

1  3t in 200 (length)

g

Tee, Cruciform, Corner and Lap Joints

rg

 2(Av 100 )

and  3

All

er

Tee, Cruciform, Corner and Lap Joints

All

ov

Lamellar Tears

a,e a,e

Repair and double scope of U/S Inspection

Not permitted

Repair and increase U/S Inspection to 100%

Not Permitted ( Note 3)

Refer to Engineer and increase U/S Inspection to 100%

o

Notes:-

Repair and double scope of U/S Inspection

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Longitudinal Weld

se

Cracks

g

qa

Fillet or Partial Pen Butt

e,g

1  10 ) if h`  6

as

Root Gap

h  3 + As drawing

All

ta

Slag Lines and Lack of Fusion/Root Penetration

DISCONTINUITIES

.

SUB-SURFACE

Fig

et it

11. Where there are two limits for one dimension both shall apply All limits are peak values unless indicated as average

m

12. Where a repair is necessary an approved procedure must be used. If on increasing the scope of inspection, further non-conformances are found, the scope shall be increased to 100% for the joint type in question. 13. May be accepted up to the limits for slag lines if the joint is subjected to longitudinal shear only. 14. All welds to the same procedure. 15. Abbreviations: Av. 100 or Av.50 indicates the average value over 100mm or 50mm length 

Equal or greater than



Equal or less than



Sum of

QCS 2014

Section 16: Structural Steelworks Part 05: Fabrication

Page 13

Table 5.2 (Continued) Weld Quality Acceptance Criteria and Corrective Actions DIMENSIONAL SYMBOLS

Notes:-

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DEFINITION OF MEASUREMENTS

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16. Where there are two limits for one dimension both shall apply All limits are peak values unless indicated as average 17. Where a repair is necessary an approved procedure must be used. If on increasing the scope of inspection, further non-conformances are found, the scope shall be increased to 100% for the joint type in question. 18. May be accepted up to the limits for slag lines if the joint is subjected to longitudinal shear only. 19. All welds to the same procedure. 20. Abbreviations: Av. 100 or Av.50 indicates the average value over 100mm or 50mm length 

Equal or greater than



Equal or less than



Sum of

END OF PART

QCS 2014

Section 16: Structural Steelworks Part 06: Bolting

Page 1

6

BOLTING ....................................................................................................... 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2

Scope References

6.2

ORDINARY BOLTED ASSEMBLIES ............................................................. 2

6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8

Bolt/Nut Combinations Differing Bolt Grades Bolt Length Washers Taper Washers Galvanized Nuts Bolt Tightening Fitted Bolts

6.3

FIT-UP WHEN USING ORDINARY BOLTS .................................................. 3

6.3.1 6.3.2

Fit-up Reaming

6.4

HIGH STRENGTH FRICTION GRIP ASSEMBLIES ...................................... 3

6.4.1 6.4.2 6.4.3 6.4.4

Bolt/Nut/Washer Combinations Tightening Calibration of Torque Equipment Discarded Bolt Assemblies

6.5

FIT-UP WHEN USING HSFG BOLTS ........................................................... 4

6.5.1 6.5.2

Fit-up Reaming

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2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 4 4 4

QCS 2014

Section 16: Structural Steelworks Part 06: Bolting

Page 2

6

BOLTING

6.1

GENERAL

6.1.1

Scope

1

This Part specifies the requirements for bolting associated with structural steelwork.

6.1.2

References

1

The following standards are referred to in this Part: BS 2583 ......................Podger spanners

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BS 3692 ......................ISO metric precision hexagon bolts, screws and nuts BS 4190 ......................ISO metric black hexagon bolts, screws and nuts.

BS 4395 ......................High strength friction grip bolts and associated nuts and washers for structural engineering.

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BS 4606 ......................Recommendations for the co-ordination of dimensions in building. Coordination sizes for rigid flat sheet materials used in building.

ORDINARY BOLTED ASSEMBLIES

6.2.1

Bolt/Nut Combinations

1

The combinations of bolts and nuts shall be not less than the following:

se

er

4.6 bolts with grade 4 nuts (BS 4190) 8.8 bolts with grade 8 nuts (BS 3692) 10.9 bolts with grade 12 nuts (BS 3692).

ov

(a) (b) (c)

as

6.2

Any bolt assemblies which seize when being tightened shall be replaced.

6.2.2

Differing Bolt Grades

1

Different bolt grades of the same diameter shall not be used in the same structure, except when agreed otherwise by the Engineer.

6.2.3

Bolt Length

1

The bolt length shall be chosen such that, after tightening, at least one thread plus the thread run-out will be clear between the nut and the unthreaded shank of the bolt and at least one clear thread shall show above the nut.

6.2.4

Washers

1

When the members being connected have a finished surface protective treatment which may be damaged by the nut or bolt head being rotated, a washer shall be placed under the rotating part

2

A suitable plate, or heavy duty, washer shall be used under the head and nut when bolts are used to assemble components with oversize or slotted holes.

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QCS 2014

Section 16: Structural Steelworks Part 06: Bolting

Page 3

Taper Washers

1

When the bolt head or nut is in contact with a surface which is inclined at more than 30 from a plane at right angles to the bolt axis, a taper washer shall be placed to achieve satisfactory bearing.

6.2.6

Galvanized Nuts

1

Nuts shall be checked after being galvanized for free running on the bolt and retapped if necessary to ensure a satisfactory tightening performance.

6.2.7

Bolt Tightening

1

Bolts may be assembled using power tools or shall be fully tightened by hand using appropriate spanners in accordance with BS 2583.

6.2.8

Fitted Bolts

1

Precision bolts to BS 3692 may be used as fitted bolts when holes are drilled or reamed after assembly so that the clearance in the hole is not more than 0.3 mm.

6.3

FIT-UP WHEN USING ORDINARY BOLTS

6.3.1

Fit-up

1

Connected parts shall be firmly drawn together. If there is a remaining gap which may affect the integrity of the joint, it shall be taken apart and a pack inserted.

6.3.2

Reaming

1

Where parts cannot be brought together by drifting without distorting the steelwork, rectification may be made by reaming, provided the design of the connection will allow the use of larger diameter holes and bolts.

6.4

HIGH STRENGTH FRICTION GRIP ASSEMBLIES

6.4.1

Bolt/Nut/Washer Combinations

1

Bolt/nut/washer combinations shall comply with BS 4395 Parts 1 or 2, as appropriate.

6.4.2

Tightening

1

The use of friction grip bolts shall comply with BS 4604. Part 1 or 2.

2

Tightening which complies with BS 4604 Part 1, may be by the torque control method, partturn method, or with load indicating devices used in accordance with the manufacturer's recommendations.

6.4.3

Calibration of Torque Equipment

1

Torque spanners and other devices shall have a calibration check at least once per shift, and shall be re-calibrated where necessary in accordance with BS 4604.

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6.2.5

QCS 2014

Section 16: Structural Steelworks Part 06: Bolting

Page 4

Discarded Bolt Assemblies

1

If, after complete tightening, a bolt or nut has to be slackened off, the whole bolt assembly is to be disposed of.

6.5

FIT-UP WHEN USING HSFG BOLTS

6.5.1

Fit-up

1

Connected parts shall be firmly drawn together with all bolts partially tightened.The joint shall then be examined and if there is any remaining gap which may affect the integrity of the joint, it shall be taken apart and a pack inserted before recommencing the tightening procedure.

6.5.2

Reaming

1

Where parts cannot be brought together by drifting without distorting the steelwork, rectification can be made by reaming, provided that the design of the connection will allow the use of larger diameter bolts.

2

Calculations shall be made to demonstrate that the connection remains adequate for the forces in the connection.

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6.4.4

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END OF PART

QCS 2014

Section 16: Structural Steelworks Part 07: Accuracy of Fabrication

Page 1

7

ACCURACY OF FABRICATION .................................................................... 2

7.1

GENERAL ...................................................................................................... 2

7.1.1 7.1.2

Scope References

7.2

PERMITTED DEVIATIONS ........................................................................... 2

7.2.1 7.2.2 7.2.3 7.2.4

Permitted Deviations In Rolled Components After Fabrication Permitted Deviations for Elements of Fabricated Members Permitted Deviations In Plate Girder Sections Permitted Deviations in Box Sections

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2 2 2 3 4 7

QCS 2014

Section 16: Structural Steelworks Part 07: Accuracy of Fabrication

Page 2

7

ACCURACY OF FABRICATION

7.1

GENERAL

7.1.1

Scope

1

This Part deals with the accuracy of fabrication of structural steel sections.

7.1.2

References

1

The following standards are referred to in this Part:

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BS 4 ............................Structural steel sections BS 4848 ......................Hot rolled structural steel sections BS 5950 ......................Structural use of steelwork in buildings

PERMITTED DEVIATIONS

7.2.1

Permitted Deviations In Rolled Components After Fabrication

1

Permitted deviations in rolled components after fabrication (including structural hollow sections) are given in Table 7.1

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7.2

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Table 7.1 Permitted Deviations in Rolled Components After Fabrication Component

Cross Section after Fabrication

2

o

1

et it

ov

Item

Deviation In accordance with the tolerances specified in BS 4 or BS 4848 as appropriate.

Squareness of Ends Not Prepared for Bearing

m

See also clause 4.4.3-1.

Plan or Elevation of End 3

Squareness of Ends Prepared for Bearing Prepare ends with respect to the longitudinal axis of the member. See also Clauses 4.4.3-2 and 4.4.3-3. Plan or Elevation

QCS 2014

Section 16: Structural Steelworks Part 07: Accuracy of Fabrication

Page 3

Table 7.1 (Continued) Permitted Deviations in Rolled Components After Fabrication Item 4

Component

Deviation

Straightness on Both Axes

 = L/1000 or 3mm

5

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.

whichever is the greater Length

Curved or Cambered

se

6

as

qa

ta

Length after cutting, measured on the centre line of the section of angles.

Deviation = L/1000 or 6mm whichever is greater

et it

o

ov

er

Deviation from intended curve or camber at mid-length of curved portion when measured with web horizontal.

Permitted Deviations for Elements of Fabricated Members

1

Permitted deviations for elements of fabricated members are given in Table 7.2

m

7.2.2

Table 7.2 Permitted Deviations for Elements of Fabricated Members Item 1

Component Position of Fittings Fittings and components whose location is crucial to the force path in the structure, the deviation from the intended position shall not exceed .

Deviation

QCS 2014

Section 16: Structural Steelworks Part 07: Accuracy of Fabrication

Page 4

Table 7.2 (Continued) Permitted Deviations for Elements of Fabricated Members Item 2

Component

Deviation

Position of Holes The deviation from the intended position of an isolated hole, also a group of holes, relative to each other shall not exceed 

Punched Holes

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.

3

The distortion caused by a punched hole shall not exceed  (see clause 4.6.3)

Sheared or Cropped Edges of Plates or Angle

as

4

qa

ta

 = D/10 or 1mm whichever is the greater

5

Flatness

ov

er

se

The deviation from a 90 edge shall not exceed 

m

et it

o

Where bearing is specified, the flatness shall be such that when measured against a straight edge not exceeding one metre long, which is laid against the full bearing surface in any direction, the gap does not exceed 

7.2.3

Permitted Deviations In Plate Girder Sections

1

Permitted deviations in plate girder sections are given in Table 7.3

QCS 2014

Section 16: Structural Steelworks Part 07: Accuracy of Fabrication

Page 5

Table 7.3 Permitted Deviations In Plate Girder Sections Item

Component

1

Depth

Deviation

Depth on centre Line

.

Flange Width

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2

Squareness of Section

B Flange width

as

3

qa

ta

Width of Bw or Bn

4

 =B/100 or 3mm whichever is greater

ov

er

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Out of Squareness of Flanges.

Web Eccentricity

m

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o

Intended position of web from one edge of flange.

5

Flanges

B Flange width

Out of flatness

 = B/100 or 3mm whichever is the greater

QCS 2014

Section 16: Structural Steelworks Part 07: Accuracy of Fabrication

Page 6

Table 7.3 (Continued) Permitted Deviations In Plate Girder Sections

Item

Component

Deviation

6

Top Flange of Crane Girder w = Rail width + 20 mm

7

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.

Out of flatness where the rail seats.

Length

Flange Straightness

ov

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Straightness of individual flanges

as

8

qa

ta

Length on centre line

9

 = L/1000 or 3mm whichever is the greater

Curved or Cambered

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o

Deviation from intended curve or camber at mid-length of curved portion, when measured with the web horizontal.

Deviation = l/1000 or 6mm whichever is the greater 10

Web Distortion Distortion on web depth or gauge length.

gauge length = web depth

 = d/150 or 3mm whichever is the greater

QCS 2014

Section 16: Structural Steelworks Part 07: Accuracy of Fabrication

Page 7

Table 7.3 (Continued) Permitted Deviations In Plate Girder Sections

Item

Component

Deviation

11

Cross Section at Bearings

12

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Squareness of flanges to web

Web Stiffeners

Web Stiffeners

whichever is greater

ov

13

 = d/500 or 3mm

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as

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ta

Straightness of stiffener out of plane after welding.

m

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Straightness of stiffener in plane after welding.

 = d/250 or 3mm whichever is greater

7.2.4

Permitted Deviations in Box Sections

1

Permitted deviations in box sections are given in table 7.4

QCS 2014

Section 16: Structural Steelworks Part 07: Accuracy of Fabrication

Page 8

Table 7.4 Permitted Deviations in Box Sections Item

Component

Deviation

1

Plate Widths Width of Bf or Bw

.

Squareness

rw .l. l

2

Plate Distortion

 = w/150 or 3mm whichever is the greater

o

Web or Flange Straightness

et it

Straightness of individual web or flanges.

m

4

ov

er

se

Distortion on width or gauge length.

gauge length = width, w

as

3

qa

ta

Squareness at diaphragm positions

 = L/1000 or 3mm whichever is the greater

QCS 2014

Section 16: Structural Steelworks Part 07: Accuracy of Fabrication

Page 9

Table 7.4 (Continued) Permitted Deviations in Box Sections Item

Component

Deviation

5

Web Stiffners Straightness in plane with plate after welding.

rw .l. l

.

 = d/500 or 3mm

whichever is the greater

Web Stiffners

ta

6

Length

whichever is the greater

o

7

 = d/250 or 3mm

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Straightness out of plane to plate after welding.

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Length on centre line.

8

Curved or Cambered Deviation from intended curve or camber at mid-length of curved portion when measured with the uncambered side horizontal. Deviation = L/1000 or 6mm whichever is the greater

END OF PART

QCS 2014

Section 16: Structural Steelworks Part 08: Erection

Page 1

8

ERECTION .................................................................................................... 2

8.1

GENERAL ...................................................................................................... 2

8.1.1

Scope

8.2

ERECTION .................................................................................................... 2

8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7

Erection Method Statement Meaning of Acceptance Provision of Setting-Out Lines by the Employer Handling and Storage Damaged Steelwork Column Base Plates and Slabs Grouting

8.3

STABILITY ..................................................................................................... 3

8.3.1 8.3.2

Temporary Restraints until Permanent Features are Built Other Temporary Restraints used by the Contractor

8.4

ERECTION LOADS ....................................................................................... 3

8.4.1

General Requirements

8.5

LINING AND LEVELLING .............................................................................. 3

8.5.1 8.5.2

Alignment of Part of the Structure Temperature Effects

8.6

SITE WELDING ............................................................................................. 4

8.6.1

General Requirements

8.7

SITE BOLTING .............................................................................................. 4

8.7.1

General Requirements

8.8

CERTIFICATION OF COMPLETION ............................................................. 4

8.8.1

General Requirements

2 2 2 2 2 2 3 3 3 3 3 3 4 4

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QCS 2014

Section 16: Structural Steelworks Part 08: Erection

Page 2

8

ERECTION

8.1

GENERAL

8.1.1

Scope

1

This Part specifies the requirements for the erection of structural steelwork.

2

Related Parts and Sections are as follows: This Section Part 5 Part 6

Welding Bolting

ERECTION

8.2.1

Erection Method Statement

1

The Contractor shall prepare a written method statement, taking into account the requirement of the design, erection procedure and programme, respectively.

2

The Contractor shall submit the method statement to the Engineer for acceptance at least two weeks before erection commences.

3

Erection shall not commence before the method statement has been accepted by the Engineer.

8.2.2

Meaning of Acceptance

1

Acceptance by the Engineer of the Erection Statement does not reduce the contractors responsibility for the safety of the erection process.

8.2.3

Provision of Setting-Out Lines by the Employer

1

The Contractor shall provide and maintain until the steelwork is accepted, setting-outlines and datum levels within, or immediately adjacent to, the Works.

8.2.4

Handling and Storage

1

Components shall be handled and stored in such a manner as to minimise the risk of surface abrasion and damage.

2

Fasteners and small fittings shall be stored under cover in dry conditions.

8.2.5

Damaged Steelwork

1

Any steelwork damaged during off-loading, transportation, storage or erection shall be restored to conform to the standards of manufacture as given in this Specification.

8.2.6

Column Base Plates and Slabs

1

Steel packings shall be supplied to allow the structure to be property lined and levelled and of sufficient size to avoid local crushing of the concrete.

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QCS 2014

Section 16: Structural Steelworks Part 08: Erection

Page 3

Base packings shall be placed so that they do not prevent subsequent grouting to completely fill all spaces directly under the base plates.

3

Base packs may be left permanently in place.

8.2.7

Grouting

1

Grouting shall not be carried out under column base plates until a sufficient portion of the structure has been aligned, levelled, plumbed and adequately braced.

2

Immediately before grouting, the space under column base plates shall be clean and free of all extraneous matter.

8.3

STABILITY

8.3.1

Temporary Restraints until Permanent Features are Built

1

The Engineer shall advise the Contractor of positions on the structure where temporary bracing or restraints are necessary until walls, floors or other non-steel structures are built. He shall also provide details of the forces and moments in these elements.

2

The Contractor shall design and provide the temporary bracing or restraints.

8.3.2

Other Temporary Restraints used by the Contractor

1

If the Contractor uses temporary restraints during erection which do not substitute for permanent features, they may be removed after the structure has been lined, levelled and plumbed provided that sufficient steelwork and or permanent bracing has been erected to ensure the stability of the structure under the worst expected conditions of dead, imposed and wind loading.

8.4

ERECTION LOADS

8.4.1

General Requirements

1

The Contractor shall ensure that no part of the structure is permanently distorted by stacking of materials or temporary erection loads during the erection process.

8.5

LINING AND LEVELLING

8.5.1

Alignment of Part of the Structure

1

Each part of the structure shall be aligned as soon as practicable after it has been erected. Permanent connections shall not be made between members until sufficient of the structure has been aligned, levelled, plumbed and temporarily connected to ensure that members will not be displaced during subsequent erection or alignment of the remainder of the structure.

8.5.2

Temperature Effects

1

Due account shall be taken of the effects of temperature on the structure and on tapes and instruments when measurements are made for setting out, during erection, and for subsequent dimensional checks. The reference temperature shall be 30oC.

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QCS 2014

Section 16: Structural Steelworks Part 08: Erection

Page 4

SITE WELDING

8.6.1

General Requirements

1

Site welding shall be carried out in accordance with Part 5 of this Section.

2

Welding shall not be permitted during inclement weather, unless adequate protective measures are taken.

8.7

SITE BOLTING

8.7.1

General Requirements

1

Bolting shall be carried out in accordance with Part 6 of this Section.

8.8

CERTIFICATION OF COMPLETION

8.8.1

General Requirements

1

When the steelwork, or portion of the steelwork, has been completed, the Contractor shall present a certificate for the Engineer and the Contractor to sign.

2

The completion of the certificate means the following:

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8.6

the Contractor's signature signifies that an inspection has been made to ensure that all connections are completed and that the steelwork is erected in accordance with this Specification and contract requirements.

(b)

the Engineer's signature signifies acceptance that the structure, or part of the structure, has been built in accordance with this Specification and the contract requirements.

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(a)

END OF PART

QCS 2014

Section 16: Structural Steelworks Part 09: Accuracy of Erected Steelwork

Page 1

9

ACCURACY OF ERECTED STEELWORK ................................................... 2

9.1

GENERAL ...................................................................................................... 2

9.1.1 9.1.2

Scope General Requirements

9.2

INFORMATION FOR SUB CONTRACTORS ................................................ 2

9.2.1

General

9.3

DEVIATIONS ................................................................................................. 3

9.3.1 9.3.2

Permitted Deviations For Foundations, Walls And Foundation Bolts Permitted Deviations of Erected Components

2 2

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QCS 2014

Section 16: Structural Steelworks Part 09: Accuracy of Erected Steelwork

Page 2

9

ACCURACY OF ERECTED STEELWORK

9.1

GENERAL

9.1.1

Scope

1

This Part the requirements for the accuracy of erected structural steelwork.

2

Related Parts and Sections are: This Section Part 7 Part 8

Accuracy of Fabrication Erection

General Requirements

1

Permitted maximum deviations in erected steelwork shall be as specified in Clause 9.4.2 of this Part taking account of the following:

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9.1.2

All measurements be taken in calm weather, and due note is to be taken of temperature effects on the structure. (See Clause 8.4.2 of this Section).

(b)

The deviations shown for I sections apply also to box and tubular sections.

(c)

Where deviations are shown relative to nominal centrelines of the section, the permitted deviation on cross-section and straightness, given in Part 7 of Section, may be added.

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(a)

INFORMATION FOR SUB CONTRACTORS

9.2.1

General

1

The Contractor shall advise sub contractors engaged in operations following steel erection of the deviations acceptable in this document in fabrication and erection, so that they can provide the necessary clearances and adjustments.

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QCS 2014

Section 16: Structural Steelworks Part 09: Accuracy of Erected Steelwork

Page 3

9.3

DEVIATIONS

9.3.1

Permitted Deviations For Foundations, Walls And Foundation Bolts

1

The permitted deviations for foundations, walls and foundation bolts are given in Table 9.1. Table 9.1 Permitted Deviations for Foundations, Walls and Foundation Bolts Item 1

Component

Deviation

Foundation Level

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Deviation from exact level.

QCS 2014

Section 16: Structural Steelworks Part 09: Accuracy of Erected Steelwork

Page 4

Table 9.1 (Continued) Permitted Deviations for Foundations, Walls and Foundation Bolts Item 2

Component

Deviation

Vertical Wall Deviation from exact position at steelwork support point.

.

Pre-set Foundation Bolt or Bolt Groups when Prepared for Adjustment

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Deviation from the exact location and level and minimum movement in pocket.

Pre-set Foundation Bolt or Bolt Groups when Not Prepared for Adjustment

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Deviation from the exact location level and protrusion.

9.3.2

Permitted Deviations of Erected Components

1

Permitted deviations of erected components is given in Table 9.2. Table 9.2 Permitted Deviations of Erected Components Item 1

Component Position at Base of First Column Erected Deviation of section centreline from the specified position.

Deviation

QCS 2014

2

Section 16: Structural Steelworks Part 09: Accuracy of Erected Steelwork

Page 5

Overall Plan Dimensions True overall dimension “ L”

Deviation in length or width

L  30 metres,  = 20 mm

.

L  30 metres,  = 20 mm +

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0.25 (L - 30) mm

where L is in metres

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Deviation of top relative to base, excluding portal frame columns, on main axes. See Clause 3.4.4 (c) of this Section regarding pre-setting continuous frames.

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Single Storey Columns Plumb

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 =  H/600 or 5 mm whichever is greater Max =  25 mm

QCS 2014

Section 16: Structural Steelworks Part 09: Accuracy of Erected Steelwork

Page 6

Table 9.2 (Continued) Permitted Deviations of Erected Components

Item 4

Component

Deviation

Multi-storey Columns Plumb

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Deviation in each storey and maximum deviation relative to base.

 h = h/600 or 3 mm

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whichever is greater

5

Gap Between Bearing Surfaces

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 H = 50 mm maximum

Alignment of Adjacent Perimeter Columns

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(See Clauses 4.4.3-3, 6.3.1 and Item 3 of Table 7.1)

critical face of columns

m

Deviation relative to next column on a line parallel to the grid line when measured at base or splice level.  = 10 mm

7

Floor Beams Level Deviation from specified level at supporting stanchion.

QCS 2014

Section 16: Structural Steelworks Part 09: Accuracy of Erected Steelwork

Page 7

Table 9.2 (Continued) Permitted Deviations of Erected Components Component

Deviation

Item 8

Floor Beams Level at Each End of Same Beam Deviation is level.

.

Floor Beams Level of Adjacent Beams within distance of 5 metres

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Deviation from relative horizontal levels (measured on centreline of top flange)

Beams Alignment

h  3 m,  = 5 mm h  3 m,  = h/600

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Horizontal deviation relative to an adjacent beam above or below.

11

Crane Gantry Columns Plumb Deviation of cap relative to base.

 =  Hc /1000 or 5 mm whichever is greater Max =  25 mm

QCS 2014

Section 16: Structural Steelworks Part 09: Accuracy of Erected Steelwork

Page 8

Table 9.2 (Continued) Permitted Deviations of Erected Components

Item 12

Component

Deviation

Crane Gantries Gauge of Rail Tracks Deviation from true gauge

Joints in Gantry Crane Rails

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 =  10 mm

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END OF PART

 = 0.5 mm

QCS 2014

Section 17: Metalwork Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2

Scope References

1.2

SUBMITTALS ................................................................................................ 3

1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9

Samples Protection Materials Mock-ups Engineering Calculations Test Reports Inspection and Production Testing Programs Shop Drawings Maintenance Manual As-Built Drawings

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QCS 2014

Section 17: Metalwork Part 01: General

Page 2

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Part provides the specification for preparation of shop drawings, engineering, testing, fabrication, delivery erection and installation of steel doors, roller shutters, aluminium doors, windows and fly screens, aluminium support and cladding systems and architectural metal work.

2

Related Sections are as follows:

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Concrete Roofing Thermal Insulation of Buildings Structural Steelworks Carpentry, Joinery and Ironmongery Glass and Glazing Painting and Decorating

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Section 5 Section 14 Section 15 Section 16 Section 18 Section 25 Section 26

.

1

References

1

The following standards are referred to in this Part:

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BS 476 ........................Fire tests on building materials and structures BS 729 ........................Hot dip galvanized coatings on iron and steel articles

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BS 1245 ......................Metal door frames (steel) BS 1282 ......................Guide to the choice, use and application of wood preservatives.

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BS 1449 ......................Steel plate, sheet and strip.

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BS 1474 ......................Wrought aluminium and aluminium alloys for general engineering purposes, bars, extruded round tube and section

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BS 1615 ......................Method for specifying anodic oxidation coatings on aluminium and alloy

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BS 1706 ......................Electroplated coatings of nickel and chromium BS 1722 ......................Fences BS 1723 ......................Brazing BS 1724 ......................Bronze welding by gas BS 2901 ......................Filler rods and wires for gas shielded and welding BS 2994 ......................Cold rolled steel Sections BS 2997 ......................Aluminium rainwater goods BS 3049 ......................Pedestrian guard rails (metal) BS 3083 ......................Hot-dip zinc coated and hot-dip aluminium/zinc coated corrugated steel sheets for general purposes BS 3987 ......................Anodic coatings on wrought aluminium for oxidation external architectural applications. BS 4147 ......................Bitumen based hot applied coating material for protecting iron and steel, including suitable primers where required. BS 4254 ......................Two-part polysulphide based sealants

QCS 2014

Section 17: Metalwork Part 01: General

Page 3

BS 4255 ......................Rubber used in pre-formed gaskets for weather exclusion from buildings BS 4300 ......................Specification (supplementary series) for wrought aluminium and aluminium alloys for general engineering purposes. BS 4315 ......................Methods of test for resistance to air and water penetration BS 4873: .....................Aluminium alloy windows BS 5368 ......................Method of testing windows. BS 5707 ......................Solutions of wood preservatives in organic solvents. BS 6213 ......................Guide to selection of constructional sealants BS 6375 ......................Performance of windows

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BS 6496 ......................Powder organic coatings for application and storing to aluminium alloy extrusion, sheet and pre-formed sections for external architectural purposes, and for the finish on aluminium alloy extrusions, sheet and pre-formed sections coated with organic coatings

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BS 6497 ......................Powder organic coatings for application and storing to ho-dip galvanized hot-rolled steel Section and steel sheet for windows and associated external architectural purposes, and for the finish on galvanized steel Section and sheet coated with organic coatings.

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BS 6510 ......................Steel windows, bills, window boards, and doors

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BS 7036 ......................Code of practice for provision and installation of safety devices for automatic power operated pedestrian door systems

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BS 7773 ......................Code for practice for cleaning and preparation of metal surfaces BS EN 288 ..................Approval of welding procedures for metallic materials

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BS EN 485 ..................Aluminium and aluminium alloys –sheet, strip and plate

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BS EN 10142 ..............Continuously hot-dip zinc coated low carbon steel sheet and strip for cold forming: technical delivery conditions.

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BS EN 10143 ..............Continuously hot-dip metal coated steel sheet and strip –Tolerances on dimensions and shape

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BS EN 10152 ..............Electrolytically zinc coated cold rolled steel flat products –Technical delivery conditions

1.2

SUBMITTALS

1.2.1

Samples

1

The Contractor shall submit samples and mock-ups in accordance with the relevant provisions of Section 1, General, and as follows: (a)

submit samples of all materials and finishes including the following: (i)

samples matching the appearance, colour, texture, and other characteristics of each finish required.

(ii)

finished samples of panels and major extrusions.

(iii)

range samples showing the complete range of variation in colour, texture, and other characteristics resulting from the manufacture, finishing, fabrication, delivery, assembly, installation, and cleaning processes.

(iv)

samples showing finishes over welds and over materials welded.

QCS 2014

Section 17: Metalwork Part 01: General

Page 4

(b)

the size of all samples to be agreed with the engineer or as noted in the contract documents

(c)

the Contractor shall submit any pre-printed or prepared manufacturer’s performance data.

Protection Materials

1

The Contractor shall provide information or direction for application and removal procedures for all protection materials used on or for samples during shipping, storage, and installation.

1.2.3

Mock-ups

1

The Contractor shall provide test mock-ups as indicated in the Project Documentation, and as required for tests

2

The Contractor shall provide visual mock-up as indicated in the Project Documentation.

1.2.4

Engineering Calculations

1

The Contractor shall submit engineering calculations as directed in the Project Documentation

2

Engineering calculations shall be submitted concurrently with the corresponding shop drawings.

3

All engineering calculations are to bear the stamp of a professional engineer.

1.2.5

Test Reports

1

The Contractor shall submit test reports for all tests specified herein. Test reports shall be submitted in a timely manner and prior to execution of any Works.

2

Product test reports: a qualified independent testing agency approved by the Engineer shall be used to indicate and interpret test results on tests on components and assemblies relative to compliance with the requirements of the Project Documentation.

3

Reconstruction test reports: a qualified independent testing agency approved by the Engineer shall be used to indicate and interpret test results on test mock-ups relative to compliance with the requirements of the Project Documentation.

4

Field test reports: a qualified independent inspecting and testing agency approved by the Engineer shall be used to indicate and interpret field test results relative to compliance with the requirements of the Project Documentation.

1.2.6

Inspection and Production Testing Programs

1

The Contractor shall submit to the Engineer a detailed description of inspection and production testing programmes and inspection reports for all types of coating of aluminium or aluminium alloy.

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Section 17: Metalwork Part 01: General

Page 5

Shop Drawings

1

Shop Drawings, shall be prepared in accordance with the relevant provisions of Section 1, General. Shop Drawings shall be prepared and approved by the Engineer prior to the fabrication of any off-site item.

1.2.8

Maintenance Manual

1

A maintenance manual describing the various materials, equipment, and procedures for cleaning and maintaining the parts of the Works included in this Section shall be submitted to the Engineer for approval upon completion of the Project.

1.2.9

As-Built Drawings

1

As-Built Drawings, prepared in accordance with the relevant provisions of Section 1, General, shall be submitted to the Engineer for approval upon completion of the Project.

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END OF PART

QCS 2014

Section 17: Metalwork Part 02: Material Types and Finishes

Page 1

2

MATERIAL TYPES AND FINISHES .............................................................. 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3 2.1.4

Scope References System Description Metals

2.2

PROTECTIVE TREATMENTS FOR METALS ............................................... 3

2.2.1

General

2.3

ALUMINIUM FINISHES ................................................................................. 4

2.3.1 2.3.2 2.3.3

General Requirements Finishes for Aluminium and Aluminium Alloys Storage and Handling of Materials

2.4

CARBON STEEL FINISHES.......................................................................... 7

2.4.1 2.4.2 2.4.3

General Painted Steel Stainless Steel Finishes

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QCS 2014

Section 17: Metalwork Part 02: Material Types and Finishes

Page 2

MATERIAL TYPES AND FINISHES

2.1

GENERAL

2.1.1

Scope

1

This part specifies the requirements for material types and finishes for non-structural metal work.

2

Related Sections and Parts are as follows:

Section 16 Section 18 Section 26

Structural Metalwork Carpentry, Joinery and Ironmongery Painting and Decorating

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General Metal Doors and Windows Architectural Metal Work Light Metal Support and Cladding System Workmanship

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This Section Part 1 Part 3 Part 4 Part 5 Part 6

.

2

References

1

The following standards are referred to in this Part:

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BS 729 ........................Hot dip galvanized coatings on iron on steel articles

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BS 1224 ......................Electroplated coatings of nickel and chromium BS 1285 ......................Metal door frames (steel)

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BS 1449 ......................Steel plate, sheet and strip

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BS 1615 ......................Method for specifying anodic oxidation coatings on aluminium and alloys

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BS 1706 ......................Electroplated coatings of cadmium and zinc on iron and steel

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BS 3083 ......................Hot-dip zinc coated and hot-dip aluminium/zinc coated corrugated steel sheets for general purposes BS 3987 ......................Anodic coatings on wrought aluminium architectural applications

of oxidation external

BS 4147 ......................Bitumen – based hot-applied coating material for protecting iron and steel, including suitable primers where required. BS 6497 ......................Powder organic coatings for application and stoving to hot dip galvanized hot-rolled steel sections and steel sheet for windows and associated external architectural purposes, and for the finish on galvanized steel sections and sheet coated with organic coatings. BS 7773 ......................Code of practice for cleaning and preparation of metal surfaces BS EN 10142 ..............Continuously hot- dip zinc coated low carbon steel sheet and strip for cold forming; technical delivery conditions BS EN 10143 ..............Continuously hot-dip metal coated steel sheet and strip-tolerances on dimensions and shape

QCS 2014

Section 17: Metalwork Part 02: Material Types and Finishes

Page 3

BS EN 10152 ..............Electrolytically zinc coated cold rolled steel flat products–Technical delivery conditions System Description

1

Materials and components used shall be as specified or be suitable equivalents as approved by the Engineer.

2

Materials not specified are to be of the best quality and suitable for the purpose intended and as approved by the Engineer.

3

All materials are to be free from any defect that may impair the strength, functioning, durability, or appearance of the work of this Section or of adjacent construction.

2.1.4

Metals

1

It is the responsibility of the Contractor to select the alloy, degree of alloy control, homogeneity, temper, metallurgical quality, degree of hardness or softness, mill tolerances, cutting tolerances and flatness required to achieve the requirements of design, quality, and colour matching of finish set forth in the Project Documentation.

2

Suitable low-friction separation materials shall be provided where metal materials are adjacent and subject by design to relative movement against one another. Suitable lowfriction separation materials are as follows:

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2.1.3

teflon strip, 750 microns thick and teflon tape, 125 microns thick

(b)

high-impact polystyrene

(c)

other materials as approved by the Engineer.

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Low-friction material shall be impervious to moisture.

2.2

PROTECTIVE TREATMENTS FOR METALS

2.2.1

General

1

Galvanized carbon steel (hot-dip) shall comply with the relevant provisions of BS 729, BS 1245, BS 6497, BS EN 10142, BS EN 10143.

2

Zinc-rich coating system shall comply with the relevant provisions of BS 3083, BS EN 10152

3

Nickel and chromium shall comply with the relevant provisions of BS 1224.

4

Zinc plating shall comply with the relevant provisions of BS 1706.

5

Aluminium/zinc-coating shall comply with the relevant provisions of BS 1615.

6

Bituminous paint shall comply with the relevant provisions of BS 4147.

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QCS 2014

Section 17: Metalwork Part 02: Material Types and Finishes

Page 4

ALUMINIUM FINISHES

2.3.1

General Requirements

1

The requirements and specification for finishes on aluminium as referred to in this Part shall comply with the following paragraphs.

2

Final colours will be selected by the Engineer from actual samples submitted by the Contractor.

3

Metal surfaces are to match the appearance, colour, and texture of samples submitted to and approved by the Engineer.

4

The Contractor shall submit a writing list of all aluminium products used in the Works. This list shall identify the location of each product and their finishes as per the following principal finishes:

(ii)

buffed

(iii)

directional textured

(iv)

non-directional textured.

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chemical finishes non-etched cleaned

(ii)

etched

(iii)

brightened

(iv)

chemical conversion coatings

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(i)

coatings

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as fabricated

(i)

anodic

(ii)

resinous and other organic coatings

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(b)

mechanical finishes:

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(a)

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(iii)

vitreous coatings

(iv)

electroplated and other metallic coatings

(v)

laminated coatings

5

All aluminium and aluminium alloy products used in the Works that are to be finished in a similar way shall be obtained from the same source unless otherwise approved by the Engineer.

6

All metal surfaces which are required by Project Documentation or manufacturer’s standards to receive a chemical conversion coat pre-treatment are to meet the minimum requirements of BS 3987 and BS 1615.

2.3.2

Finishes for Aluminium and Aluminium Alloys

1

Unless otherwise specified for one of the alternative finishes listed Clause 2.2.1 in the specific Project Documentation, the finish in general for aluminium shall be as follows:

QCS 2014

Page 5

Exterior exposed aluminium: All metal surfaces exposed to the exterior, including framing members, shall receive either a two or three coat polyvinyl di-fluorine (PVDF) liquid coating as follows: surfaces shall receive a thermally-cured, pigmented, PVDF coating system, containing not less than 70 % of the fluoropolymer resin

(b)

the coating system is to be spray applied under factory conditions to a pre-treated base metal in a two-coat, two-bake process or three-coat, three-bake process in accordance with the coating system manufacturers recommendations

(c)

unless otherwise stated in the Project Documentation, the coating system shall include a primer for added substrate protection as recommended by the manufacturer to meet any coating system guarantees

(d)

finished coating thickness is to be minimum of 55 microns dry film finish (18 microns primer, 18 microns colour coat, and 18 microns clear top coat to seal and protect the system). The final dry film thickness shall be 55 to 65 microns

(e)

the coating system is to be applied by a licensed applicator approved by the coating system manufacturer. The applicator is to propose a program of records and samples are to be made available to the Engineer upon request

(f)

the surface quality of the coating is to be smooth and free of flow lines, streaks, blistering, and other imperfections. The coating will be opaque and be uniform in colour and tonality, within the range of approved upper and lower limit samples when viewed under a uniform light source such as north daylight or light source approved by the Engineer

(g)

prior to production coating, the Contractor is to present for approval full-size extrusions and sample panels representative of the maximum proposed range of colour and tonality to be expected in the finished work. The number of full-size sample panels for each coating colour is to be as approved by the Engineer

(h)

to assure consistency of paint colour and tonality in the finished work, the Contractor should propose and implement a quality control program as approved by the Engineer. The quality control program is to be vertically integrated, and include controls by the coating manufacturer and applicator, as well as by the Contractor during assembly and installation of the finished work

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(a)

if required, the quality control program will include the use of co-ordinated empirical inspection methods, such as the use of calibrated multi-angle spectrophotometers to provide 3 independent checks of paint colour and tonality at the point of paint application, during assembly, and during installation

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(j)

no production coating application is to commence prior to approval of this quality control program, any installed work with coating defects or variation in colour or tonality in excess of the approved sample range will be subject to rejection

(k)

the colour and finish are subject to the sample approval procedures specified herein and shall include: (i)

surface exposed to view

(ii)

concealed surfaces

(l)

provide a compatible field touch-up PVDF coating system formulated for air-drying at ambient temperature.

(m)

the organic coating shall not peel, check, crack, chalk or change

QCS 2014

Page 6

Interior used aluminium: All surfaces exposed to the interior and not exposed to the exterior shall receive a high-performance acrylic enamel organic non-metallic coating as follows: the coating is to be spray applied under factory conditions to pre-treated base metal in a one-coated process in accordance with the coating system manufacturer’s recommendations

(b)

unless otherwise stated in the Project Documentation, the coating system shall include a primer for added substrate protection as recommended by the manufacturer to meet any coating system guarantees

(c)

the finished coating thickness shall be a minimum of 25 microns dry film thickness (typical) unless otherwise approved by the Engineer

(d)

the coating system to be applied by a licensed applicator approved by the coating system manufacturer. The applicator is to propose a program of records and samples of the entire coating production for approval by the Engineer, and which records and samples shall be made available to the Engineer upon request

(e)

the surface quality of the coating shall be smooth and free of flow lines, streaks, blistering or other imperfections. The coating is to be opaque and be uniform in colour and tonality; within the range of approved upper and lower limit samples when viewed under a uniform light source such as north daylight or light source approved by the Engineer

(f)

prior to production coating the Contractor will present for approval full-size extrusions representative of the maximum proposed range of colour and tonality to be expected in the finished work.

(g)

to assure consistency of paint colour and tonality in the finished work, the Contractor should propose and implement a quality control program as approved by the Engineer. The quality control program to be vertically integrated, and include controls by the coating manufacturer and applicator, as well as by the Contractor during assembly and installation of the finished work. If necessary, such a quality control program is to include the use of co-ordinated empirical inspection methods, such as the use of calibrated multi-angle spectro-photometers to provide 3 independent checks of paint colour and tonality at the point of paint application, during assembly, and during installation.

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(a)

no production coating application should commence prior to approval of this quality control program by the Engineer. Notwithstanding the implementation of an approved quality control program, any installed work with coating defects or variation in colour or tonality in excess of the approved sample range will be subject to rejection

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(i)

the colour and finish are subject to the sample approval procedures specified herein and are to include a one-coat acrylic enamel to match Engineer’s sample

(j)

provide a compatible field touch-up acrylic enamel coating system formulated for airdrying at ambient temperature in a colour to match the factory applied finish

(k)

the organic coating shall not peel, check, crack, chalk or change colour for a period of 5 years from the completion of the Project.

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Page 7

2.3.3

Storage and Handling of Materials

1

Material shall not be shipped, delivered or supplied when the finish of such material: (a)

has not been inspected and tested in the manner and by the means specified above and as approved

(b)

does not meet all the specifications for the finishes set forth in the alloy manufacturer’s instructions

(c)

does not fall within the colour and tonality range approved by the Engineer

(d)

has been rejected by the Engineer

(e)

has not otherwise been processed in accordance with the specified requirements.

Protection of Aluminium. All aluminium surfaces in contact with blockwork, concrete, render or other alkaline materials shall be coated with two coats of black bitumen solution or similar approved protective coating. Alternatively, shims of fibre, neoprene, or other materials which will not interact with the aluminium or other adjacent materials may be provided and gaps filled with backer rod and sealant as approved by the Engineer.

2.4

CARBON STEEL FINISHES

2.4.1

General

1

Requirements and specification for finishes on carbon steel as referred to this Section shall comply to the following:

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all surfaces of steel members incorporated in Works shall be finished as required in this Section

(b)

if concealed from view, steel surfaces are to receive a finish in accordance with Section 16, Structural Steel, and Section 26 Painting

(c)

if exposed to view, steel surfaces are to receive the following coating system:

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surface preparation: BS 7773

(ii)

primer: fast curing epoxy primer coat

(iii)

intermediate coat: high-build epoxy-polyamide paint

(iv)

top coat: aliphatic acrylic polyurethane finish system.

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2.4.2

Painted Steel

1

The Contractor will propose and implement a quality program for approval by the Engineer. The quality control program is to be vertically integrated, and include controls by the steel fabricator and the steel finisher, as well as by the Contractor to provide independent checks of steel quality and finish at the point of fabrication, finishing, and during installation.

2

Preparation of steel shall be as follows: (a)

steel received from the mill will be inspected for any defects or damage which could adversely affect the fabrication and finishing of the steel. All steel members are to be blast cleaned prior to final fabrication and assembly

QCS 2014

Page 8

all fabrication is to be done prior to finishing. All welds are to be ground smooth and finished to match adjacent surfaces, all burrs and foreign particles removed, and any other defects remedied prior to finishing

(c)

prior to finishing all fabricated steel is to be inspected and if, in the determination of the coating applicator, the steel is not sufficiently cleaned to ensure a high-quality finish, the steel is to be further cleaned as required to achieve the finish desired.

(d)

verify that all surfaces to be painted are dry, clean and free of dust, dirt, oil, wax, grease, or other contaminants

(e)

after steel members are installed, inspect steel for damage and staining. Repair or replace damaged members. All repair procedures are subject to approval by the Engineer who will have the right to reject any installed work notwithstanding any rededication procedures instituted.

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(b)

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Painting applications shall be as follows:

steel is to be shop-painted with one coat of fast-curing epoxy primer and one coat of epoxy intermediate coat as specified herein. The epoxy primer coat is to be in a contrasting colour from the epoxy intermediate coat

(b)

all steel to be painted in accordance with the recommendations of the coating manufacturer

(c)

mix and apply all coatings in accordance with paint manufacturer’s recommendations. Apply paint only under the climatic conditions recommended by paint manufacturer

(d)

check dry film thickness after application of each coat in accordance with the recommendations of the manufacturer

(e)

inspect finished steel members thoroughly prior to shipping to the Site. Package, ship, store and protect primed steel prior to installation

(f)

prior to application of the finish coat, inspect the primed substrates for any defects or conditions which may affect the application and quality of the finish coat

(g)

spray or roller apply the finish coating in accordance with paint manufacturer’s recommendations. If roller applied, finish coat is to be rolled in one direction; avoid backrolling of any kind. Avoid combining application procedures; all surfaces are to be rolled or all surfaces are to be sprayed

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(h)

the surface quality of the coating is to be smooth and free of flow lines, sags, dry spray, overspray, imbedded particles, and other imperfections

(i)

the coating is to be opaque and uniform in colour and tonality when viewed under a uniform light source such as north daylight. Inspection shall be by visual comparison with previously approved range samples and if necessary, include the use of coordinated empirical inspection methods, such as the use of calibrated multi-angle spectrophotometers.

2.4.3

Stainless Steel Finishes

1

Stainless steel finishes as referred to in this Section shall comply with the following.

2

Stainless steel shall comply with BS 1449 Part 2.

QCS 2014

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Section 17: Metalwork Part 02: Material Types and Finishes

Page 9

Unless otherwise specified in the Project Documentation, the quality of metal work components manufactured from stainless steel shall comply with the following: (a)

externally

Type 316

(b)

internally

Type 304

Unless otherwise specified in the Project Documentation, the finish of metal work components manufactured from stainless steel shall comply with the following: (a)

non visible surfaces

2D mill finish (e.g., roof flashings)

(b)

visible surfaces

3B brush polished finish.

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The finish is to be uniform and free from blemishes, scratches, and other defects. Notwithstanding the above, the finish shall be appropriate for its function and selected so as not to invalidate its warranty. The grain of stainless steel and brushed finishes are to run in the same direction for contiguous or adjacent components.

6

For special applications (e.g. use in swimming pools or in environments where exposure to chemicals may occur), the usage of stainless steel type shall be as stated in the Project Documentation.

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END OF PART

QCS 2014

Section 17: Metalwork Part 03: Metal Doors and Windows

Page 1

3

METAL DOORS AND WINDOWS ................................................................. 2

3.1

ALUMINIUM DOORS AND WINDOWS ......................................................... 2

3.1.1 3.1.2 3.1.3

Scope of Work References Detailed Specification

3.2

FLYSCREENS ............................................................................................... 4

3.3

AUTOMATIC BI-PARTING DOOR OPERATORS ......................................... 4

3.3.1 3.3.2 3.3.3 3.3.4 3.3.5

General Requirements Safety Control Logic Drive System Track Fail Safe

3.4

FIXING ALUMINIUM WINDOWS AND DOORS ............................................ 5

3.4.1

General Requirements

3.5

STEEL DOORS AND WINDOWS ................................................................. 6

3.5.1 3.5.2 3.5.3

General Requirements Steel Doors and Frames Steel Windows

3.6

INSTALLATION OF STEEL DOOR FRAMES ............................................... 7

3.6.1

General Requirements

3.7

ROLLER SHUTTER FIRE DOORS ............................................................... 7

3.7.1 3.7.2 3.7.3

General Components Electrically Operated Doors

3.8

INSTALLATION ........................................................................................... 10

3.8.1

General Requirements

3.9

SUBMITTALS .............................................................................................. 10

3.9.1

General Requirements

4 4 4 5 5 5 6 6 7 7

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Section 17: Metalwork Part 03: Metal Doors and Windows

Page 2

3

METAL DOORS AND WINDOWS

3.1

ALUMINIUM DOORS AND WINDOWS

3.1.1

Scope of Work

1

This Part provides specification for supply and installation of steel and aluminium doors and windows.

2

Windows and doors are collectively referred to as “units” in this Section.

3

Related Sections and Parts are as follows: General Materials Classification Workmanship

Section 1 Section 16 Section 18 Section 25

General Structural Metalwork Carpentry, Joinery and Ironmongery Glazing

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This Section Part 1 Part 2 Part 6

References

1

Standards referred to in this Part are as follows:

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BS 476........................Fire tests on building materials and structures BS 729........................Hot dipped galvanized coatings on iron and steel articles

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BS 990........................Steel windows generally for domestic and similar buildings

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BS 1245......................Metal door frames BS 1282......................Guide to the choice, use and application of wood preservatives

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BS 1449......................Steel plate, sheet and strip.

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BS 1474...................... Wrought aluminium and aluminium alloys for general engineering purpose bars, extruded round tubes and sections

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BS 3987......................Anodic oxide coatings on wrought aluminium for oxidation external architectural applications BS 4254......................Two-part polysulphide-based sealants BS 4255......................Rubber used in pre-formed gaskets for weather exclusion from buildings BS 4873......................Aluminium alloy windows BS 5368......................Method of testing windows BS 5707......................Solutions of wood preservatives in organic solvents BS 6213......................Guide to selection of constructional sealants BS 6375......................Performance of windows BS 6496......................Powder organic coatings for application and stoving to aluminium alloy extrusion, sheet and pre-formed sections for external architectural purposes, and for the finish on aluminium alloy extrusions, sheet and pre-formed sections coated with organic coatings BS 6510......................Steel windows, gills windows boards, and doors

QCS 2014

Section 17: Metalwork Part 03: Metal Doors and Windows

Page 3

BS 7036......................Code of practice for provision and installation of safety devices for automatic power operated pedestrian door systems BS EN 485..................Aluminium and aluminium alloys - Sheet, strip and plate BS EN 10142..............Continuously hot-dip zinc coated low carbon steel sheet and strip for cold forming: technical delivery conditions NFPA 80 .....................Standard for Fire Doors and Fire Windows Detailed Specification

1

Alternative alloys may be used where integral colour anodising is required provided the physical properties of the alloy meet relevant BS Standards for the specific material.

2

All screws, nuts bolts, reverts, washers and other fastenings are to be aluminium or stainless steel (Type 316 S16).

3

The units are to be fabricated at the manufacturer’s works as far as possible and delivered complete and ready for installation. Aluminium windows shall be to BS 4873, BS 1474, BS 3987, BS 6496, and BS EN 485.

4

The overall sizes of assembled units are to be maintained within a tolerance of ± 1.5 mm. Frame assemblies to be square with a maximum difference in the diagonals of 4 m.

5

The finished units to be free from all sharp edges, burrs and the like.

6

Joints in frames are to be made by screw spleen, shear block or other approved system capable of accommodating the thermal movement of the unit and providing tightly fitting and inconspicuous joints.

7

The main web of the aluminium outer frame should not be less than 1.2 mm thick. Frames to be self-draining and no holes for fastenings are to be located in the external channel at sill level.

8

All opening units are to be fully weather stripped using siliconized woven polypropylene, wool pile or neoprene retained in dovetailed or undercut grooves formed in the aluminium extrusions. The weather-stripping should be capable of being removed without disturbing the glazing system and without removing the outer frame from the structure.

9

The design of the units should permit re-glazing without the need to remove the outer frame from the structure.

10

All hardware is to be supplied and fixed by the unit manufacturer, and should match the finish of the surfaces of the units and be replaceable without removing the outer frame from the structure. Fasteners are to be designated so that they cannot be released from the outside by the insertion of a thin blade or other simple tool.

11

Windows are to meet the performance requirements of severe exposure to wind. Horizontal sliding units are to be supported on rustproof and dustproof bearing devices that may easily be repaired or replaced and that prevent contact between the unit and the track. Horizontal and vertical sliding units to be separated and not slide upon each other.

12

The mechanism for vertical sliding windows is to be accessible for adjustment, repair or replacement after the windows have been installed.

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3.1.3

QCS 2014

Section 17: Metalwork Part 03: Metal Doors and Windows

Page 4

No window is to be openable or removable from the outside when it is fastened in a closed position except by the use of special tools or by breaking part of the window or door.

14

All opening windows are to be fitted with flyscreens.

15

All unit surfaces which will be visible in the finished work are to be protected after manufacture by low tack tape or other suitable means capable of being removed after exposure to the high temperatures prevalent in Qatar to leave clean, undamaged surfaces.

16

Sill frames to slope outward (level frames are not allowed).

17

Weepholes where required are to be as detailed in the shop drawings

3.2

FLYSCREENS

1

Flyscreens are to be fabricated in accordance with Clause 3.1.3.

2

The frames to be fabricated from substantial, rigid sections and be easily removable from the window to permit maintenance, cleaning and repair. The frames are to allow the replacement of the mesh and be finished (anodised, powder coated, etc.) to match the windows in which they will be fitted.

3

The frames are to be infilled only with 0.4 mm aluminium wire woven to a 1.5 mm mesh, stretched tightly and evenly, and be free from visible joints.

3.3

AUTOMATIC BI-PARTING DOOR OPERATORS

3.3.1

General Requirements

1

Automatic bi-parting door operators are to be approved 240 V/50 Hz fully electric operators, fully housed in extruded aluminium or stainless steel housing.

3.3.2

Safety Control Logic

1

The equipment is to incorporate the following safety control logic:

auto retry (three times) at safety “creep” speed (1/3 speed) to detect obstruction.

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(b)

automatic reversing if obstructed during the closing sequence (fully adjustable sensitivity).

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(c)

auto revert to normal mode after successful retry.

(d)

fully adjustable speed control with independent settings for Opening, Closing, Final Opening, Final Closing.

(e)

auto stop if obstructed during opening sequence (fully adjustable sensitivity).

3.3.3

Drive System

1

The equipment is to incorporate the following drive system: (a)

squirrel cage motor with output shaft and gearbox drive shaft shall use constant rated 7 kg torque capacitor for start and run. No intermediate belts, pulleys and couplings which are subject to failure, breakage, shearing or loss of tension shall be used

(b)

thermal protection: the motor must be able to be held in the stalled position indefinitely under full electric current without resultant damage to the windings

QCS 2014

Section 17: Metalwork Part 03: Metal Doors and Windows

Page 5

(c)

chain drive with minimum tensile strength of 1,950 kg and 12.5 mm pitch, directly connected to door leaf carriage assemblies. Chains or belts of lesser tensile strength will not be permitted

(d)

auto re-close circuitry to ensure doors close if partially opened (i.e. high wind condition)

(e)

self lubricating planetary gearbox with spiral bevel drive.

Track

1

The track is to be replaceable, made of extruded aluminium, hard coat anodise, carrying adjustable hanger bars supported by fully sealed raced fibber glass reinforced track wheels (min 50 mm diameter) for smoother wear and increased life.

3.3.5

Fail Safe

1

Depending on the location of doors the following systems shall be used:

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3.3.4

bi-parting doors to exterior: doors drive fully open automatically on power failure/fire alarm. Fail-safe shall consist of a 12v DC/110 vac inverter also incorporating battery alarm/monitory to alert user if power is low. Doors automatically return to original function mode when power is returned or fire signals are de-activated

(b)

bi-parting doors within building which serve to Section off or divide fire zones:

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(a)

doors to close under power failure/smoke alarm

(ii)

continuous operations under power failure (min. 50 operations required)

(iii)

to be operable manually.

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(i)

FIXING ALUMINIUM WINDOWS AND DOORS

3.4.1

General Requirements

1

Windows are to be fixed with sufficient fastenings to comply with Clause 3.1.3, and in no case will the number be less than the minimum specified in BS 6510 for the nearest applicable co-ordinating size.

2

All units are to be fixed square, level and plumb without distortion.

3

Where the method of fixing is be screw fastenings direct to concrete or blockwork surrounds, the screws are to extend a minimum of 25mm into the reveal and the plugs be of proprietary manufacture sized to suit the screw. Wooden plugs will not be permitted. Holes in the frames are be predrilled and the screws countersunk so as to avoid scratching, gouging or locally distorting the frame.

4

Frames are to be protected from alkaline materials in accordance with Clause 2.2.1 or by approved isolating tape.

5

Timber sub-frames to be treated in accordance with BS 1282 and to meet specified requirements of BS 5707. Treatment certificates to be submitted to the Engineer.

6

Timber sub-frames to be primed or sealed before the installation of the units.

7

Joints between the frames of external units and the surrounding construction are to be sealed in accordance with BS 6213 BS 4254 and Clause 2.2.1 in such a way as to form a complete weatherproof seal between the frame and the surround. The sills of sliding doors are to be bedded in mastic. Rubber used in pre-formed gaskets for weather exclusion to the building shall be to BS 4255.

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3.4

QCS 2014

Section 17: Metalwork Part 03: Metal Doors and Windows

Page 6

After installation all opening units to be eased and adjusted to provide free operation and all moving parts are to be lubricated.

3.5

STEEL DOORS AND WINDOWS

3.5.1

General Requirements

1

Steel doors and frames shall comply with the provisions of BS 1245 and steel windows and frames shall comply with the provisions of BS 990.

3.5.2

Steel Doors and Frames

1

The specification for proprietary steel doors shall be as follows unless otherwise specified in the Project Documentation.

2

All steel doors shall be manufactured in properly equipped workshops by tradesmen proficient in such work. All machinery employed shall be capable of accurately preparing, producing and finishing doors

3

The door shall be finished, 45 mm or 55 mm thick of double skinned, insulated sheet steel construction and shall be fabricated from two zink coated steel sheets not less than 1.6 mm thick with lock seam joints at sides. The door faces shall be free of seams or joints. Top and bottom of the doors shall be either welded flush or closed with recessed spot-channel closures. The doors shall be provided with continuous welded “U” shaped reinforcing channels to head and foot. Door construction shall be one of the following:

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not less than 1mm steel interlocking vertical channels of “Z” shaped members spaced not more than 300 mm apart or horizontal channels not more than 350 m apart

(b)

not less than 1 mm steel horizontal “U” shaped sections spaced in parallel rows not over 220 mm on centre welded in alternating sequence to the inside face of each outer sheet so that horizontal stiffening occurs approx

(c)

a continuous truss-formed inner core of not less than 1 mm sheet metal spot-welded to the face sheet every 70 mm horizontally and vertically over the entire surface of both sides.

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(a)

The doors shall be insulated with mineral wool or pressure injected polyurethane foam for sound and thermal insulation.

5

Doors clearance shall not exceed the following:

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(a)

3mm at jamb and heads

(b)

3 mm at meeting stile of pair doors with round or bevelled edges and 6 mm for doors with square edges

(c)

3mm at bottom measured from finished floor line.

6

Doors shall be provided with a sound deadening material to eliminate sound incident to the normal operation of the door as necessary or required by the Engineer.

7

The finished work shall be rigid, neat in appearance and free from defects, warp, or buckle. Moulded members shall be sharp in detail, straight, and true. Corner joints shall be coped or mitered, well-formed, in true alignment, welded and cleaned off.

8

Spot welding shall be used where practicable. Construction joints shall be welded along their full length. Exposed welded joints shall be cleaned off and dressed smooth.

9

The doors shall be suitably reinforced, morticed and tapped to receive all ironmongery.

QCS 2014

Section 17: Metalwork Part 03: Metal Doors and Windows

Page 7

Steel doors shall be finished as detailed in the Project Documentation. They shall be cleaned, filed, ground smooth and either painted with one coat of redhead primer prior to the finished painting or stove enamelled to a colour chosen by the Engineer.

11

Door frames are to be formed of not less than 1.2 mm nominal thickness mild steel hot dip galvanized after manufacture or, alternatively, may be made from hot dip galvanized steel sheet complying with BS EN 10142.

12

Door frames shall be given primer coat and finish as specified for the matching steel doors.

13

Where frames support door leaves in excess of 60 kg require one-hour fire resisting door assemblies, the minimum steel thickness is to be increased to 1.6 mm.

3.5.3

Steel Windows

1

Steel windows shall be constructed and assembled in accordance with the specification for proprietary steel windows shall be as detailed in the Project Documentation. In addition, steel windows shall comply with the provisions of BS 5368 and BS 6375 for testing and performance.

2

Steel windows and frames shall be manufactured in properly equipped workshops by tradesmen proficient in such work. All machinery employed shall be capable of accurately preparing, producing and finishing window frames.

3

Steel windows and frames made of hot dip galvanised steel shall additionally conform to BS 729.

4

Steel windows shall be finished as shown in the Project Documentation. They shall be cleaned, filed, ground smooth and either painted with one coat of redhead primer prior to the finished painting or stove enamelled to a colour chosen by the Engineer

3.6

INSTALLATION OF STEEL DOOR FRAMES

3.6.1

General Requirements

1

Frames will be fixed plumb, level and securely to prevent deflection or movement.

2

Frames built-in as the surrounding structure is constructed are to be fixed with cramps at maximum 600 mm centres. One cramp is to be located 200 mm from the bottom of the frame and 200 mm from the top or at the nearest adjacent bed joint. Voids in the backs of frames are to be filled in solid with grout as the work proceeds.

3

Frames which are to be built-in are to be braced with temporary struts to prevent distortion. Base ties to be removed after the blockwork has set and before the floor finish is laid.

4

Frames to previously prepared openings are to be fixed with screw fastenings extending into the structural reveal at least 40 mm and at maximum 450 mm centres. One fastening to be located 200 mm from the bottom of the frame and one 200 mm from the top.

3.7

ROLLER SHUTTER FIRE DOORS

3.7.1

General

1

Operation of rolling shutter fire doors shall be manual (push up, chain hoist or waist high crank hoist) or motor operated as stated in the Project Documentation.

2

Mounting of door shall be either interior face mounted on a prepared opening or interior mounted between jambs and under a lintel in a prepared opening.

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QCS 2014

Section 17: Metalwork Part 03: Metal Doors and Windows

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3

Fire rating of doors to be 3 hours rated sized in accordance with BS 476, the Project Documentation and tested and approved by the Civil Defence Department.

4

Automatic Closing. To be fitted with an automatic closing device, triggered by a closing mechanism by melting of a fusible link at 71 ºC unit to be in operative during normal operations. The release mechanism to be easily reset. Smoke detection is also to be fitted to the release device.

5

Quality Assurance furnish each overhead roller shutter door as a complete unit produced by one manufacturer, including hardware, accessories, mounting and installation of components.

(b)

inserts and anchorages: Furnish inserts and anchoring devices to be set in concrete or built into masonry to install units. Provide setting out drawings, templates, instructions, and directions to install the anchorage devices.

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(a)

Components

1

The shutter door panel or curtain shall include at minimum the elements as follows:

(b)

each end of the slats to be fitted with malleable iron end locks, continuous, to act as wearing surface in the guides to maintain slat alignment and to prevent flame passage

(c)

the curtain shall be reinforced with a stainless steel or galvanized steel bottom bar of two (2) angles. Lift handles to be provided on both sides of the door.

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slats, formed in continuous lengths of stainless steel to BS 1449 or galvanized steel

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The spring counter balance shall comply with the following: the counter balance shall be housed in a steel pipe of diameter and wall thickness to restrict maximum defection to 2.5 mm/m of door width

(b)

springs shall be the helical torsion type designed to include an over load factor of 25 % and for optimum ease of operation. Springs to be grease packed and mounted on a cold rolled steel inner shaft

(c)

spring tension shall be adjustable from outside of end bracket plate

(d)

ball bearings shall be sealed to minimise wear of pipe rotation around inner shaft

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(a)

Bracket plates shall comply with the following:

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3.7.2

(a)

plates are to be made of stainless or galvanized steel thickness 6.35 mm carrying a pipe counter balancing shaft to house ends of door coil

(b)

the drive end bracket plate shall be fitted with a sealed ball bearing

(c)

the door shall be equipped with an oscillating governor as required to control the speed of descent.

4

Guides/wall angles shall be stainless or galvanized steel angles of 4.76 mm minimum thickness.

5

Hoods to house the coil are to be fabricated of stainless or galvanized steel.

6

Locking shall one of the following as stated in the Project Documentation: (a)

slide bolts - on bottom bar or manual push up, suitable for pad locks

(b)

hand chain lock - locking bracket to be provided on guide angle

(c)

locking disc - to be provided on crank box of crank hoist

QCS 2014

(d) 7

Section 17: Metalwork Part 03: Metal Doors and Windows

Page 9

integral gearing - on motor to provide locking of door.

The finish on galvanized surfaces shall be as follows: (a)

baked on coat of epoxy modified polyester on slabs and hood

(b)

shop coat of rust inhibiting metallic primer on all remaining ungalvanized surfaces, except bearings.

Electrically Operated Doors

1

Electric door operators shall conform to BS 7036

2

Unless otherwise indicated as having manual operation, provide electric operators for doors. Provide an electric door operator assembly of size and capacity recommended and provided by the door manufacturer, complete with electric motor and factory-prewired motor controls, gear-reduction unit, solenoid-operated brake, remote control stations, control panels conduit and wiring from controls to motor and central stations, and accessories required for proper operations

3

Disconnect mechanism - provide a hand operated disconnect or a mechanism for automatically engaging a sprocket-and-chain operated and releasing brake for emergency manual operation. Mount disconnect and operator so they are accessible from floor level. Include interlock device to automatically prevent motor from operating when emergency operator is engaged

4

Door operator type - provide a wall or bracket-mounted door operator units consisting of electric motor, worm gear drive from motor to reduction gear box, chain or worm gear drive from a reduction box to a gear wheel mounted on a counterbalanced shaft, and a disconnect release for manual operation. Provide a motor and drive assembly of horsepower and design as determined by the door manufacturer to the size of door required. The operator shall be designed so that motor may be removed without disturbing the limit-switch adjustment and without affecting the emergency auxiliary operator

5

Electric motors - provide high-starting torque, reversible, Class A insulated electric motors with overload protection. Size the motor to move the door in either direction, from any position, at not less than 0.2 m nor than 0.3 m per second. The wiring requirement and current characteristics of the motors shall be co-ordinated with the building electrical system. Supply totally enclosed, fan-cooled type motors, fitted with a plugged drain.

6

Remote control station - provide a momentary contact, three button control station with pushbutton controls labelled “Open”, “Close”, and “Stop”. Supply a keyed lockout feature with a key cylinder masterkeyed to the building system. Provide interior units with a fully guarded, surface-mounted, heavy-duty, general purpose NEMA type 1 enclosure

7

Automatic reversing control - supply each door with an automatic safety switch, extending the full width of the door bottom, and located within neoprene or rubber astragal mounted to bottom of the door rail. Contact with switch before closing will immediately stop downward travel and reverse direction to a fully opened position. Connect to control circuit through retracting safety cord and reel, or self-coiling cable. Provide electrically actuated automatic bottom bar. Ungalvanized or non stainless steel surfaces to be coated with rust inhibiting metallic primer on exposed ferrous surfaces, except bearings

8

Fail safe - depending on the location of doors the below systems shall be used for circumstances as follows:

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3.7.3

(a)

bi-parting doors to exterior: doors drive fully open automatically on power failure/fire alarm. Fail-safe shall consist of a 12 V DC/110 V AC inverter also incorporating battery alarm/monitory to alert user if power is low. Doors automatically return to original function mode when power is returned or fire signals are de-activated

QCS 2014

(b)

Section 17: Metalwork Part 03: Metal Doors and Windows

Page 10

bi-parting doors within building which serve to section off or divide fire zones: (i)

doors to close under power failure/smoke alarm

(ii)

continuous operations under power failure (min. 50 operations required)

(iii)

to be operable manually

INSTALLATION

3.8.1

General Requirements

1

Installation of units shall be undertaken by the manufacturer’s authorised representative and in accordance with manufacturer’s standards and instruction.

2

Installation shall comply with the latest NFPA 80.

3

After installation, doors are to be tested with multiple closing/opening and witnessed for normal operation.

3.9

SUBMITTALS

3.9.1

General Requirements

1

Provide product data, roughing-in diagrams, and installation instruction for each type and size of overhead coiling door

2

Provide operating instruction and maintenance information

3

Provide information describing fire release system including electrical rough-in instruction.

4

Provide shop drawings for special components and installation that are not dimensioned or detailed in manufacturer’s data sheet.

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3.8

END OF PART

QCS 2014

Section 17: Metalwork Part 04: Architectural Metal Work

Page 1

4

ARCHITECTURAL METAL WORK ............................................................... 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2

Scope References

4.2

HANDRAILS AND BALUSTERS ................................................................... 2

4.2.1 4.2.2 4.2.3

General Requirements Expansion Fitting and Fixing

4.3

DOWNPIPES AND GUTTERS ...................................................................... 4

4.3.1

General Requirements

4.4

FINISHES ...................................................................................................... 4

4.4.1

General Requirements

2 2

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Section 17: Metalwork Part 04: Architectural Metal Work

Page 2

ARCHITECTURAL METAL WORK

4.1

GENERAL

4.1.1

Scope

1

This Part provides specification for miscellaneous types of metal work not included elsewhere.

2

Related Sections and Parts are as follows:

Section 1 Section 13 Section 16

General Masonry Structural Metalwork

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General Material Types and Finishes Workmanship

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4

References

1

The following standards are referred to in this Part:

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4.1.2

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BS 729 ........................Hot dip galvanized coatings on iron and steel artivles

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BS 970 ........................Wrought steels for mechanical and allied engineering purposes

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BS 1387 ......................Screwed and socketed steel tubes and tubulars and plain end steel tubes suitable for welding or for screwing to BS 12 threads

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BS 1471 ......................Wrought aluminium and aluminium alloys for general engineering purposes

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BS 1473 ......................Wrought aluminium and aluminium alloys for general engineering purposes - forging stock

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BS 1474 ......................Wrought aluminium and aluminium alloys for general engineering purposes- bars, extruded round tubes and sections

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BS 1490 ......................Aluminium and aluminium alloy ingots and castings for general engineering purposes BS 1615 ......................Method for specifying engineering purposes

adonic

oxidation

coatings

for

general

BS 2997 ......................Aluminium rainwater goods BS 4360 ......................Weldable structural steels BS 6180 ......................Protective barriers in and about buildings BS 6323 ......................Seamless and welded steel tubes for automobile, mechanical and general engineering purposes

4.2

HANDRAILS AND BALUSTERS

4.2.1

General Requirements

1

Protective handrails and balusters shall be 1100 mm high and shall comply with the provisions of BS 6180 for Building.

QCS 2014

2

Section 17: Metalwork Part 04: Architectural Metal Work

Page 3

Handrails and balusters shall be manufactured from material complying with the relevant provisions of the appropriate British Standard, as set out in Table 4.1. Table 4.1 Materials for Handrails and Balusters Material

Handrails Solid

Tubular

Solid

Tubular

BS

Grade

BS

Grade

BS

Grade

BS

Grade

4360

43A

1387

-

4360

43A

1387

-

-

or 6323 Pt 2

HFW2

HFW2

970 Pt 2

316S3 1

6323 Pt 8

LW17K M

970 Pt 1

316S3 1

6323 Pt 8

LW17K M

Aluminium

1474

6082

1474

6082

1490

LM6

1474

6082

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Stainless Steel

6082

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1471

6323 Pt 2

.

-

or

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Mild Steel

Balusters

-

or 1471

6082

After manufacture, mild steel and aluminium balusters shall be hot dip galvanized or anodised, as appropriate, in accordance with BS 729 or BS 1615, Grade AA25.

4.2.2

Expansion

1

Expansion joints shall be provided in horizontal members where required by design.

2

Expansion joints shall also be provided where the handrail or balustrade coincides with an expansion joint in the structure to which it is fixed.

3

Expansion joints shall be as detailed in the Project Documentation.

4.2.3

Fitting and Fixing

1

Mortises in concrete or blockwork to receive handrails and balustrades are to be formed as follows:

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(a)

with a minimum distance of 50 mm between the outer edge of the mortise and the outer edge of the concrete of blockwork excluding any finishing materials.

(b)

to the same shape as the handrail or balustrades allowing for a minimum clearance all round of 13 mm, e.g., a 51 mm diameter hole for a 25 mm diameter standard.

(c)

to allow a minimum fixed depth of 100 mm in the concrete or blockwork excluding any finishing material.

2

Mortises are to be thoroughly cleaned and wetted and made good with Class M5 mortar in accordance with Part 2 of Section 13, well compacted around the member being fixed

3

The handrail or balustrades should be securely located in position, true to line and level until the fixings have attained full strength.

QCS 2014

Section 17: Metalwork Part 04: Architectural Metal Work

Page 4

Handrails and balustrades are not to be fixed to concrete or blockwork by means of screw fastenings. Drilled bolt anchorages and similar dry fixings may only be used with the approval of the Engineer and shall comply with the relevant provisions of BS 1473.

5

After installation handrails and balustrades are not to be used as strutting or supports for other work and shall be wrapped with polythene sheet or similar, securely taped to protect the finished work until completion.

4.3

DOWNPIPES AND GUTTERS

4.3.1

General Requirements

1

Aluminium rainwater items such as gutters, downpipes and outlets shall comply with the relevant provisions of BS 2997.

2

Rainwater items made of materials other than aluminium shall be as specified in the Project Documentation.

4.4

FINISHES

4.4.1

General Requirements

1

Finishes for metals covered in this Part shall be as detailed in Part 2 of this Section unless described otherwise.

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END OF PART

QCS 2014

Section 17: Metalwork Part 05: Light Metal Support and Cladding System

Page 1

5

LIGHT METAL SUPPORT AND CLADDING SUPPORT ............................... 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2

Scope References

5.2

PERFORMANCE REQUIREMENTS ............................................................. 2

5.2.1

General Requirements

5.3

COMPONENTS ............................................................................................. 3

5.3.1

General Requirements

2 2 2

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Section 17: Metalwork Part 05: Light Metal Support and Cladding System

Page 2

LIGHT METAL SUPPORT AND CLADDING SUPPORT

5.1

GENERAL

5.1.1

Scope

1

This Part, which provides reference of specification for metal light weight cladding and support framing, is to be used in conjunction with Part 4 of Section 25, Glazed Curtain Walling.

2

Related Parts and Sections are as follows:

Section 1 Section 16 Section 25

General Structural Metalwork Glass and Glazing

.l. l

General Material Types and Finishes Workmanship

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.

5

References

1

The following standards referred to in this Section:

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BS 5368 ......................Method of testing windows BS 6375 ......................Performance of windows

PERFORMANCE REQUIREMENTS

5.2.1

General Requirements

1

Performance of individual and aggregate components of the Work of this section are to be designed, fabricated, assembled, transported, installed and protected so that that no evidence of the following will be apparent, visually or measurable, when Work of this Section is subject to the pressures, loads, temperatures, and conditions specified.

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(a)

damage of any kind

(b)

deflections as specified in the project specification

(c)

panel flatness in excess of that specified herein

(d)

offset from the true alignment between consecutive components in line in excess of 1.0 mm in 6 metres

(e)

water Infiltration in accordance with BS 5368, Part 2

(f)

air Infiltration in accordance with BS 5368, Part 3 and BS 6375

(g)

colour variation in accordance with Part 2 of this Section

(h)

oil canning: panel surfaces are to remain flat without noticeable (detectable) oil canning or surface deformation.

QCS 2014

Section 17: Metalwork Part 05: Light Metal Support and Cladding System

Page 3

5.3

COMPONENTS

5.3.1

General Requirements

1

Components are to be manufactured from extruded or sheet aluminium, unless otherwise indicated. Substitutions for aluminium may be considered only for such components that are not finished or exposed to the weather.

2

Metal Panels: metal panels are to be fabricated from the specified alloy of aluminium. Thickness (gauge) of aluminium sheet shall be as specified in the project specifications

(b)

metal panels are to comply with the profiles indicated on the Drawings

(c)

panels are to be fabricated so that the grain of all panels is oriented in the same direction upon installation

(d)

panel support construction to result in a panel visual flatness acceptable to the Engineer

(e)

panels subject to impact and where indicated on the Drawings are to be reinforced with aluminium members or other suitable method as approved by the Engineer

(f)

extruded aluminium stiffeners and other panel stiffening devices to be designed to prevent telegraphing or read-through of the stiffening device on the exposed face of the panel

(g)

panel anchorage is to be designed to permit replacement without disturbing contiguous work. All panels shall be easily removable and replaceable for inspection of the seam or sub-roof system.

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(a)

END OF PART

QCS 2014

Section 17: Metalwork Part 06: Workmanship

Page 1

6

WORKMANSHIP ........................................................................................... 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2

Scope References

6.2

EXAMINATION .............................................................................................. 2

6.2.1

General Requirements

6.3

FABRICATION AND ASSEMBLY .................................................................. 2

6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8

General Requirements Fabrication and Assembly Manufacturer’s Standards Jointing and Reinforcing: Welding Visual Consistency of Metal Panels Sealant and Gasket Applications Application of Sealant

6.4

INSTALLATION ............................................................................................. 6

6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6

General Requirements Anchors and Connections Corrosion Protection Lightning Protection Installation of Insulation and Safing (Fire Protection) Flashing

6.5

FIELD QUALITY CONTROL .......................................................................... 8

6.5.1

Site Tests

6.6

CLEANING .................................................................................................... 9

6.7

PROTECTION ............................................................................................... 9

6.7.1

General Requirement

2 2

2 3 3 3 4 4 5 5 6 6 7 7 8 8 8

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Section 17: Metalwork Part 06: Workmanship

Page 2

WORKMANSHIP

6.1

GENERAL

6.1.1

Scope

1

This Part provides general specification for workmanship of fabrication and assembly of architectural metalwork items

2

Related Parts and Sections are as follows:

Section 1 Section 25

General Glass and Glazing

.l. l

General Materials Classification Metal Doors and Windows Architectural Metal Work Light Metal Support and Cladding System

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This Section Part 1 Part 2 Part 3 Part 4 Part 5

.

6

References

1

The following standards are referred to in this Part:

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BS 1723 ......................Brazing

BS 1724 ......................Bronze welding by gas

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BS 2901 ......................Filler rods and wires for gas-shielded are welding BS 5368 ......................Methods of testing windows

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BS 6375 ......................Performance of windows

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BS EN 288 ..................Approval of welding procedures for metallic materials

EXAMINATION

6.2.1

General Requirements

1

Prior to the start of the installation, the building to be inspected to verify all conditions and dimensions as being acceptable to receive the Work of this Section.

2

Should any conditions be found that may prohibit proper execution of the Work, the Contractor is to immediately notify the Engineer in writing of these conditions. Installation is not to proceed until remedial action, acceptable to the Engineer, has been executed.

6.3

FABRICATION AND ASSEMBLY

6.3.1

General Requirements

1

Use no materials, equipment or practices that may adversely affect the functioning, appearance and durability of the completed works.

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QCS 2014

Section 17: Metalwork Part 06: Workmanship

Page 3

The works are to be installed in compliance with the specified criteria without buckling, opening of joints, undue stress on fasteners, sealants and gaskets, opening of welds, cracking of glass, leakage, noises or other harmful effects.

3

Conform to the materials, finishes, shapes, profiles, sizes, thicknesses, and joint locations required by the Project Documentation.

4

Match all materials to produce continuity of line, texture and colour.

5

All work to be of the highest quality, in accordance with the best trade practices, and performed by skilled workmen. All work shall be to the approval of the Engineer.

6

To the fullest extent practical, fabrication and assembly is to be executed in the workshop.

7

All components exposed in the finished work are to be free from wrapping, oil-canning effects, telegraphing of welds, studs, and other fasteners; streaks, and tool and die marks.

8

Exposed metal edges are to be finished to match typical finished surfaces.

9

To the fullest extent possible, all fabrication is to be done prior to finishing.

6.3.2

Fabrication and Assembly

1

The design of the works should endeavour to keep Project site operations to a minimum. Manufacturing, finishing, and assembly processes shall, wherever possible, be carried out off-site and under controlled environmental conditions.

2

Assembly procedures to be carried out on the Project site are to be simple to execute and capable of execution within the time allowed in the Project construction schedule.

6.3.3

Manufacturer’s Standards

1

Materials, components, and systems incorporated in the Work are to be mixed, applied and installed in accordance with the instructions and recommendations of the respective manufacturers.

2

Standards referred to in Section 25, Glazing, to apply to this Section.

6.3.4

Jointing and Reinforcing:

1

Accurately fit and firmly secure all exposed metal joints with metal-to-metal hairline joints.

2

All fastenings are to be installed at approved spacings. Fasteners are not to penetrate primary gutters and drainage systems. Fasteners may penetrate the secondary system; however, they must be properly sealed.

3

All screws and bolts up to and including 8 mm and all that are tapped into a aluminium shall be 300 Series stainless steel.

4

All bolts 10 mm and larger to be stainless steel.

5

No self-drilling fasteners are to be allowed outboard of the primary air-seal line of metal roofs and exterior wall cladding.

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Section 17: Metalwork Part 06: Workmanship

Page 4

All jointing and splicing of members are to be concealed. Exposed fasteners to occur only where approved by the Engineer. Where exposed in finished surfaces, screw heads shall be Phillips oval-head countersunk type, finished to match adjacent surfaces. Pop rivets are not to be used.

7

Conceal all joint sealants unless otherwise indicated in the Project Documentation.

8

All work is to be properly reinforced for hardware, anchors, and other attachments.

6.3.5

Welding

1

All welding of steel are to be in accordance with the recommendations of BS EN 288.

2

Steel welding is to be done by skilled mechanics qualified by test as contained in BS EN 288 and as applicable to the material thickness and type of welded joint on which the welders will be employed.

3

All welding is to be done with electrodes and/or methods recommended by the suppliers of the metals being welded. The type, size, and spacing of welds are to be as shown on the approved shop drawings. Welding materials and methods are to be such as not to cause distortion, discoloration, or result in any other adverse effect on the required profiles and finishes or visible surfaces of the work.

4

Welding of aluminium alloys and the qualifications of aluminium welders shall conform to BS 2901, Part 4.

5

Welding of stainless steel shall be by TIG welding or other methods subject to approval. Use double bevel butt welds, backing bars to remove heat, jigging, tack welds and any other measures necessary to minimise distortion to conform to BS 2901, Part 2.

6

Welds splatter and welding oxides on exposed surfaces to be removed. All exposed welds are to be finished to match and blend with adjacent parent metal prior to final finish application.

7

Stud welding is to be done by mechanics trained by the manufacturer of the stud setting system. The manufacturer will develop specific programs and instructions in co-operation with the fabricator to suit the needs of the specific details. The fabricator is to exercise particular care that all recommendations of the manufacturer are followed.

8

Brazing where required shall comply to BS 1723, Parts 1, 2 and 3.

9

Welding of bronze metals shall be to BS 1724.

10

Visible marks (telegraphing) on finished surfaces due to welding of studs will not be acceptable.

6.3.6

Visual Consistency of Metal Panels

1

All exposed flat metal panels are to be designated, fabricated, and installed in such a manner that they appear visually flat when viewed from any angle. Any short length distortions, ripples, waves, oil canning, or telegraphing of fasteners will not be permitted.

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Section 17: Metalwork Part 06: Workmanship

Page 5

Provisions are to be made to allow for differential thermal movement between framing members and the exposed metal components without noise and without distortion of the exposed face.

3

In the event that metal flatness requires interpretation by measurement, this is to be done by measuring and calculating the slope between any two points on the exposed surface 25 mm apart. This slope should not exceed 0.5 % from the nominal surface plane, when measured at an ambient temperature of 25 C.

6.3.7

Sealant and Gasket Applications

1

Sealing mechanisms (sealants and gaskets) shall be provided when required by the Project Documentation or required for a permanently weathering installation. The sealing mechanism for each location and use shall be as indicated in the Project Documentation. In those locations where a mechanism is necessary but is not indicated, it shall be of a type recommended by the Contractor and approved by the Engineer.

2

Unless otherwise specified sealants for perimeter caulking are to be either one part acrylic or one, two or three part polyurethane sealants having elastometric properties and not subject to ultraviolet degradation.

3

Sealant is to be used with the joint primer and filler recommended by the manufacturer for the type of material and width of joint to which it is to be applied. Exposed sealants are to match the colour of the adjacent metal component.

4

Bond breaker tape is to be self-adhesive polyethylene tape or other plastic tape recommended by the manufacturer of the sealant.

5

Joint backing is to be closed-cell polyethylene, non-bleeding neoprene, butyl rod or other flexible, permanent, durable non-absorptive material recommended for compatibility by the manufacturer of the sealant.

6

Specific alloys, compounds, etc. of gasket materials shall be appropriate for the function intended and are subject to approval by the gasket manufacturer and Engineer for compatibility and peel adhesion testing.

6.3.8

Application of Sealant

1

Sealants and primers are to be applied in the exact manner specified by the manufacturer and are not be used when the shelf life shown on the tins or cartridges has expired.

2

The minimum width and depth of the sealant is to be 6mm and for wider joints the depth shall be not less than half the width of the joint.

3

The surfaces of the joint are to be free from laitance, grease, loose particles, etc., and temporary protective coatings are to be removed from metal components. All surface are to be cleaned as necessary to ensure they are suitable for adhesion of the sealant and should be dry.

4

Unless the sealant manufacturer recommends otherwise:

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(a)

the joint surfaces are to be primed.

(b)

joint backing is to be used to control the depth of sealant.

QCS 2014

(c)

Section 17: Metalwork Part 06: Workmanship

Page 6

where the joint design will not permit the use of joint backing, an adhesive backed polyethylene bond breaker tape is to be installed to prevent three sided adhesion.

Adjacent surface to the joint be masked with tape to prevent staining by the primer or sealant. The tape should be removed as soon as the joint has been sealed by drawing it across, and not away, from the joint.

6

The sealant to be applied with sufficient pressure to completely fill the joint, so as to exclude all air pockets and to ensure adhesion of the material to the joint bond surfaces equally on opposite sides. The surface of the sealant is to be tooled smooth and flush with the adjacent surfaces unless detailed otherwise.

7

Apply sealants and gaskets under the climatic conditions recommended by the manufacturers. All surfaces to receive sealants shall be treated (cleaned, primed or unprimed) in accordance with the instructions of the sealant manufacturer.

8

All exterior glazing gaskets shall be vulcanised, injection moulded, or heat-welded at the corners to form a continuous closure.

6.4

INSTALLATION

6.4.1

General Requirements

1

The Works are to be erected plumb, square, level, and correctly aligned within the following limitations:

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offset from true horizontal, vertical, and design location is not to exceed plus or minus 3 mm per 4 m nor plus or minus 12 mm over any one length or part thereof of the building.

(b)

maximum offset from true alignment between abutting components or components separated by less than 75 mm should not exceed 1 mm.

(c)

all tolerances shall be non-cumulative.

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Joint widths as indicated are the design joint width at an ambient temperature of 25 C. Installation procedures are to be adjusted to take into account the ambient temperature at the time of installation.

3

Care is to be exercised to properly support and reinforce units against racking during hoisting and installation.

6.4.2

Anchors and Connections

1

Anchors and connections are to be provided to comply with requirements for adjustability, movement and load transfer

2

Connections between different materials to be designed to allow for the differential thermal movement of the respected materials

3

Anchors and connections that are designed for movement are to be of such construction that friction is low enough to allow for such movement without buckling or distortion of the finished surface and other damage and without causing binding and noises

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Section 17: Metalwork Part 06: Workmanship

Page 7

Self-drilling, self-threading fasteners are to be Type 316 stainless steel, unless otherwise indicated

5

Metal surfaces shall be separated in such a manner that metal does not move on metal. Materials used for this purpose should be low-friction components, sealants, or gaskets as applicable

6

Anchorages to structural steel should not induce rotational forces in supporting members

7

All anchors, connections, fixings, and fasteners to be Type 316 stainless steel, unless otherwise indicated

8

Where indicated in the Project Documentation, bolted fasteners exposed to view are to be a corn-head bolts with matching nuts as approved by the Engineer

9

The total thickness of a shim pack is not to exceed a dimension equal to the diameter of the fastener/anchor

10

Shim packs that resist compressive forces only may be high-impact plastic. Shims subject to shear forces are to be stainless steel plates pinned together to form a monolistic shim.

6.4.3

Corrosion Protection

1

No metals, including alloys of the same base metal, are to be placed together in a manner, combination or location likely to give rise to damage by electrolytic action or other corrosion

2

Isolation of dissimilar metal surfaces to prevent electrolytic action is to be accomplished by materials which are impervious to moisture and non-absorptive

3

All steel parts are to receive a protective treatment commensurate with their respective functions and locations

4

Where used to the exterior of air-seals, or in any location vulnerable to moisture, steel shall be hot-dip galvanized after fabrication

5

Field welds on galvanized steel shall be treated with an approved field cold galvanizing process

6

Aluminium surfaces in contact with mortar, concrete, fireproofing, plaster, masonry, or absorptive materials of any kind shall be coated with an anti-galvanic material, impervious to moisture.

6.4.4

Lightning Protection

1

All metal cladding components, including panels, glazing frames, mullions, transoms, fixings, and support structures are to be fully bonded electrically to ensure electrical continuity of the building envelope

2

All metal cladding components, as above, are to be connected to the building ground by earthing jumper cables and connections

3

Provide for the installation of lightning arrestors, air terminals, and similar items without electrical bonding to the metal cladding components.

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QCS 2014

Section 17: Metalwork Part 06: Workmanship

Page 8

Installation of Insulation and Safing (Fire Protection)

1

Install thermal insulation and safing where indicated and as required to meet overall fire separation requirements

2

Provide insulation with a minimum R-value of R-10 behind any opaque exterior surface which has conditioned space behind

3

Install insulation using welded or mechanically fixed impaling and/or retaining clips. Attachment methods are not to penetrate waterproofing membranes. Adhesive attachment of insulation is not permitted

4

Install foil tape around perimeter of foil-free of insulation board to adjacent metal framing to achieve a positive vapour barrier

5

Seal between foil-face of safing and foil-back of insulation at curtain wall with a smoke resistant sealant to provide a positive smoke barrier between floors.

6.4.6

Flashing

1

Where required or otherwise necessary to prevent leakage, flashing is to be formed from appropriate thickness of stainless steel, aluminium, or 1.5 mm thick neoprene (polychloroprene) or EODM sheet as part of a cured/uncured elastrometic sheet flashing system. Stainless steel flashing is to be a minimum 1.0-mm thick; aluminium flashing to be a minimum 1.5 mm thick

2

Where vertical or horizontal joints occur to accommodate movement, an elastrometric flashing system is to be used unless otherwise detailed in the Project Documentation and approved by the engineer.

3

Elastromeric flashing connecting to work of other Sections is to be provided by the work of this Section, including the attachment systems to this Work and to other work (except waterproofing or roofing)

4

Where elastomeric or other flashing connects to roofing and waterproofing work, provide 200 mm of flashing beyond the point of attachment to the Work of this Section. The connection to roofing work is to be provided by the roofing installer. Connections of such flashing to other than water proofing work is to be provided by the work of this Section

5

Elastomeric flashing exposed to view is to be bonded to the substrata without blistering; joints are to be neat and as infrequent as possible. Elastomeric flashing not supported by substrate material shall receive another layer of 1.5 mm flashing for reinforcement, fully bonded to the finish layer and the substrate and extending at least 25 mm beyond the unsupported area.

6.5

FIELD QUALITY CONTROL

6.5.1

Site Tests

1

The Contractor is to engage an independent testing and inspecting agency to perform field inspections and tests and to prepare test reports.

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6.4.5

(a)

the testing agency is to conduct and interpret tests and state in each report whether tested Work complies with or deviates from requirements

QCS 2014

Section 17: Metalwork Part 06: Workmanship

Page 9

(b)

the Contractor is to correct deficiencies in or remove and replace work that inspections and test reports indicate do not comply with specified requirements

(c)

additional testing at Contractor’s expense, is to be performed to determine compliance of corrected Work with specified requirements.

Air Infiltration. Test areas of installed system indicated in the Project Documentation or as directed by the Engineer, BS 5368 and BS 6375.

3

Water Penetration. Test areas of installed system indicated in the Project Documentation or as directed by the Engineer for compliance with system performance requirements according to BS 5368 and BS 6375 at minimum differential pressure of 20 % of inward acting wind-load design pressure. Minimum Design Loads for Buildings and Other Structures, but not less than 300 Pa.

6.6

CLEANING

1

Clean the entire work not more than four (4) days prior to date scheduled for inspections that establish the date of Substantial Completion.

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clean all components of the Work in accordance with the recommendations of the manufacturers

(b)

clean the work from the topmost levels down in order to avoid staining of cleaned surfaces from cleaning solution residue and runoff

(c)

clean glass with approved glass cleaning solutions only and ensure that cleaning solution is completely removed from the surface after cleaning. Do not clean glass when it is exposed to direct sunlight.

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PROTECTION

6.7.1

General Requirement

1

Protect the works from material, equipment or procedures that may impair the functioning, appearance, or durability of the work or other construction.

2

Protect the installed work from damage by subsequent construction activities.

3

Protection materials, such as plastic membrane tapes and adhesive sheeting, are to be suitable for the intended protection application and protection period.

4

Protection materials are to be installed in a manner that will not trap harmful moisture or otherwise contaminate the Work.

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END OF PART

QCS 2014

Section 18: Carpentry, Joiner and Ironmongery Part 01: General

Page 1

1

GENERAL ............................................................................................................... 2

1.1

GENERAL REQUIREMENTS .................................................................................. 2

1.1.1 1.1.2 1.1.3

Scope References Definitions

1.2

TIMBER TYPES ...................................................................................................... 3

1.2.1

General Description

1.3

QUALITY ................................................................................................................. 3

1.3.1

General Description

1.4

MOISTURE CONTENT ........................................................................................... 5

1.4.1

General Description

1.5

STORAGE OF MATERIALS .................................................................................... 6

1.5.1

General Requirements

2 2 3 3

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QCS 2014

Section 18: Carpentry, Joiner and Ironmongery Part 01: General

Page 2

1

GENERAL

1.1

GENERAL REQUIREMENTS

1.1.1

Scope

1

Section 9 specifies materials, accessories, and workmanship for the use of wood in building construction. Part 1 of Section 18 defines general specifications as applicable.

2

Related Sections are as follows:

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This Section: Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 References

1

The following standards are referred to in this Section:

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1.1.2

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BS 476 ........................Fire tests on building materials and structures BS 729 ........................Hot dip galvanised coatings on iron and steel articles

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BS 1088 ......................Plywood for marine craft

BS 1142 ......................Specification for fibre building boards

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BS 1186 ......................Quality of timber and workmanship in joinery

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BS 1202 ......................Nails

BS 1203 ......................Synthetic resin adhesive for plywood

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BS 1204 ......................Synthetic resin adhesives (phenolic and aminoplastic) for wood

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BS 1210 ......................Wood screws BS 1282 ......................Guide to the choice, use and application of wood preservatives

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BS 2572 ......................Phenolic laminated sheet and expoxy cotton fabric laminated sheet BS 3444 ......................Specification for blackboard and lamination board BS 3621 ......................Thief resistant locks BS 3794 ......................Decorative laminated plastic sheet BS 4072 ......................Wood preservation by means of copper/chromium/arsenic BS 4079 ......................Compositions BS 4756 ......................Ready mixed aluminium priming paints for woodwork BS 4965 ......................Decorative laminated plastic sheet veneeral boards and panels BS 5268 ......................Preservative Treatments for Constructional timbers Part 5 BS 5358 ......................Plywood for marine craft BS 5589 ......................CP for preservation of timbers BS 5666 ......................Wood preservatives and treated timber BS 5707 ......................Solutions of wood preservatives in organic solvents BS 6459 ......................Door closers, mechanical performance

QCS 2014

Section 18: Carpentry, Joiner and Ironmongery Part 01: General

Page 3

BS 6462 ......................Casement stays, mechanical performance BS 6566 ......................Plywood BS 7036 ......................CP for installation of safety devices for automatic power operated pedestrian door systems BS 7352 ......................Strength and durability performance of metal hinges BS 8201 ......................Timber flooring BS EN 635 ..................Plywood, clarification by surface appearance BS EN 1014 ................Wood preservatives, creosote and creosoted timber methods of sampling and analysis TRADA .......................Wood information sheets Definitions

1

Concealed surfaces: Surfaces which after installation in the building will be concealed by the surrounding work, not merely by decoration.

2

Semi-concealed surfaces: Surfaces such as the internal parts of cupboards or fittings which are not visible when the fittings are closed.

3

Class 1 finish: Refers to the exposed surfaces of joinery which are selected for clear finish.

4

Class 2 finish: Refers to the exposed surfaces of joinery which are selected for painting.

1.2

TIMBER TYPES

1.2.1

General Description

1

Softwood is to comply with the relevant provisions of BS 1186, Part 1.

2

Hardwood is to comply with the relevant provisions of BS 1186, Part 1. Planed representative samples of each hardwood species specified are to be submitted to the Engineer before the manufacture of any joinery work.

3

The following hardwoods are approved for use:

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1.1.3

(a)

Iroko

(b)

Afrormosia

(c)

Dark Red Meranti

(d)

Opepe

4

Under no circumstances shall Light Red Meranti be used.

5

Where Teak is specified no alternative hardwood will be acceptable.

1.3

QUALITY

1.3.1

General Description

1

Timber should comply with the requirements of Table 1.1 and should be free of the following defects:

QCS 2014

Section 18: Carpentry, Joiner and Ironmongery Part 01: General

Page 4

(a)

unsound knots, dead knots, loose knots and knot holes.

(b)

sapwood on any external hardwood or Class 1 finish surface.

(c)

splits extending through the piece from one surface to another and ring shakes.

(d)

decay and insect attack other than pinholes as defined in Tables 1.1 and 1.2.

Except in Class 1 finish work, defects arising from manufacture and knots may be cut or bored out and replaced with a plug or inserts of the same species, well glued in. The plug is to be the full depth of the hole and the grain to be in the direction of the grain of the piece into which it is inserted. The width of any plug or insert should not be more than 6 mm greater than the maximum limit of the knot size.

3

In jointed panels each piece is to be of the same species and in Class 1 finish work all the exposed surfaces of each piece are to have the same character of grain and are to be matched.

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Table 1.1 Quality of Timber

Class 1 Finish

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Exposed Surfaces

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Features

Class 2 Finish

Pin knots up to 6 mm diameter only unless the knots are specified as a feature.

Up to 25mm width 25-50mm width 50-100mm width Over 100mm width

Checks, Width splits Length and Depths Shakes

0.3 mm 300 mm One quarter of timber

Pitch pockets

Not Permitted

Not Permitted unless cut out and filled

Plugs and inserts

Not Permitted

Width not to be 6mm greater than maximum limit of permitted knot size

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Rate of Growth

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- one half of timber - 15mm - one quarter - 25mm

1.5 mm (filled if over 0.5 mm) 300 mm One Quarter of timber

Not unduly conspicuous

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Knots

Not fewer than 8 growth rings per 25 mm at any point on any cross section

Slope of grain

Not greater than 1 in 10 in softwoods and 1 in 8 in hardwoods

Boxed Heart

Permitted in softwoods only if there is no shake on exposed surfaces

Pitch

Not permitted

Permitted if hard

Pin-holes

Not permitted

Permitted if filled

QCS 2014

Section 18: Carpentry, Joiner and Ironmongery Part 01: General

Page 5

Table 1.2 Quality of Timber Features

Concealed and Semi-Concealed Surfaces

Knots

Up to 45mm width 45-60mm width 60-100mm width Over 100mm width

Checks, Width splits Length and Depths Shakes

-

two-thirds of timber 20mm one half 50mm

Any width Not continuous for whole length One Half of timber

Pitch pockets

Permitted Width not to be 6mm greater than maximum limit of permitted know size

.

Plugs and inserts

No specified requirement

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Not fewer than 8 growth rings per 25mm at any point on any cross section

Slope of grain

Not greater than 1 in 10 in softwoods and 1 in 8 in hardwoods

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Rate of Growth

Boxed Heart

Permitted in softwoods Permitted

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Pitch

Permitted

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Pin-holes

MOISTURE CONTENT

1.4.1

General Description

1

All timber is to be kept in stores, properly stacked, for a minimum period of three months to ensure conditioning to a maximum moisture content from time of delivery and during site storage to be no more than the following:

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timber 50mm and less in thickness to have a moisture content of 19% or less

(b)

boards to have a moisture content of 19% or less

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timber over 50mm thick to have a moisture content of 25% or less.

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(a)

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Particular care is to be taken to ensure that all carpentry and joinery timbers, plywood, blockboard and other timber based composite board, whether in prefabricated or loose form, are delivered and maintained at the required maximum moisture content stated. Refer to BS 6566 Part 5 for moisture content in plywood.

3

When instructed by the Engineer the Contractor is to make available a moisture meter for the testing of moisture content on site. The test is to be carried out according to the instrument manufacturer’s instructions at a point not nearer than 600 mm from either end or at the centre if the length is less than 1200 mm.

4

For information related to use of moisture meters refer to the following Timber Research and Development Association (TRADA) wood information sheets, reference: (a)

No. 14

Moisture in timber 4284 910

(b)

No. 18

Moisture metres for wood 461795.

QCS 2014

Section 18: Carpentry, Joiner and Ironmongery Part 01: General

Page 6

1.5

STORAGE OF MATERIALS

1.5.1

General Requirements

1

The Contractor is to comply with the following requirements when dealing with structural timbers (rough carpentry): protect timber and other products from dampness both during and after the delivery to the site.

(b)

pile timber in stacks in such a manner as to provide air circulation around the surfaces of each piece.

(c)

stack plywood and other board products so as to prevent warping.

(d)

locate stacks on well drained areas, supported at least above ground and cover as necessary for protection from driving rain and prolonged sun exposure, whilst providing ventilation.

ta

The Contractor is to comply with the following requirements when dealing with architectural timber (finished carpentry and shopwork). joinery is to be stacked on bearers on level, dry floors. Components are to be staggered or separated with spacers as necessary to prevent damage by and to projecting ironmongery, beads, etc.

(b)

components which cannot be immediately unloaded into conditions of storage recommended by the manufacturer or approved by the Engineer are not to be delivered to the site.

(c)

during transit and while stored on site, doors are to be stacked horizontally in piles, each pile on not fewer than three cross bearers laid level and true.

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END OF PART

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 02: Wood Treatment

Page 1

2

WOOD TREATMENT .................................................................................... 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3

Scope References Submittals

2.2

PRESERVATIVE TREATMENT .................................................................... 2

2.2.1 2.2.2 2.2.3

General Application Standard Pressure Treated Preservative Other Preservative Treatments

2.3

FIRE RETARDANT TREATMENT ................................................................. 3

2.3.1

General Application

2.4

INSECT TREATMENT ................................................................................... 3

2.4.1

General Application

2 2 2

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 02: Wood Treatment

Page 2

WOOD TREATMENT

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the use of preservative, insect protection and fire retardant treatment for wood construction, inclusive of Structural Timbers and Architectural woodwork. Unless stated otherwise in the Project Documentation, the guide to choice, use and application of wood preservatives is BS 1282.

2

Related Sections are as follows:

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This Section Part 1 Part 3 Part 4 Part 5 Part 6

.

2

References

1

The following standards are referred to in this Part:

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2.1.2

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BS 1282 ......................Guide to the choice, use and application of wood preservatives

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BS 5268 ......................Preservative treatments for constructional timbers BS 5707 ......................Solutions of wood preservatives in organic solvents

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BS 6566 ......................Plywood

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BS EN 1014 ................Creosote and creosoted timber Submittals

1

In accordance with the Project Documentation, provide certification as specified that required preservation treatment or fire retardant has been completed, or in the absence of specific requirement that at minimum the manufacturers required standard application has been used.

2

Provide a sample of woodwork as indicated by the engineer with required coatings or treatment application for testing where required.

2.2

PRESERVATIVE TREATMENT

2.2.1

General Application

1

The preservative treatment is to be applied by pressure impregnation or the double vacuum process. Dipping, deluging, spraying, brushing or other methods which only provide shallow protection are not permitted.

2

The treatment to be carried out under factory conditions at the source of supply of the timber and the Contractor is to provide a Certificate of Impregnation when required by the Engineer.

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 02: Wood Treatment

Page 3

Treatment is to be carried out after all cutting and shaping has been completed. If subsequent cutting of the timber is unavoidable all freshly exposed surfaces are to receive a liberal application of the preservative recommended in the relevant treatment specification.

2.2.2

Standard Pressure Treated Preservative

1

Wood members and plywood exposed to weather or in contact with plaster, masonry or concrete, including wood framing of openings in exterior walls of concrete or masonry, roofed structures; wood sills, sole plates, furring; and, wood members used in connection with roofing and flashing materials to be treated in accordance with BS 1282, BS 5268, BS 6566, and/or BS 5707.

2.2.3

Other Preservative Treatments

1

Creosote and creosoted timber where used as structural timber to be sampled or analysed to BS EN 1014.

2.3

FIRE RETARDANT TREATMENT

2.3.1

General Application

1

Each piece of treated material will bear identification of the testing agency and will show the performance rating. Treatment and performance inspection, is to be by an independent and qualified testing agency that establishes performance ratings.

2.4

INSECT TREATMENT

2.4.1

General Application

1

All hardwood and softwood for permanent incorporation in the Works is to be treated with preservative to provide protection against damage from insect larvae, termites and fungal decay to BS 6566, Part 7. Organic solvent type preservatives are to contain a water repellent. Certificates are to be provided confirming all necessary treatments required have been completed.

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END OF PART

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 03: Structural Timber

Page 1

3

STRUCTURAL TIMBER ................................................................................ 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2 3.1.3 3.1.4

Scope References Submittals Product Delivery, Storage and Handling

3.2

FRAMING MATERIALS ................................................................................. 3

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

Structural Timber Plywood (used for Rough Carpentry) Rough Hardware - General Workmanship for Structural Timber Non-Structural Framing Plywood Sheeting

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 03: Structural Timber

Page 2

3

STRUCTURAL TIMBER

3.1

GENERAL

3.1.1

Scope

1

This part specifies requirements for wood framing, sheathing, subflooring, trusses, light timber construction and rough hardware as used in buildings.

2

Related Sections and Parts are as follows:

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General Wood Treatment Architectural Timber Joinery Fasteners and Adhesives Ironmongery

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This Section Part 1 Part 2 Part 4 Part 5 Part 6 Part 7 References

1

The following standards are referred to in this Part:

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3.1.2

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BS 1088 ......................Plywood for marine craft

BS 4079 ......................Plywood for marine craft

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BS 1186 ......................Quality of timber and workmanship in joinery BS 1203 ......................Synthetic resin adhesives (phenolic and amnioplastic) for plywood

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BS 6566 ......................Plywood

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BS EN 635 .................Plywood

Submittals

1

The Contractor shall submit shop drawings showing framing connection details, fasteners, connections, dimensions, treatment and finishes in accordance with the relevant provisions of Section 1, General

3.1.4

Product Delivery, Storage and Handling

1

Protect lumber and other products from dampness both during and after delivery at site.

2

Pile lumber in stacks in such manner as to provide air circulation around surfaces of each piece. Stack plywood and other board products so as to prevent warping.

3

Locate stacks on a well drained area, supported at least six inches above grade and cover as necessary for protection from driving rain and prolonged sun exposure whilst providing ventilation.

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 03: Structural Timber

Page 3

3.2

FRAMING MATERIALS

3.2.1

Structural Timber

1

Unless otherwise specified, each piece of lumber is to bear the grade mark, stamp, or other identifying marks indicating grades of material, and rules or standards under which produced.

2

Structural members shall be: (a)

any species to be used as structural timber is to be grade listed as in BS 1186 Part 1

(b)

the design of members and fastenings is to conform to BS 1186 Part 2.

Furring, blocking, nailers and similar items used for framing as structural timber shall conform to Tables 1.1 and 1.2, Quality of Timber.

4

Size references, unless otherwise specified, are nominal sizes, and actual sizes to be within manufacturing tolerances allowed by the standard under which the product is produced.

5

The moisture content of timber at the time of delivery and during site storage is to be as described in Clause 1.4.1-1 of Part 1 of this Section.

6

Framing timber is to have a minimum extreme fibre stress in bending of 7500 kPa unless otherwise approved by the Engineer.

3.2.2

Plywood (used for Rough Carpentry)

1

Each sheet of plywood is to bear the mark of a recognized association or independent inspection agency which will maintain continuing control over the quality of the plywood. The mark is to identify the plywood by veneer grade, group number, span rating where applicable, and glue type.

2

Plywood is to be free from bow, twist and warp.

3

The core in 3-ply is not to be more than 60% of the total thickness.

4

In plywood having more than 3 plies, the faces, and all plies with the grain running in the same direction as the faces, to have a combined thickness of between 40% and 60% of the total thickness of the plywood.

5

All plywood thicker than 10mm is to made of not less than 5 plies.

6

No face ply to be thicker than 3mm and no inner ply to exceed 5mm.

7

The direction of the grain of the veneer is to be at right angles in adjacent plies except in the case of boards comprising an even number of plies, when the grain of the center is to follow the same direction.

8

All plywood which is to be installed externally is to be manufactured using Type WBP adhesives to BS 1203, BS 1088 and BS 4079.

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 03: Structural Timber

Page 4

All plywood which is to be installed internally is to be manufactured using Type BR adhesives to BS 1203.

10

Face plies for Class 1 finish are to be of one or two pieces of firm, smoothly cut veneer. When of two pieces, the joint should be approximately at the center of the board and the veneers are to be matched for color. The veneer is to be free from knots, unless specified as a feature, insect holes, splits, dote, glue stain, filling or inlaying or any other kind of defect. No end joints are permissible.

11

Face splits for Class 2 finish are to present a solid surface free from open defects. Occasional splits not wider than 0.8mm at any point and not longer than one tenth of the length of any panel of slightly open joints may be filled with a suitable filler. Neatly made repairs consisting of inserts of the same species as the veneer, which present solid, level, hard surfaces and are bonded with an adhesive equivalent to that used for bonding the veneers are permissible. No end joints are permissible.

3.2.3

Rough Hardware - General

1

Rough hardware includes items for structural timber construction such as frame cramps, ties, anchors, framing connectors, joist hangers and similar items.

3.2.4

Workmanship for Structural Timber

1

Timber for carpentry work is to be finished sawn to the sizes shown on the drawings. A tolerance of +3.0 mm to -0.5 mm is permissible.

2

Joints are to be constructed so that they will transmit the loads and resist the stresses to which they will be subjected. The surfaces should be in good contact over the whole area of the joint before fastenings are applied. Unless otherwise specified all joints are to be secured with a suitable type and sufficient number of nails.

3

Holes for bolts are to be drilled from both sides of the timber. No nails, screws or bolts are to be placed in split ends. If splitting is likely holes for nails are to be predrilled at diameters not exceeding four-fifths of the nail.

4

Temporary bracing is to be provided to maintain structural timbers in position and to ensure stability during construction.

5

All cutting for services to be the minimum required to accommodate the services and comply with the following:

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9

6

(a)

notches shall be “U” shaped and be formed by straight cuts to drilled holes

(b)

notches and holes not to be positioned in a member where the remainder of the cross section contains a knot or other defect which would affect the strength

(c)

notches in joists are to be located at the top and not be deeper than one eight of the depth of the joist located within one quarter of the span from the centre of bearing. Holes in joists are to be located through the centre of the depth i.e., on the neutral axis.

Joists are to extend a minimum of 75 mm beyond the nearest edge of the supporting plate or member and be laid in parallel lines.

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 03: Structural Timber

Page 5

Where joists are to be notched over supports, the depth of the notch should not exceed twofifths of the depth of the joist. The bearing surface of the notch is to be cut smooth and true in relation to the surface on which it bears.

8

A clear 12 mm to be maintained around all joists if they extend into blockwork walls and they are to receive an additional liberal coating of preservative on all surface adjacent to walls. A 50 mm gap is to be left between joists and flanking walls.

9

Herring-bone strutting is to be constructed of 50 x 38 mm pieces nailed to form a system of crossing diagonals in a straight line transversely across the joists. Each diagonal strut is to be wedged tightly between the top and bottom edges of adjacent joists before being secured by nails.

3.2.5

Non-Structural Framing

1

Timber sections, stud partitions, bulkheads, etc., are to be accurately cut so that they fit together tightly without distortion. Each joint is to be fixed with at least two nails.

2

All timber sections to be fixed plumb, level and square to ensure that the lining material can be positioned accurately and securely to give flat surfaces, free from undulations.

3

The spacing of members should not exceed the permissible span of the lining material as recommended by the manufacturer. All edges of the lining material to be supported except where other methods of supporting the edges are provided e.g., tongued and grooved joints.

4

Holes for services to pass through the center of timber sections and the diameter of the hole should not exceed one third the width or thickness of the timber.

5

Additional supports are to be provided for appliances and fixtures.

6

Framing, grounds and bearers are to be fixed to the substrata at maximum 450mm centers using masonry nails unless described as “plugged and screwed” or “bolted”.

3.2.6

Plywood Sheeting

1

Wall and roof sheeting is to comply with the relevant provisions of BS EN 635 and BS 6566.

2

Wall Sheeting: Panels 1200 mm wide and 87 mm thick are to have supports at 400 mm centres if constructed without corner bracing and framing. Panels 100 mm thick are to have supports at 600 centres, if constructed without corner bracing or framing.

3

Roof Sheeting: minimum.

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7

Panels 87mm thick or greater shall have supports at 400 mm centres

END OF PART

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 04: Architectural Timbers

Page 1

4

ARCHITECTURAL TIMBER .......................................................................... 2

4.1

GENERAL REQUIREMENTS ........................................................................ 2

4.1.1 4.1.2 4.1.3 4.1.4

Scope References Submittals Product Delivery, Storage and Handling

4.2

TIMBER MATERIALS (NON-STRUCTURAL FRAMES) ............................... 3

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8

Grading and Marking Sizes Specific Items Moisture Content Fire Retardant Treatment Preservative Treatment Fixing of Exterior Shopwork Fixing of Interior Shopwork

4.3

PLYWOOD .................................................................................................... 5

4.3.1 4.3.2 4.3.3

Softwood Plywood Hardwood Plywood Marine Plywood

4.4

WOOD PANELING ........................................................................................ 5

4.4.1 4.4.2 4.4.3

General Board Planking Wall Sheet Paneling

4.5

BLOCKBOARD AND LAMINBOARD ............................................................. 6

4.5.1 4.5.2

General Requirements Fixing Laminated Timber Boards

4.6

LAMINATED PLASTIC SHEET ..................................................................... 6

4.6.1 4.6.2

General Requirements Fixing Laminated Plastics

4.7

MISCELLANEOUS WOOD PRODUCTS....................................................... 7

4.7.1

Building Board (Handboard)

4.8

STAIRWORK AND HANDRAILS ................................................................... 7

4.8.1

Wood Handrails

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 04: Architectural Timbers

Page 2

4

ARCHITECTURAL TIMBER

4.1

GENERAL REQUIREMENTS

4.1.1

Scope

1

This part includes specifications for fabrication and installation of exterior and interior finished carpentry and millwork, and plastic laminate covered counters, cabinets, and other such items.

2

Related Sections are as follows:

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This Section Part 1 Part 3 Part 3 Part 5 References

1

The following references are referred to in this Part:

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BS 476 ........................Fire tests on building materials and structures

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BS 1088 ......................Plywood for marine craft

BS 1142 ......................Specification for fibre building boards

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BS 1282 ......................Choice, use and application of wood preservatives BS 2572 ......................Phenolic laminated sheet and epoxy cotton fabric laminated sheet

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BS 3444 ......................Specification for blockboard and lamin board

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BS 4072 ......................Use of copper/chromium/arsenic compositions BS 4079 ......................Plywood for marine craft

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BS 4965 ......................Decorative laminated plastic sheet veneered boards and panels

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BS 5268 ......................Part 5 - preservative treatment of structural timber BS 5589 ......................Code of Practice for preservation of timber

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BS 5666 ......................Methods of analysis of wood preservatives and treated timber BS 5707 ......................Specification of solutions for timber BS 6566 ......................Plywood BS EN 635 ..................Plywood Part 2 Hardwood 4.1.3

Submittals

1

In accordance with the Project Documentation, provide Shop Drawings and Samples as specified, or at minimum as follows: (a)

shop Drawings showing detailed finished work such as cabinetry, counters, built-in furniture requiring shopwork finished carpentry should have large scale shop drawings provided.

(b)

samples of architectural woodwork) with final surface finishing and any required coatings of paint, varnish, stain or other coatings, at approximate size of 700 x 100 mm.

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 04: Architectural Timbers

Page 3

(c)

samples of plastic laminate finish on plywood or particle board at size of 300 x 15 mm

(d)

certificates indicating preservative treatments treatment of materials as meets the project requirements.

(e)

certificates indicating requirements.

moisture

content

of

materials

or as

fire meets

retardant the

project

Product Delivery, Storage and Handling

1

Protect shopwork items from dampness both during and after delivery to site.

2

Store finished shopwork in weathertight well ventilated structures or in space in existing buildings designated by the Engineer.

3

Do not install finished shopwork in any room or space where concrete, masonry, or plaster work is not completed and dry.

4.2

TIMBER MATERIALS (NON-STRUCTURAL FRAMES)

4.2.1

Grading and Marking

1

Members are to bear the grade mark, stamp, or other identifying marks indicating grades of materials, and rules or standards under which produced.

4.2.2

Sizes

1

Size references, unless otherwise specified are nominal sizes, and actual sizes are to be within manufacturing tolerances allowed by the standard under which the product is produced.

4.2.3

Specific Items

1

Timber for (shopwork), exterior walkways handrails, shelves, handrails, seats, cabinets and other such items is specified in the Project Documentation and drawings.

4.2.4

Moisture Content

1

Moisture content of timber and shopwork at the time of delivery to the site should be as follows:

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4.1.4

(a)

interior finished timber, trim and shopwork 30 mm or less in thickness, moisture content to be 12 % minimum on 85 % of the work and a maximum of 15 % on the remainder.

(b)

exterior treated or untreated finished timber 100 mm or less in thickness, moisture content to be 15 % minimum.

4.2.5

Fire Retardant Treatment

1

Where timber members and plywood are specified to be fire retardant treated, the treatment is to be in accordance with BS 476.

2

Treatment and performance inspection is to be by an independent and qualified testing agency.

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 04: Architectural Timbers

Page 4

Each piece of treated material is to bear the identification of the testing agency and should indicate performance in accordance with such a rating.

4.2.6

Preservative Treatment

1

All softwood for permanent incorporation in the Works to be treated with preservative to provide protection against damage from insect larvae, termites and fungal decay. Organic solvent type preservatives are to contain a water repellant.

2

The preservative treatment is to be applied by pressure impregnation or the double vacuum process. Dipping, deluging, spraying, brushing or other methods which only provide shallow protection are not permitted.

3

The treatment is to be carried out under factory conditions at the source of supply of the timber and the Contractor is to provide a Certificate of Impregnation when required by the Engineer.

4

Treatment is to be carried out after all cutting and shaping has been completed. If subsequent cutting of the timber is unavoidable all freshly exposed surfaces are to receive a liberal application of the preservative recommended in the relevant treatment specification. Refer to BS 1282, BS 4072, BS 5268, BS 5589, BS 5666 and BS 5707.

4.2.7

Fixing of Exterior Shopwork

1

Fixing of exterior shopwork:

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all edges of timber members exposed to weather are to be end grain.

(b)

all shopwork is to be primed and back painted before fixing.

(c)

shopwork is to be nailed, screwed or bolted at each support (blocking).

(d)

all joints are to be close fitted, mitred, tongue and grooved, rebated or lapped to exclude water.

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(a)

Edges of members in contact with concrete or masonry are to have a square corner caulking rebate.

3

Staff beads are to have a caulking rebate.

4.2.8

Fixing of Interior Shopwork

1

Except where special profiles are shown, trim is to be standard stock molding and all members to be of the same species. All finished shopwork is to be free from pitch pockets. Plywood is to be a minimum 12 mm thick, unless otherwise shown or specified.

2

No interior woodwork is to be set until primed and back-painted; or until all concrete, masonry and plaster in buildings is complete and dry.

3

Interior shopwork which is to receive a transparent finish is to be primed and back-painted only on surfaces to be concealed. Secure trim with fine finishing nails and with screws and glue where required. Set nails for putty stopping.

4

All members such as moulding strips, chair rails, and base strips which are less than 4.25 m in length are to be from one piece of timber, back channeled and molded as shown.

5

Interior trim and items of shopwork to be painted may be fabricated from jointed, builtup, or laminated members, unless otherwise shown on the drawings.

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Section 18: Carpentry, Joinery and Ironmongery Part 04: Architectural Timbers

Page 5

PLYWOOD

4.3.1

Softwood Plywood

1

Softwood plywood is to comply with the relevant provisions of BS EN 635 Part 2.

2

Fire resistant softwood plywood is to meet all requirements for flamespread and smoke developed when tested in accordance with BS 476.

3

Plywood is to bear the label of the testing agency designating rate of flame spread, fuel contributed and smoke developed.

4

Each sheet of plywood is to bear the mark of a recognized association or independent inspection agency that will maintain a continuing control over the quality of the plywood. The mark is to identify the plywood by species group or identification index, and show the glue type, grade, and compliance with BS 6566.

4.3.2

Hardwood Plywood

1

Hardwood plywood is to comply with the relevant provisions of BS EN 635 Part 2.

2

Fire resistant hardwood plywood

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core is to be exterior type softwood plywood; face and back veneer to be untreated; factory seal planed edges, to prevent loss of fire retardant by the manufacturers

(b)

plywood panels are to meet all requirements for flamespread, smoke developed and fuel contributed, when tested in accordance with BS 576

(c)

each panel is to bear the label of testing agency designating rate of flame spread, fuel contributed and smoke developed.

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Marine Plywood

1

Marine plywood shall comply with the relevant provisions of BS 1088 and BS 4079.

4.4

WOOD PANELING

4.4.1

General

1

This part specifies requirements for use of board planks or sheet panelling of unfinished or pre-finished surfaces for use as wall covering, wainscots, or built-in type furniture such as counter surfaces.

4.4.2

Board Planking

1

Timber type and finish to be applied is to be as specified by the Project Documentation.

2

Unless specified otherwise board planks are to be as follows:

4.4.3

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4.3.3

(a)

timber stock to be 19 mm thick with each board in one piece floor to ceiling, V-cut as shown on plans

(b)

blind nail each board at each bearing on furring strips.

Wall Sheet Paneling

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 04: Architectural Timbers

Page 6

Use hardwood plywood, premium grade, with unfinished or factory prefinished surface. Project drawings will specify, thickness and if surface will be vertical V-grove random planked, or flush grooved.

2

Joints are to be tightly butted and plumb.

3

Panelling is to be laid vertically and blind nailed to wood furring.

4

Wood mouldings are to be solid wood members of the same species as the wall paneling.

5

The Type of finish required on factory prefinished wall panels to be as specified on the drawings.

4.5

BLOCKBOARD AND LAMINBOARD

4.5.1

General Requirements

1

Blockboard and laminboard to be free from bow, twist and warp and conform to BS 3444.

2

On 3-ply boards the thickness of the veneers to be a minimum of 2.5 mm and a maximum of 3.6 mm.

3

Cores are to consist of strips of wood of the same species throughout any one board. In blockboard the width of each strip is not to be less than 8 mm and not more than 25 mm, and in laminboard it is not to be less 7 mm.

4

The strips are to be laid side by side with the grain parallel and run in the longer direction of the board. The strips may be butted end to end provided there is not gap at the butt and that the butts in adjacent strips are staggered by at least 150 mm. The strips are to be assembled in such a manner that the finished board is the equivalent of a solid slab free from all voids.

5

The grain of each veneer is to be parallel to that of the corresponding veneer and that of the veneers next to the core to be at right angles to the direction of the strips in the core.

6

Face plies Class 1 and Class 2 finish to be as for plywood except that Class 1 finish veneers may be of one or more pieces. When of more than one piece it is to be well jointed and matched for colour at the joints. The pieces are to be equal in width subject to a deviation of ± 10% and not less than 250 mm wide.

4.5.2

Fixing Laminated Timber Boards

1

Blockboard and laminboard are to be fixed with the laminations running in the direction of the longest span.

2

Blockboard and laminboard are not to be used externally.

3

Plywood is not to be installed with exposed edges in external work.

4

The new edges formed by cut-outs in laminated timber boards for sinks, taps and the like are to be liberally coated with waterproof glue to form a seal.

4.6

LAMINATED PLASTIC SHEET

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 04: Architectural Timbers

4.6.1

General Requirements

1

Laminated Plastic is to comply with BS 2572 and BS 4965.

Page 7

(a)

standard grade: thickness is to be not less than 1.59 mm for horizontal work and 0.08 mm for vertical work

(b)

bending grade: thickness is to be not less than 0.60 mm for on site bending to a radius of 75 mm or less

(c)

post formed grade: minimum thickness to be 1.1 mm.

Fixing Laminated Plastics

1

Adhesive to be used in accordance with the manufacturer’s recommendations and be approved by the sheet surfacing manufacturer. Adhesives other than a contact type are to be bonded in presses.

2

Where veneers are next to each other they are to be matched both for colour and pattern.

3

When not otherwise specified, the Contractor is to apply to the back face a sheet of similar timber veneer the same thickness as the face veneer, ensuring that moisture content of the veneers is equal.

4

When using laminated plastics, a sheet of similar material and thickness to the face sheet is to be applied to the back face unless otherwise specified. The material to be conditioned before fixing in accordance with the manufacturer’s recommendations.

5

Edges of laminated plastics are to be chamfered at all external angles. Standard grade is to be used for flat work and postforming grades for shaped work. The material is to be bonded to chipboard, blockboard or plywood of at least 15 mm thickness.

6

Joints are to be made level by positioning cores splines or dowels and tightened by means of drawbolts. Joints between postformed sections should be mitred at 45º for accurate positioning. Vertical joints are to be bevelled to produce a V joint.

4.7

MISCELLANEOUS WOOD PRODUCTS

4.7.1

Building Board (Handboard)

1

Building board is to comply with the relevant provisions of BS 1142.

4.8

STAIRWORK AND HANDRAILS

4.8.1

Wood Handrails

1

To be installed in one piece and one length when practical. Where rails change slope or direction, a special or curved section is to be used.

2

Ends of rails are to be returned to the wall.

3

Rails are to be secured with wood screws to metal brackets at approximately 450 mm centres as detailed in the Project Documentation.

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 04: Architectural Timbers

Page 8

Wall handrails for stairs are to start on line with the first riser and terminate on line with the last riser, or as indicated in the project documentation.

5

Joints are permitted only where the rail changes direction or slope, or where necessary for field erection or shipping. Scarf or dowel all joints to provide smooth and rigid connections. Glue all joints. Joints are to be fitted to show not more than a hair-line crack.

6

Handrails are to be completely shop fabricated in accordance with approved shop drawings.

7

Brackets for wood handrails are to be cast aluminum with satin polish finish or extruded aluminum with a mechanical applied medium satin finish or malleable iron castings or as specified in the project documentation.

8

Anchor brackets as detailed in the drawings. Install brackets within 300 mm of end of handrails and at evenly spaced intervals between, not exceeding 1500 mm on centres and at intervals between as shown on drawings.

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END OF PART

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 05: Joinery

Page 1

5

JOINERY ....................................................................................................... 2

5.1

GENERAL REQUIREMENTS ........................................................................ 2

5.1.1 5.1.2

Scope References

5.2

WORKMANSHIP ........................................................................................... 2

5.2.1

Joinery Workmanship

5.3

TIMBER DOOR TYPES ................................................................................. 3

5.3.1 5.3.2 5.3.3 5.3.4

Flush Doors Fire Resisting Door Assemblies Hanging Timber Doors Door and Window Frames, Sub-frames and Linings

5.4

PURPOSE MADE FITTINGS......................................................................... 5

5.4.1

General Requirements

5.5

ARCHITRAVES, QUADRANTS, BEADS ....................................................... 6

5.5.1

General Requirements

5.6

TIMBER SKIRTINGS ..................................................................................... 6

5.6.1

General Requirements

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 05: Joinery

Page 2

5

JOINERY

5.1

GENERAL REQUIREMENTS

5.1.1

Scope

1

This Part specifies workmanship and special detail construction for doors, windows, architraves, beads, and timber skirting, and speciality wood flooring of block or parquet strips.

2

Related Sections are as follows:

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This Section Part 1 Part 2 Part 3 Part 4 Part 6 Part 7 References

1

The following standards are referred to in this Part:

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5.1.2

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BS 476 ........................Fire tests on building materials and structures BS 729 ........................Hot dip galvanised coatings on iron and steel articles BS 1202 ......................Nails

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BS 1186 ......................Quality of timber and workmanship in joinery

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BS 1204 ......................Synthetic resin adhesives (phenolic and aminoplastic) for wood

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BS 1210 ......................Wood screws BS 3794 ......................Decorative laminated plastic sheet

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BS 4756 ......................Ready mixed aluminium priming paints for woodwork

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BS 5358 ......................Solvent-borne priming paints for woodwork

WORKMANSHIP

5.2.1

Joinery Workmanship

1

Timber used for joinery work is to be finished to the sizes indicated in the Project Documentation and to BS 1186.

2

The joinery to be constructed exactly as shown on the drawings. Where types of joints are not specifically indicated they are to be recognised forms of joints for each position and shall be made so as to comply with BS 1186, Part 2.

3

All joints are to be glued and screwed or doweled to BS 1204, BS 1210 or BS 1186 as applicable.

4

Exposed and semi-concealed joinery is to be planed and sanded to remove all machinery and other surface defects so that after application of the specified finish imperfections in manufacture will not be apparent.

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Section 18: Carpentry, Joinery and Ironmongery Part 05: Joinery

Page 3

Exposed edges and corners are to be sanded off to form a “ pencil rounded” arris.

6

Architraves, cover fillets, skirtings and the like are to be accurately shaped to fit the contour of any irregular surface against which they are required to form a close connection.

7

Joinery for painting on site is to be primed before delivery to the site to BS 4756, BS 5358.

5.3

TIMBER DOOR TYPES

5.3.1

Flush Doors

1

Minimum door leaf thickness is to be: internal door

40 mm

(b)

external door

45 mm

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.

5

Solid core doors to be comprise of softwood timber battens laminated together with a minimum 4mm plywood skin. The core laminations softwood are to be a maximum 50 mm wide and are to be laid alternately to balance stresses.

2

Semi-solid core doors are to contain a minimum 50% timber and are to be constructed on the stressed skin principle having a minimum 4 mm plywood skin.

3

Exterior quality doors are to be constructed using Type WBP adhesives and an exterior quality 4 mm plywood skin.

4

All facing materials including veneered materials are to be such that the following defects do not appear on the finished surfaces: lifting at edges

(b)

blistering

(c)

sinking or raising of the surface due to knots or other defects in the core material

(d)

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ripple effect whereby the construction of the core is seen on the face of the door. to BS 3794

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2

Doors are to be hardwood lipped on both horizontal and vertical edges. Lippings to be solid and measured at least 8 mm on the face of the door. Lippings to doors with a Class 1 finish are to match the face skin.

5

If the construction of the door is such that the lock, hinges or bolts can only be fitted where blocks are provided to receive them, the position and extent of the blocks are to be indicated by a suitable markings on the edge of the door. Where a surface mounted closer or a flush bolt is specified, blocks shall also be suitably positioned to receive them.

6

Where a flush or mortised door closer is specified a solid timber rail insert minimum 75 mm wide is to be provided for all door types. Closers are to not be fixed to the end grain of solid core doors.

7

Openings for glazing or grilles in semi-solid core doors are to be formed with a sub-frame all round the opening minimum 36 mm wide.

QCS 2014

8

Section 18: Carpentry, Joinery and Ironmongery Part 05: Joinery

Page 4

The maximum deviation from a true plane on either face of a door when measured by a straightedge is to be: (a)

(bow in length : 3 mm

(b)

horizontal bow : 2 mm

(c)

deviation from the true plane (twist) : 4 mm

(d)

the ends of the braces are to be splay notched to the ledges and the ends of the ledges set back 15 mm from the edges of the door. The direction of the braces should be upwards from the hanging stile.

Fire Resisting Door Assemblies

1

Half-hour and one-hour fire resisting door assemblies are to have a minimum fire resisting performance when tested in accordance with BS 476, Part 8 of 30/30 and 60/60 respectively.

2

The door and frame of fire resisting door assemblies are to be supplied by the same manufacturer and be installed strictly in accordance with his instructions.

3

A copy of the Test Certificate shall be submitted to the Engineering for each type of door assembly supplied.

4

The doors to generally comply with the requirements of Part 5.2.1 and are to have a minimum 4 mm plywood skin.

5

The doors are to be marked on the hanging stile with an appropriate reference indicating the fire resisting performance of the door assembly.

6

Doors are to be fitted with an automatic self-closing device and be hung on a minimum of three hinges, manufactured from non-combustible material having a melting point in excess of 850ºC. Rising butt hinges are not acceptable as an automatic self-closing device. No „HOLD OPEN OPTION‟ is permitted unless the magnetic catch is operated by the fire alarm system.

5.3.3

Hanging Timber Doors

1

The maximum clearance between frames and door when hung is to be 3 mm.

2

The maximum clearance between an internal door and finished floor level is to be 6 mm (unless noted to be undercut) and between an external door and threshold or finished floor level to be 3 mm.

3

External doors and doors exceeding 20 kg in weight are to be hung on three 100 mm x 75 mm hinges as a minimum.

4

Hinges to be stainless steel, aluminium or brass as noted in the project documentation or as directed by the Engineer and to BS 729 where applicable.

5.3.4

Door and Window Frames, Sub-frames and Linings

1

Frames, sub-frames and linings are collectively referred to as “frames” in this Part.

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5.3.2

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 05: Joinery

Page 5

Frames are to be manufactured with either mortise and tenon or tongued joints so as to be square and flat.

3

The backs of frames are to be painted with two coats of primer to BS 5358, or BS 4756 before installation.

4

Frames to be fixed plumb, level and securely to prevent deflection or movement.

5

Frames built-in as the surrounding structure is constructed are to be fixed with cramps at maximum 600 mm centres. One cramp to be located 200 mm from the bottom of the frame and one 200 mm from the top or at the nearest adjacent bed joint. All cramps are to be secured to the frame by two screws. Alternative fixing methods are to be approved by the Engineer and to BS 1202, BS 1204, and BS 1210 as applicable.

6

Frames which are to be built-in are to be temporarily braced sufficient to prevent distortion.

7

Frames to previously prepared openings are to be fixed with screw fastenings at maximum 450 mm centres. One fastening is to be located 200 mm from the bottom of the frame and one 200 mm from the top.

8

Packing between the frame and reveal to accurately position the frame in a previously prepared opening is to be hardwood, located only where the fastenings tighten against the reveal.

9

Screw fastenings are to extend into the structural reveal by at least 40 mm or the thickness of the frame excluding any stop, whichever is the greater.

10

Door frames which occur in wet areas should not extend below the finished floor level.

5.4

PURPOSE MADE FITTINGS

5.4.1

General Requirements

1

Fittings to be constructed in accordance with Part 7 and are to be installed plumb and true.

2

Critical site dimensions are to be checked before commencing manufacture of the fittings and no fittings dimension is to be altered without the approval of the Engineer.

3

All surfaces are to be smooth and free from splinters and no parts to have exposed rough or sharp edges whether on the inside or outside of the fitting.

4

Where a door overlaps the frame or another door the face of the rebate is not to be more than 1.5 mm from the face of the frame or door at any point.

5

Where a door is fitted into the surrounding framework the clearance between each edge of the door and the frame or another door should not be more than 1.5 mm.

6

Door hinges or pivots are to be fitted in alignment.

7

Drawers should slide freely and be fitted with runners and guides so that there is no undue play in any direction which could produce wedging or jamming.

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Section 18: Carpentry, Joinery and Ironmongery Part 05: Joinery

Page 6

Where a drawer overlaps the frame, the face of the rebate is not to be more than 1.5 mm from the face of the frame at any point when the drawer is closed.

9

Where a drawer is fitted into the surrounding frame work the clearance around the edge of the drawer when closed is not to be more than 1.5 mm.

5.5

ARCHITRAVES, QUADRANTS, BEADS

5.5.1

General Requirements

1

Architraves, quadrants, beads and the like are to be in unjointed lengths between angles or ends of runs. Angle joints to be mitred.

2

Architraves and quadrants should not be installed until after the wall coverings have been formed or constructed.

3

Glazing beads where required are to be wrought splayed and rounded and be neatly mitred and fixed with small brads or lost-head mails.

5.6

TIMBER SKIRTINGS

5.6.1

General Requirements

1

Skirting are to be fixed with screws at maximum 600 mm centres.

2

Angle joints to be mitred. Joints in the running length should be kept to a minimum and where necessary be splayed.

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END OF PART

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 06: Fasteners and Adhesives

Page 1

6

FASTENERS AND ADHESIVES ................................................................... 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2

Scope References

6.2

FASTENERS ................................................................................................. 2

6.2.1 6.2.2 6.2.3

Nails and Screws Fastenings Pellating

6.3

ADHESIVES .................................................................................................. 3

6.3.1

General Requirements

6.4

ROUGH HARDWARE AND FRAME CRAMPS ............................................. 3

6.4.1 6.4.2

General Products

2 2

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 06: Fasteners and Adhesives

6

FASTENERS AND ADHESIVES

6.1

GENERAL

6.1.1

Scope

1

This part deals with the specification of fasteners and adhesives.

2

Related Sections are as follows:

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General Framing furring and blocking Wood doors Architectural timbers Joinery

References

1

The following standards are referred to in this Part:

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6.1.2

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Page 2

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BS 729 ........................Hot dip galvanised coatings on iron and steel articles. BS 1202 ......................Nails

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BS 1210 ......................Wood screws

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BS 1204 ......................Synthetic resin adhesives (phenolic and aminoplastic) for wood

FASTENERS

6.2.1

Nails and Screws

1

Nails and screws are to comply with BS 1202, Part 1 and BS 1210 respectively.

6.2.2

Fastenings

1

Fastenings in external areas are to be sheradised, galvanised or non-ferrous.

2

Nails are not to be less than 25 mm long or 2½ times the thickness of the member through which the nails are being driven, whichever is the greater.

3

Screws are not be less than 12 mm long or twice the thickness of the member through which the screws are being driven, whichever is the greater.

4

Regardless of the specified minimum lengths, nails and screws are not to be longer than the total thickness of the members being joined, less 5 mm.

5

Nail heads should be punched, and screw heads not required to be pellated to be countersunk, not less than 2 mm below surfaces which will be visible in the finished work, the holes filled with putty or a proprietary filler and sanded smooth and flush.

6

Plugs for screw fastenings into blockwork or concrete are to be of proprietary manufactured sized to suit the screw. Wooden plugs will not be permitted.

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 06: Fasteners and Adhesives

Page 3

Pellating

1

Screw heads which are to be pellated are to be countersunk 6 mm below the timber surface. Pellets to be cut from matching timber not less than 6 mm thick, glued in with the grain matched, planed and sanded off flush with the face.

2

Screw heads are to be pellated where the timber surface is to receive a clear finish.

6.3

ADHESIVES

6.3.1

General Requirements

1

Adhesives used in carpentry and joinery work should be synthetic resin adhesives complying with BS 1204, Parts 1 and 2 Type WBP for all external work and Type BR for internal work.

6.4

ROUGH HARDWARE AND FRAME CRAMPS

6.4.1

General

1

This Part specifies fasteners and fastening systems used for Structural Timber construction and within some framing with Architectural woodwork.

6.4.2

Products

1

Cramps to be mild steel size 2 x 25 x 250 mm girth, galvanised after fabrication to BS 729, turned up at one end and drilled twice for 3 mm diameter screws and fishtailed at the other end for building in.

2

Furnish rough hardware, except nails, with a standard plating, applied after punching, forming and assembly of parts. Galvanised anchors and bolts (with nuts and washers), straps, and hangers except bolts may be cadmium plated, or zinc-coated by electro-galvanising process. Aluminium-alloy nails, plated nails, or zinc-coated nails, for nailing woodwork exposed to weather are to be used. Bolt heads and nuts bearing on wood should be fitted with washers. For work exposed to the weather, washers of cast iron, or zinc or cadmium coated steel are to be used. Special nails as required for use with ties, anchors, framing connectors, joint hangers and similar items are to be used in accordance with the item manufacturers instructions or as directed by the Engineer.

3

Joist Ties: Are to be mild steel flats, 5 mm by 32 mm size with ends bent 30 degrees from horizontal, and extending at least 40 mm onto the framing. Each end to be punched for three spikes.

4

Wall anchors for Joists and Rafters: Provide a mild steel strap, 5 mm by 32 mm with wall ends bent 50 mm, or provide 9.5 mm by 127 mm pin through the strap and build into masonry. Provide anchors parallel to framing long enough to extend at least 406 mm onto framing and punch for three spikes. Provide anchors at right angles to framing; long enough to extend onto three joists or rafters, punched for spiking at each bearing.

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END OF PART

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 07: Ironmongery

Page 1

7

IRONMONGERY ........................................................................................... 2

7.1

GENERAL ...................................................................................................... 2

7.1.1 7.1.2

Scope References

7.2

PRODUCTS ................................................................................................... 2

7.2.1 7.2.2

General Finish

7.3

FITTING AND TESTING ................................................................................ 3

7.3.1

General Requirements

7.4

STANDARD IRONMONGERY FOR INTERNAL DOORS ............................. 3

7.4.1

General Requirements

7.5

ELECTROMAGNETIC LOCKING SYSTEMS ................................................ 4

7.5.1 7.5.2 7.5.3 7.5.4 7.5.5 7.5.6 7.5.7 7.5.8

Scope Quality Assurance Submittals Delivery and Storage Warranties System Description Locking Devices Power Supply and Control Unit

2 2 2 3

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 07: Ironmongery

7

IRONMONGERY

7.1

GENERAL

7.1.1

Scope

1

This Part deals with the specification of ironmongery items.

2

Related Sections are as follows: Section 1 Section 17 Section 21

Page 2

General Metal Work Electrical Works

References

1

The following standards are referred to in this Part:

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BS 3621 ......................Specification for thief resistant locks

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BS 5725 ......................Emergency Exit Devices BS 6462 ......................Casement stays

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BS 6459 ......................Door closers BS 7036 ......................CP for powered doors

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BS 7352 ......................Specification for metal hinges BS EN 60730 ..............Electrically operated door locks

PRODUCTS

7.2.1

General

1

The Contractor is to provide and fix ironmongery required by the Project Documentation complete, including all necessary screws, bolts, plugs and other fittings. The use of nails for fixing ironmongery will not be permitted. The Contractor to hand over all work in a finished state and to the satisfaction of the Engineer.

2

All ironmongery is to be of first quality and be obtained form an approved manufacturer. Butt hinges are to be aluminium alloy, stainless steel or brass as specified with double stainless steel washers to BS 7352.

3

The Contractor will be required to submit for approval samples of all items of ironmongery that he proposes to use.

4

All doors are to be provided with an approved floor stop plugged and screwed to the floor or wall and all opening areas of aluminium work (louvered doors) are to be provided with appropriate stays (friction type to plant room or service area doors opening out) to BS 6462. The size, materials, finishes, type and quality of ironmongery will be as described in the Project Documentation.

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Section 18: Carpentry, Joinery and Ironmongery Part 07: Ironmongery

Page 3

Finish

1

The finish of the various items of ironmongery is to be as described in the Project Specification or shown on the Drawings.

2

Ironmongery not obtainable from the same range and/or manufacturer as the general ironmongery for the Works is to match the general ironmongery as closely as possible.

3

Ironmongery to metal windows and doors is generally to match the general framing and is to be supplied and fixed with matching metal fixing screws and bolts and additional plates.

7.3

FITTING AND TESTING

7.3.1

General Requirements

1

All screws used for fixing ironmongery are to be of the correct type, material, finish, size and shape to the approval of the Engineer.

2

The hinges on which doors, windows, flyscreen doors, etc., are hung are to be carefully housed or let into the door, window, flyscreen doors, etc., and to the frames.

3

All fittings are to be removed before commencing any painting operations and are to be refixed in place after all painting works are completed and approved by the Engineer.

4

All ironmongery is to be carefully wrapped and protected until the completion of the work and any items or parts which are damaged or defaced or found to be defective are to be replaced at the Contractor’s expense before handing over.

5

On completion of all locks, catches and similar items of ironmongery they are to be properly cleaned, tested and oiled, and all keys are to be clearly labelled with metal tags approximately 50 x 20 mm and securely fixed to the keys and handed to the Engineer. Thief resistant locks are to BS 3621.

6

Door closers are to be fitted a maximum of two weeks before handover. Power door closers are to BS 7036 and other standard closers to BS 6459 as applicable.

7

All floor and door springs are to be fully charged with oil and their operation checked to the satisfaction of the Engineer.

8

Hinges are to be fitted in a standard position 250 mm from the top or bottom edge of the door to the centre of the hinge. Where a third hinge is fitted it is to be located centrally between the top and bottom hinges.

9

Locks are to be fitted so that the centre of the handle is at height of 1020 mm from the bottom of the door and to BS 3621 as applicable.

7.4

STANDARD IRONMONGERY FOR INTERNAL DOORS

7.4.1

General Requirements

1

Each door leaf is to be fitted with 1½ pairs of 100 x 75 mm satin anodised aluminium, stainless steel or brass, double stainless steel washered butts unless otherwise noted in the Particular Project documentation and drawings.

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7.2.2

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 07: Ironmongery

Page 4

Where a supplier cannot offer the particular required ironmongery the Contractor is to produce samples of other supplier’s items most nearly matching the general ironmongery and/or produce alternative ironmongery by the main supplier most closely conforming with the specification for the approval of the Engineer and to BS 7352.

3

All locks are to be provided with 2 keys on a key ring neatly labelled.

4

‘Master Key’ locking systems are as stated in the Project Documentation.

5

All knob sets are to include for the appropriate mortise latch or lock with a 70 mm backset and with standard face-plates and roses unless otherwise noted.

7.5

ELECTROMAGNETIC LOCKING SYSTEMS

7.5.1

Scope

1

This Part covers the furnishing and installation of a complete low-voltage electromagnetic locking device door control and monitoring system. Specified for all new or existing exterior doors as designated on drawings by a hardware set number.

2

Supply and install all electric hardware devices, mounting brackets, power supplies, switches and controls, monitoring console and other components of the system as specified and to BS 7036.

3

Supply templates, wiring diagrams and installation instructions necessary for the coordination of the work and for proper installation, connection and operation of the system.

4

Provide all outlets, junction boxes, conduit, connectors, wiring, and other accessories necessary to complete the system installation. Requirements to be in accordance with Section 21, Electrical Works.

5

Requirements for conduit, wiring, devices, boxes and other items required to provide line current (110V-AC to 125V-AC) to refer Section 21, Electrical Works.

7.5.2

Quality Assurance

1

Manufacturer's Qualifications: Approval of the Engineer is required for products or services of proposed manufacturer, supplier and installer and will be based upon the following criteria:

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(a)

Locking devices, power supplies, controls and monitoring system to be products of a single manufacturer regularly and currently engaged in production of electromagnetic security locking systems.

(b)

The manufacturer's products to have been in satisfactory operation on at least three similar installations for not less than three years..

(c)

The installer to be a permanent organisation approved by the manufacturers, having facilities and employing trained personnel with technical qualifications and experience to prepare the installation, to install the required system and to provide periodic maintenance. The installer is to maintain a parts inventory and employ trained personnel at a location within a 100 mile radius of the project. The installer should have been installing security systems for a period of not less than three years.

QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 07: Ironmongery

Page 5

2

Door and frame components, including locking device, are to have been tested by an approved independent testing laboratory.

7.5.3

Submittals

1

In accordance with procedures of Section 1, General, the Contractor is to furnish manufacturer's literature and product data including, but not limited to the following: (a)

complete descriptive data and details for each component, including dimensions, finishes, wiring diagrams, test reports, operation, and installation instructions.

(b)

details for the complete system, including colour-coded wiring diagrams, interface with other systems, specific locations of all concealed components, operation, maintenance procedures, and information concerning requirements not included in printed data.

Delivery and Storage

1

Components of the system are to be delivered to the job site in their original cartons, labelled with complete information for identification and containing installation instructions, screws and mounting accessories.

2

Store equipment in a dry storage facility and in an orderly manner, protected from the damage by weather and construction operations.

7.5.5

Warranties

1

A written manufacturers warranty for a period of not less than five years from the date of final acceptance against manufacturing defects in principal components of the system, including the control console, electromagnetic locks and power-control units to be provided. Components under warranty which prove to be defective are to be satisfactorily repaired or replaced without additional cost to the Client.

2

A written service contract for a period of two years from the date of final acceptance providing for periodic inspection and call-back service and prompt adjustment, repair or replacement of malfunctioning components without additional cost to the Client is to be provided.

7.5.6

System Description

1

The locking system is to be a "fail-safe open" system so that all doors will fail unlocked in the event of a power failure. The electromagnetic locking system should not be connected to the emergency power supply.

2

Electromagnetic locks are to release immediately (authorised exit) if one of the following occurs, without setting off alarms.

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7.5.4

(a)

fire alarm is activated by sprinkler system

(b)

power fails

(c)

key operated switch is activated

(d)

console release switch is activated

(e)

other authorised release is activate

QCS 2014

3

Section 18: Carpentry, Joinery and Ironmongery Part 07: Ironmongery

Page 6

Electromagnetic locks are to release after 30 seconds (field adjustable 10 to 30 seconds) unauthorised exit but immediately notify central console if one of the following occurs and shall set off local alarms: (a)

exit device push bar is activated

(b)

push plate operator is activated

(c)

pull station operator is activated

(d)

other unauthorised release is activated

Electromagnetic locks are to be controlled by time devices and be wired through the console to allow locks to be unlocked or locked as required during certain time of day. Field programmable time clocks are to be provided so that each exit can be individually controlled.

5

Each lock is to be wired through a separate power supply and be controlled and monitored by a central control console and additionally monitored by a second console.

6

The lock control wiring is to be supervised so that any break between lock and console will cause a notice at the console.

7

Manual Doors: Pushing on the cross bar of either exit device shall activate an irreversible 30 second time delay device (field adjustable 10 to 30 seconds) and set of an alarm (unless authorised exit device has been activated first in which case the alarm will not sound), and in 30 seconds electromagnet will release and allow the door to open in accordance with BS 5725.

8

Automatic Doors: A push plate wall switch or other method to operate automatic doors should to conform to BS EN 60730 Section 2.12, and wired through a 30 second time delay (field adjustable 10 to 30 seconds) so that the switch will not open the doors until the delay release of electromagnet has occurred. When the electromagnet is deenergised, normal switches to operate the automatic doors will be operable.

9

An Exit device is to be installed on each exterior door equipped with an electromagnetic lock to accomplish activation of 30 second time delay.

7.5.7

Locking Devices

1

Locks are to be electromagnetic type, without a mechanical linkage utilising no moving parts, and securing the door to its frame solely by electromagnetic force. For a pair of swinging doors, the two electromagnetic devices are to be mounted in a common housing. For bi-parting sliding doors the unit is to be designed with an electromagnetic component mounted in stile of one leaf and the armature in the other.

2

The lock are to have an internal, replaceable voltage kick-back protection.

3

A door status switch, single pole double throw adjustable for sensitivity, is to be semi or fully concealed within the lock housing to prevent tampering and attempts to defeat the system.

4

The door-mounted armature is to have provisions for adjusting alignment to compensate for normal door wear and tear.

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QCS 2014

Section 18: Carpentry, Joinery and Ironmongery Part 07: Ironmongery

Page 7

7.5.8

Power Supply and Control Unit

1

The power supply-control unit is to power and control the electromagnetic lock. One unit to be provided for each entrance and be capable of supplying and controlling a pair of doors. If located more than 12 m from the lock, the wire size will be increased for the additional voltage drop.

2

The unit will have provisions for interfacing with a panic hardware exit switch.

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END OF PART

QCS 2014

Section 19: Pluming work Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2

Scope References

1.2

REGULATIONS AND STANDARDS ............................................................. 2

1.2.1 1.2.2

Qatar General Electricity & Water Corporation Compliance with Standards

1.3

CONTRACTOR’S RESPONSIBILITY ............................................................ 2

1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6

General Approval to Carry Out Plumbing Works Registration of Plumbers and Plumbing Contractors Notice of Intent Existing Services Maintenance Period Requirements

1.4

CRAFTSMEN................................................................................................. 3

1.4.1 1.4.2

Workmanship Qualifications

1.5

MATERIALS .................................................................................................. 3

1.5.1

General

1.6

DRAWINGS ................................................................................................... 4

1.6.1 1.6.2 1.6.3 1.6.4

Explanation of Project Drawings Shop Drawings Co-ordination Drawings Record Drawings

1.7

SITE WORKS ................................................................................................ 5

1.7.1 1.7.2 1.7.3 1.7.4 1.7.5

Openings Painting Co-operation with other Trades. Protection of Finish Clean-Up

1.8

OPERATION AND MAINTENANCE MANUALS ............................................ 6

1.8.1

General Requirements

2 2

2 2 3 3 3 3 3 3 3 4 4 4 5

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QCS 2014

Section 19: Pluming work Part 01: General

Page 2

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies the requirements for the construction and installation of all works associated with the supply, storage and distribution of potable water, with the exception of those works normally undertaken by the Qatar General Electricity & Water Corporation (QGEWC).

1.1.2

References

1

Related Sections are as follows:-

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General Mechanical and Electrical

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1

REGULATIONS AND STANDARDS

1.2.1

Qatar General Electricity & Water Corporation

1

The Contractor shall conform to all the requirements of the “Rules and Regulations for Plumbing Works” as prepared by QGEWC.

1.2.2

Compliance with Standards

1

It is required that certain products, components and materials covered in this Section comply with the provisions of particular standards (e.g. British Standards). Where there is a conflict between a particular referenced standard and the requirements of QGEWC, the latter shall prevail.

2

The Contractor shall conform to any requirements QGEWC may have with respect to ensuring that products, components and materials comply with any referenced standard. Such requirements may include, but not be limited to, samples, test results and supporting documentation.

1.3

CONTRACTOR’S RESPONSIBILITY

1.3.1

General

1

The Contractor is responsible for obtaining all necessary approvals and permits required to complete the Works.

1.3.2

Approval to Carry Out Plumbing Works

1

Approval to carry out plumbing works must be obtained from QGEWC for new installations and extensions or alternations to existing installations.

2

All approval procedures shall be as required by QGEWC.

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1.2

QCS 2014

Section 19: Pluming work Part 01: General

Page 3

Registration of Plumbers and Plumbing Contractors

1

All plumbers and plumbing contractors shall be approved by QGEWC.

2

All QGEWC water supply works shall be carried out by a contractor or sub-contractor prequalified and approved by the QGEWC. Proof of such approval shall be required in writing prior to the Works commencing on Site and the name of any sub-contractor to be used shall be entered in the appropriate forms when the tender is submitted.

1.3.4

Notice of Intent

1

The Contractor shall notify QGEWC in writing at least 14 days prior to the commencement of any plumbing works.

2

During the course of the Works, QGEWC or its nominated representative shall have full access to the Works.

1.3.5

Existing Services

1

The Contractor is responsible for locating and identifying all existing services in the area of the work or likely to be affected by the Work.

1.3.6

Maintenance Period Requirements

1

The Contractor is responsible for all the maintenance period requirements for all parts and components of the Works covered in this Section. Such requirements shall include, but not be limited to, the requirements of the Project Documentation and the manufacturer’s recommendations.

1.4

CRAFTSMEN

1.4.1

Workmanship

1

Construction of each part of the Works covered in this Section shall be undertaken by experienced craftsmen capable of performing the tasks allocated to them in a professional and competent manner.

2

If required by the Engineer, the Contractor shall instruct craftsmen to demonstrate their ability to perform tasks allocated to him.

1.4.2

Qualifications

1

Where the Project Documentation specifies that specialist craftsmen are required to undertake a specific work task, the Contractor shall furnish the Engineer with copies of qualifications pertinent to performing such work tasks for those craftsmen who will be undertaking the work.

1.5

MATERIALS

1.5.1

General

1

All materials, components and products shall comply with the relevant provisions of Section 1, General, subject to the provisions of Clause 1.2.2 of this Part.

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QCS 2014

Section 19: Pluming work Part 01: General

Page 4

All materials, components and products shall be supplied by experienced and approved manufacturers as designated in the Project Documentation and to the written approval of the Engineer.

1.6

DRAWINGS

1.6.1

Explanation of Project Drawings

1

For purposes of clearness and legibility, the Project Drawings are essentially diagrammatic, and although size and location of equipment are drawn to scale where possible, the Contractor shall make use of all data in all of the Contract Documents and shall verify this information prior to and during construction.

2

Scale and figure dimensions are approximate and are for estimating purposes only. Before proceeding with any part of the Work, the Contractor shall assume all responsibility for the fitting of his materials and equipment to other parts of the Works.

3

All work not shown in complete detail shall be installed in conformance with accepted standard practice and manufacturer’s recommendations.

4

All items shall be installed in a manner and in locations avoiding all obstructions, preserving headroom and keeping openings and passageways clear. Changes shall be made to the location of equipment and materials as may be necessary in order to accomplish this.

5

The drawings are essentially diagrammatic to the extent that many offsets, beds, traps, special fittings and exact locations are not indicated. The Contractor shall carefully study the drawings and premises in order to determine the best methods, exact locations, route, building obstructions, etc., and shall install all apparatus and equipment in the available locations.

6

Work indicated on drawings, but not mentioned in Specifications, or vice versa, shall be performed as if specifically mentioned or indicated by both. Any supplementary labour or materials required for a complete, approved, and properly operating installation shall be furnished by the Contractor.

1.6.2

Shop Drawings

1

The Contractor shall prepare shop drawings for all parts of the Works to be installed or constructed under this Section and submit them to the Engineer for approval. The shop drawings shall include diagrams, illustrations, schedules, general arrangements of equipment and appurtenances in relation to buildings and structures, method statements and details of specialised installation and construction work.

1.6.3

Co-ordination Drawings

1

These shall be prepared by the Contractor to show how interdisciplinary work will be coordinated. The location, size and details of fixings, box-outs, ducts, holes, pipe chases and plinths shall be shown on the detailed layout drawings which are co-ordinated with all other work disciplines.

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QCS 2014

Section 19: Pluming work Part 01: General

Page 5

Record Drawings

1

The Contractor shall prepare Record Drawings of all works constructed or installed under this Section. These shall be prepared as work proceeds. They shall provide a record of any modification to materials and equipment, and to the layout, arrangement and installation of the Works.

1.7

SITE WORKS

1.7.1

Openings

1

The Contractor shall co-operate with all trades in obtaining information as to openings required in walls, slabs and footings for all piping and equipment. Sleeves shall be accurately located and placed in forms before concrete is poured. Where several pipes pass through floors in close proximity, the Contractor may provide a single framed opening in lieu of individual sleeves. Framed openings shall be to the approval of the Engineer and shall be provided with 100 mm high curbs, on all sides. The Contractor shall pay all extra costs for cutting of holes as a result of incorrect, delayed or neglected locations of sleeves or frame openings.

1.7.2

Painting

1

All finished painting shall be done as specified in the Project Documents. All apparatus and equipment, not specified otherwise, shall be provided with a shop prime coat. All exposed ironwork, tanks pipes, and fittings without factory finish, including pipe hangers and rods shall be primed and painted with one coat of black asphalt varnish suitable for hot surfaces. Exposed pipe threads in bare or insulated piping shall be thoroughly cleaned and painted with two coats of metallic paint or red lead.

1.7.3

Co-operation with other Trades.

1

The Contractor shall so organise work progress to harmonise with the work of all trades so that work may proceed as expeditiously as possible. The Contractor shall be responsible for the correct placing of the Works and the connection thereof to the work of all related trades.

1.7.4

Protection of Finish

1

The Contractor shall provide adequate means for, and shall fully protect, all finished parts of materials and equipment against damage from whatever cause during the progress of the work and until final completion. All materials and equipment in storage and during construction shall be covered in such a manner that no finished surfaces will be damaged or marred and all moving parts shall be kept perfectly clean and dry. All damaged or defective work shall be replaced prior to applying for final acceptance.

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1.6.4

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Section 19: Pluming work Part 01: General

Page 6

Clean-Up

1

During the progress of work, premises shall be kept reasonably free of the debris, waste materials and rubbish resulting from work carried out under this Section. Upon completion and before final acceptance of the Works, all debris, temporary protective coverings, rubbish, left-over materials, tools and equipment shall be removed from the Site. Exposed piping, machinery and other apparatus shall be thoroughly cleaned of cement, plaster, paint and other materials; grease and oil spots shall be removed with cleaning solvent. Surfaces shall be carefully wiped and all cracks and corners scraped clean. Chromium or nickel plated materials and equipment shall be thoroughly polished. The entire installation shall be left in a neat, clean and usable condition.

1.8

OPERATION AND MAINTENANCE MANUALS

1.8.1

General Requirements

1

The Contractor shall prepare Operation and Maintenance Manuals for all mechanical, electrical and electronic equipment installed under this Section.

2

Operation and Maintenance Manuals shall conform to the requirements of Clause 1.1.4 of Section 9.

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END OF PART

QCS 2014

Section 19: Plumbing Work Part 02: Water Distribution

Page 1

2

WATER DISTRIBUTION ............................................................................... 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3

Scope References Quality Assurance

2.2

WATER SYSTEMS........................................................................................ 3

2.2.1 2.2.2 2.2.3 2.2.4

General Requirements Cold Water Systems Hot Water Systems Pressurised Systems

2.3

PUMPS .......................................................................................................... 5

2.3.1 2.3.2 2.3.3 2.3.4 2.3.5

General Requirements Lift Pumps Circulation Pumps Pipework Connections Control

2.4

WATER DISTRIBUTION PIPEWORK ........................................................... 6

2.4.1 2.4.2 2.4.3

General Requirements Pipe Materials Pipework Jointing

2.5

PIPE FIXINGS ............................................................................................... 7

2.5.1 2.5.2

General Requirements Spacing of Pipe Fixings

2.6

TAPS, VALVES AND PROTECTION DEVICES ............................................ 9

2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.6.6

Draw-off Taps Drain Taps Ball Float Valves Servicing Valves Stopvalves Backflow Protection Devices

2.7

PIPE INSTALLATIONS ................................................................................ 12

2.7.1 2.7.2 2.7.3 2.7.4

General Requirements Pipework Expansion Pipe Sleeves Concealed Pipework

2.8

INSULATION OF WATER PIPES ................................................................ 13

2.8.1 2.8.2

General Application

2.9

MISCELLANEOUS ...................................................................................... 14

2.9.1 2.9.2

Electrical Work Related to Plumbing Works Water Meter Cabinet

2

2 2 3

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3 3 4 4 5 5 5 5 6 6 6 7 7 7 9 10 10 10 11 11 12 12 12 12 13 13 14 14

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Section 19: Plumbing Work Part 02: Water Distribution

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WATER DISTRIBUTION

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the requirements for the installation, testing and commissioning of services supplying water for use within buildings. It covers the system of pipes, fittings and connected appliances installed to supply any building with water for ablutionary, cleaning, sanitary and laundry purposes.

2

Related Sections and Parts are as follows:

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General Mechanical and Electrical

ta

Section 1 Section 9

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General Cold Water Storage Hot Water Storage Commissioning of Systems

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This Section Part 1 Part 4 Part 5 Part 6

.

2

References

1

The following standards are referred to in this Part:

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2.1.2

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BS 864 .......................Capillary and compression fittings for copper tubes and copper alloy.

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BS 1010 ......................Specification for draw-off taps and stopvalves for water services (screw-down pattern). BS 1212 ......................Specification for float operated valves (excluding floats).

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BS 1394 ......................Stationary circulating pumps for heating and hot water service systems. BS 1968 ......................Specification for floats for ballvalves (copper).

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BS 1972 ......................Specification for polythene pipe (Type 32) for above ground use for cold water services. BS 2456 ......................Floats (plastics) for float operated valves for cold water systems. BS 2494 ......................Specification for elastomeric joint rings for pipework and pipelines. BS 2580 ......................Specification for underground plug cocks for cold water services. BS 2871 ......................Specification for copper and alloy tubes. BS 2879 ......................Specification for draining taps (screw-down pattern). BS 3505 ......................Specification for unplasticized polyvinyl chloride (PVC-U) pressure pipes for cold potable water. BS 3958 ......................Thermal insulating material. BS 4127 ......................Specification for light gauge stainless steel tubes. BS 4346 ......................Joints and fittings for use with unplasticized PVC pressure pipes. BS 4991 ......................Propylene copolymer pressure pipe. BS 5114 ......................Specification for performance requirements for joints and compression fittingsfor use with polyethylene pipes.

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Section 19: Plumbing Work Part 02: Water Distribution

Page 3

BS 5154 ......................Specification for copper alloy globe, globe stop and check, check and gate valves. BS 5163 ......................Specification for predominantly key-operated cast iron gate valves for waterworks purposes. BS 5412 ......................Specification for the performance of draw-off taps with metal bodies for water services. BS 5413 ......................Specification for the performance of draw-off taps with plastics bodies for water services. BS 5422 ......................Method for supplying thermal insulating materials on pipes, ductwork and equipment BS 5433 ......................Specification for underground stopvalves for water services.

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BS 6144 ......................Expansion vessels using an internal diaphragm, for unvented hot water supply systems.

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BS 6281 ......................Devices without moving parts for the prevention of contamination of water by backflow.

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BS 6282 ......................Devices with moving parts for the prevention of contamination of water by backflow. BS 6283 ......................Safety devices for use in hot water systems.

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BS 6437 ......................Specification for polyethylene pipes (type 50) in metric diameters for general purposes.

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BS 6572 ......................Specification for blue polyethylene pipes up to nominal size 63 for bellow ground use for potable water.

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BS 6700 ......................Specification for design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages.

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BS 7671 ......................Requirements for electrical installations. DIN 8079 ....................Pipes made of chlorinated PVC

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DIN 8080 ....................Pipes made of chlorinated PVC Quality Assurance

1

Items and equipment specified in this Part shall be provided by experienced and approved manufacturers and fabricators as designated in the Project Documentation or to the written approval of the Engineer.

2.2

WATER SYSTEMS

2.2.1

General Requirements

1

Internal hot and cold water supply installations shall be constructed so that water delivered is not liable to become contaminated to the extent that it is hazardous to health or is unfit for its intended use.

2.2.2

Cold Water Systems

1

Cold water systems shall be capable of providing cold water at the locations and in the quantities required and specified in the Project Documentation.

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2.1.3

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Section 19: Plumbing Work Part 02: Water Distribution

Page 4

All cold water draw-off points shall be served via a cold water storage tank. The cold water storage tank will be served directly from the Qatar General Electricity & Water Corporation (QGEWC) supply mains.

2.2.3

Hot Water Systems

1

Hot water systems shall be capable of providing hot water at the locations, in the quantities and at the temperatures required and as specified in the Project Documentation.

2

To promote maximum economy of fuel and water the hot water distribution system should be designed so that hot water appears quickly at the taps when opened. To this end, dead legs should be as short as possible. The hot water pipe feeding a spray tap for hand washing should not exceed 1 metre in length. When draw-off points are situated at a distance from the hot water storage vessel, consideration should be given to the use of a separate water heater installed close to those draw-off points. When this is impracticable a secondary circuit with flow and return pipes to the storage vessel should be considered. Secondary circuits inevitable dissipate heat and should be avoided where possible

2.2.4

Pressurised Systems

1

Whether hot or cold water is involved, it shall be ensured that no part of the system bursts due to the hydraulic pressures to which it is subjected. The pressures in the system shall never exceed the safe working pressures of the component parts. The maximum working pressure in a sealed primary circuit shall not exceed 3 bar but it shall be capable of passing a test at 1.5 times the working pressure at the working temperature. The maximum working pressure in an unvented hot water storage vessel or secondary circuit shall not exceed 6 bar.

2

Where necessary the supply pressure shall be controlled by using an atmospheric break tank or pressure reducing valves. If the supply to a storage type water heater is through a pressure reducing valve of the type that permits backflow, the working pressure in the system shall be assumed to be the maximum pressure upstream of the valve. Where reliance is placed on pressure reducing valves to limit the maximum working pressure, these shall comply with BS 6283: Part 4.

3

Provision shall be made to accommodate expansion of water by one of the following alternative methods:

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(a)

allow the expansion water to travel back along the cold feed pipe, provided that heated water cannot reach any communication pipe or branch feeding a cold water outlet

(b)

where reverse flow along the cold feed is prevented by a stopvalve a with loose jumper, replace this valve by one with a fixed jumper

(c)

where reverse flow along the cold feed is prevented, provide an expansion vessel in accordance with BS 6144 to accommodate expansion water. This vessel shall be sized in accordance with the volume of water heated and the water temperature rise so as to limit the pressure to the maximum working pressure for the system. The expansion vessel shall accommodate an expansion equal to 4% of the total volume of water heated. Any discharge from relief valves shall be readily visible and disposed of safely.

QCS 2014

Section 19: Plumbing Work Part 02: Water Distribution

Page 5

PUMPS

2.3.1

General Requirements

1

The installation of a pumped system should be undertaken by competent specialists experienced in such work.

2

Pumps shall be installed in accordance with the manufacturer’s recommendations and in an accessible location such that they may be readily maintained.

3

All pumps and associated equipment shall be capable of continuous operation in ambient 0 temperatures of up to 50 C.

4

Pumps shall be low speed and quiet in operation.

5

Pumps shall be firmly mounted. Measures to prevent vibration shall be taken where necessary.

6

No pump, required to increase pressure in or rate of flow from a supply pipe or any fitting or appliance connected to a supply pipe, shall be connected unless prior written approval from QGEWC is obtained.

7

Pumps located externally shall be provided with a suitable sun shade.

2.3.2

Lift Pumps

1

Centrifugal pumps with electric motors shall be used.

2

The pumps may be either the vertical type or horizontal type and shall be directly coupled to their electric motors.

3

Pump capacity shall be as stated in the Project Specification.

4

Where the pumping system has duty and standby pumps, the pumps shall be used alternately.

2.3.3

Circulation Pumps

1

Circulating pumps shall comply with the relevant provisions of BS 1394: Parts 1 and 2.

2

Circulating pumps shall be suitably suppressed to prevent radio and television interference.

3

Pump capacity shall be as stated in the Project Specification.

2.3.4

Pipework Connections

1

Flexible connections shall be used so as to prevent the transmission of pump and motor noise via pipework.

2

All pipework connections to and from the pump shall be adequately supported and anchored against thrust.

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2.3

QCS 2014

Section 19: Plumbing Work Part 02: Water Distribution

Page 6

Inlet and outlet pipework connections to lift pumps shall be fitted with gate valves complying with the relevant provisions Clause 2.10 of this Part.

4

Inlet and outlet pipework connections to circulating pumps shall be fitted with servicing valves complying with the relevant provisions Clause 2.9 of this Part.

2.3.5

Control

1

Pump control shall be as described in the Project Documentation.

2.4

WATER DISTRIBUTION PIPEWORK

2.4.1

General Requirements

1

Every pipe, pipe joint and connected fitting shall be capable of withstanding, without damage or deterioration, sustained temperatures of up to 40C for cold water installations and up to 70C, with occasional short-term peaks of up to 100C for heated water applications.

2

Pipes, pipe joints, pipe linings and connected fittings shall be made of materials that do not impart taste, colour, odour or toxicity to the water nor promote or foster microbial growth under the conditions where they are going to be installed.

3

If pipes, pipe joints or fittings are of dissimilar metals, measures shall be taken to prevent corrosion. Dissimilar metals shall be avoided in below ground installations.

2.4.2

Pipe Materials

1

Copper pipework shall comply with the relevant provisions of BS 2871: Part 1; underground pipes shall be to Table Y with a coating of seamless continuous PVC sheeting and above ground pipes shall be to Table X. Copper and copper alloy tube fittings should comply with the relevant provisions of BS 864: Part 1, Type B or BS 864: Part 2, Type A.

2

The use and installation of polyethylene pipework shall comply with the relevant provisions of BS 1972 (above ground use), BS 6437 (general purposes) and BS 6572 (below ground use). Copper alloy tube fittings for polyethylene pipes shall comply with the relevant provisions of BS 864: Part 3. Joints for polyethylene pipes shall comply with the relevant provisions of BS 5114 and BS 3505.

3

The use and installation of polypropylene pipework shall comply with the relevant provisions of BS 4991 and shall be Series 1.

4

The use and installation of unplasticized PVC (PVC-U) pipework shall comply with the relevant provisions of BS 3505. Solvent welded joints and fittings for PVC-U pipes shall comply with the relevant provisions of BS 4346: Part 1. Mechanical joints and fittings for PVC-U pipes shall comply with the relevant provisions of BS 4346: Part 2. PVC-U pipework shall only be used for cold water applications.

5

The use and installation of chlorinated PVC (CPVC) pipework shall comply with the relevant provisions of DIN 8079 and DIN 8080.

6

Stainless steel pipework shall comply with the relevant provisions of BS 4127.

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QCS 2014

Section 19: Plumbing Work Part 02: Water Distribution

Page 7

Pipework Jointing

1

Jointing of pipes shall be in accordance with the relevant provisions of BS 6700

2

All proprietary joints shall be made in accordance with the manufacturer’s instructions.

3

Care shall be taken to establish satisfactory jointing techniques for all water service pipework. All burrs shall be removed from the ends of the pipes and any jointing materials used shall be prevented from entering the water system

4

All piping and fittings shall be cleaned internally and be free from particles of sand, soil metal filings and chips etc.

5

Jointing systems using elastomeric sealing rings shall be Type W, complying with the relevant provisions of BS 2494, and shall be obtained from the pipe manufacturer.

2.5

PIPE FIXINGS

2.5.1

General Requirements

1

Copper and stainless steel piping shall be secured by clips or brackets made from copper or copper-alloy.

2

Steel piping shall be secured by clips or brackets made from steel, copper alloy or suitable plastic. Copper clips or brackets shall not be used for fixing steel piping.

3

PVC-U, polyethylene, polypropylene and CPVC piping shall be secured by clips or brackets made from suitable metal or plastic. Allowance shall be made for free lateral movement within the clips and brackets.

4

Piping that is insulated shall be secured on clips or brackets that allow sufficient space behind the back of the pipe and the batten or wall to which the pipe is fixed for the insulation to be properly installed.

2.5.2

Spacing of Pipe Fixings

1

The spacings for fixings for internally located piping shall be in accordance with Table 2.1, 2.2, 2.3 and 2.4 as applicable. The figures given are based on an ambient temperature of 20C. For other temperature ranges the pipe manufacturer should be consulted.

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2.4.3

QCS 2014

Section 19: Plumbing Work Part 02: Water Distribution

Page 8

Table 2.1 Maximum Spacing of Fixings for Internal Piping Nominal size of pipe

Spacing on horizontal run

Spacing on vertical run

(mm)

(metres)

(metres)

Copper (light gauge) and

15

1.200

1.800

stainless steel complying with

22

1.800

2.400

BS 2871: Part 1 or BS 4127:

28

1.800

2.400

Part 2

35

2.400

3.000

42

2.400

3.000

54

2.700

3.000

76

3.000

3.600

108

3.000

3.600

3.000

3.600

3.600

4.200

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Type of Piping

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Table 2.2 Maximum Spacing of Fixings for Internal Piping Nominal size of pipe

Spacing on horizontal run

Spacing on vertical run

(mm)

(metres)

(metres)

15

1.800

2.400

22

2.400

3.000

28

2.400

3.000

35

2.700

3.000

42

3.000

3.600

54

3.000

3.600

76

3.600

4.500

108

3.900

4.500

133

3.900

4.500

159

4.500

5.400

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Copper (heavy gauge)

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Type of Piping

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QCS 2014

Section 19: Plumbing Work Part 02: Water Distribution

Page 9

Table 2.3 Maximum Spacing of Fixings for Internal Piping Type of Piping

Nominal size of pipe

Spacing on horizontal run

Spacing on vertical run

(inches)

(metres)

PVC-U complying with BS 3505

0.530

1.060

and CPVC complying with DIN

1

0.610

1.220

8079 and 8080

3

/4

0.685

1.370

1

0.760

1.520

1

1 /4

0.840

1.680

1

1 /2

0.915

1.830

2

1.065

/8

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3

2.130

1.370

2.740

1.525

3.050

1.830

3.660

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(metres)

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Tables 2.4 Maximum Spacing of Fixings for Internal Piping

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Polyethylene and polypropylene

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complying with BS 1972 or

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BS 4991 respectively

Nominal size of pipe

Spacing on horizontal run

Spacing on vertical run

(inches)

(metres)

(metres)

/8

0.300

0.500

½

0.400

0.800

/8

0.400

0.800

1

0.400

0.800

1 /4

1

0.450

0.900

1

1 /2

0.550

0.900

2

0.550

1.100

2 /2

1

0.600

1.100

3

0.700

1.200

4

0.700

1.400

3

3

2.6

TAPS, VALVES AND PROTECTION DEVICES

2.6.1

Draw-off Taps

1

Metal bodied draw-off taps shall conform to the relevant provisions of BS 5412: Parts 1-5.

2

Plastic bodied draw-off taps shall confirm to the relevant provisions of BS 5413: Parts 1-5.

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Section 19: Plumbing Work Part 02: Water Distribution

Page 10

Taps not fixed directly to an appliance shall be screwed into a suitable pipe fitting.

4

The fitting, or the pipe immediately adjacent to the tap, shall be firmly secured to a suitable support so as to prevent strain on the pipe and its joints when the tap is operated.

2.6.2

Drain Taps

1

Draining taps shall comply with the relevant provisions of BS 2879.

2

Draining tap shall be of the screwdown type with a removable key and shall be fixed over a drain or have provision for discharging the water to the nearest convenient point for disposal.

2.6.3

Ball Float Valves

1

Except for interconnected tanks arranged to store water at the same level, every pipe supplying water to a storage tank shall be fitted with a float operated valve or some other equally effective device to control the inflow of water and maintain it at the required level. The inlet control device shall be suitable for the particular application, taking into account the supply pressure and the temperature of the water in the cistern.

2

When a float operated valve is used it shall either:

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comply with BS 1212: Part 2 or 3 and be used with a float complying with BS 1968 or BS 2456 of the correct size corresponding to the length of the lever arm and the water supply pressure; or

(b)

where any other float operated valve or other level control device is used, it shall comply with the performance requirements of BS 1212 where applicable to the circumstances of its use and shall be clearly marked with the water pressure, temperature and other characteristics for which it is intended to be used.

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Every float operated valve shall be securely fixed to the cistern it supplies and where necessary braced to prevent the thrust of the float causing the valve to move and so alter the water level at which it shuts off. This water level shall be at least 25 mm below the lowest point of the warning pipe connection or, if no warning pipe is fitted at least 50 mm below the lowest point of the lowest over flow pipe connection

4

Every pipe taking water from a cistern of capacity exceeding 18 litres shall be fitted with a servicing valve close to the storage cistern, tank or cylinder.

5

Every ball float valve shall be so placed that it is readily accessibly for examination, maintenance and operation.

2.6.4

Servicing Valves

1

Servicing valves shall be located in accessible positions so as to enable the flow of water to individual or groups of appliances to be controlled and to limit the inconvenience caused by interruption of supply during repairs.

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A servicing valve shall either comply with the requirements for stopvalves as specified in Clause 2.13 of this Part or shall be capable of withstanding a static pressure 1.5 times the maximum pressure it will be subjected to in use, be leaktight when closed against the latter pressure and, when installed on any pipe pressurised from the mains or on any pipe under a static pressure exceeding 1 bar, shall be operable only by means of a key, screwdriver or coin inserted into a slot on the valve. Screwdown servicing valves shall not be of loose jumper design. Copper alloy gate valves complying with the relevant provisions of BS 5154 may be used as servicing valves.

3

A servicing valve shall be fitted upstream of, and as close as practicable to, every float operated valve connected to a supply pipe.

4

Pipes taking water from a storage tank of capacity exceeding 18 litres shall be fitted with a servicing valve. The valve shall be fitted as close to the storage tank as practicable. Pipes taking water from storage tanks with a capacity that does not exceed 18 litres shall not be fitted with servicing valves.

2.6.5

Stopvalves

1

The use and installation of stopvalves shall comply with the relevant provisions of BS 6700.

2

Stopvalves fitted to service pipes shall comply with the relevant provisions of the British Standards referenced in Table 2.5.

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Table 2.5

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Nominal Size of Pipe

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Stopvalves Fitted to Service Pipes

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50 mm or smaller

Above Ground

Below Ground

BS 1010: Part 2

BS 2580

BS 2580

BS 5433

BS 5433 BS 5163

BS 5163

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50 mm or larger

Standard

3

Stopvalve components of fittings incorporating stopvalves shall comply with the requirements for stopvalves.

4

Stop valves shall be so placed that they may be readily inspected, operated and maintained.

5

When a stopvalve is installed on an underground pipe it shall be enclosed in a pipe guard or chamber under a surface box of the correct grade for the traffic loading relevant to the location.

2.6.6

Backflow Protection Devices

1

Every pipe through which water is supplied to a point of use or draw-off where backflow or backsiphonage is likely to occur shall be fitted with a backflow protection device.

2

Pipe interrupters for backflow protection shall comply with the relevant provisions of BS 6281: Part 3.

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Section 19: Plumbing Work Part 02: Water Distribution

Page 12

Vacuum breakers for backflow protection shall comply with the relevant provisions of BS 6282: Part 2 and 3.

4

Check valves for backflow protection shall comply with the relevant provisions of BS 6282: Part 1. Any additional installation instruction issued by the manufacturer or supplier of the check valve shall also be complied with.

5

Combined check valve and vacuum breaker for backflow protection shall comply with the relevant provisions of BS 6282: Part 4.

6

Double check valve assembly for backflow protection shall comply with the relevant provisions of BS 6282: Part 1, with a draining tap complying with the relevant provisions of BS 2879 connected between them.

2.7

PIPE INSTALLATIONS

2.7.1

General Requirements

1

Pipe runs within buildings should not be laid exactly horizontal but to a slight fall to reduce the risk of air locks forming.

2.7.2

Pipework Expansion

1

In installations with limited straight runs and many bends and offsets, thermal movement is accommodated automatically. In installations that do not have limited straight runs and many bends and offsets, allowance for expansion and contraction of the pipes shall be made by forming expansion loops, by introducing changes of direction to avoid long straight runs or by fitting proprietary expansion joints. This is particularly important where temperature changes are considerable and where the pipe material has a relatively large coefficient of expansion.

2

The maximum length of a straight run for each different pipe material to be used shall be detailed in the Project Specification or shown on the Project Drawings.

2.7.3

Pipe Sleeves

1

Where a pipe enters a building it shall be accommodated in a sleeve that has previously been solidly built-in and the space between the pipe and the sleeve shall be filled with nonhardening, non-cracking, water-resistant material for a minimum length, of 150 mm at both ends to prevent the passage of water, gas or insects.

2.7.4

Concealed Pipework

1

Concealed pipework shall be housed in properly constructed builders work ducts or wall chases and have access for maintenance and inspection.

2

Ducts and chases should be constructed as the building structure is erected and should be finished smooth to receive pipe fixings.

3

No pipe or joint in or under a building shall be embedded in any wall or solid floor or in any material below a solid floor at ground level except for the following:

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Section 19: Plumbing Work Part 02: Water Distribution

Page 13

the enclosing of any pipe and associated pipe joints in a purpose made duct or chase in a solid floor in such a way that the pipe and pipe joints can be exposed for purposes of examination, repair or replacement without endangering the structural integrity of the building

(b)

the enclosing of any pipe and associated pipe joints in a purpose made chase in a solid wall (but not within the cavity of a hollow wall) in such a way that the pipe and pipe joints can either be capped off and isolated or be exposed for purposes of examination, repair or replacement without endangering the structural integrity of the building

(c)

the enclosing of any pipe and associated pipe joints in any internal wall that is not a solid wall

(d)

the enclosing of any pipe within a purpose made pipe sleeve or duct in or under any solid floor in such a way that the pipe may be removed and replaced; for pipes laid in such a way, there shall be an inspection access point at each joint.

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(a)

No pipe or pipe joint shall be located under floorboards or a suspended floor, at ground floor level unless every pipe and pipe joint is accessible for examination.

5

Where access panels are formed in floor panels of structural chipboard or plywood, the structural stability of the building shall not be affected.

6

All pipe laid in ducts shall be adequately supported by clipping as specified in Table 2.1.

2.8

INSULATION OF WATER PIPES

2.8.1

General

1

Thermal insulating materials shall comply with BS 5422 and BS 3958 where applicable.

2

Thermal insulating materials shall be applied in accordance with the manufacturer’s recommendations. They shall be kept dry before, during and after application, except for water which may be required for the purpose of mixing. Gaps shall not be left at the joints of the insulating materials.

3

Where necessary, the insulating material shall be resistant to, or protected by a suitable covering against, mechanical damage, rain, moist atmosphere, groundwater and vermin.

4

Examples of suitable materials of insulating purposes are:

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(a)

polyurethane foam

(b)

foamed or expanded plastics

(c)

corkboard

(d)

amoliated vermiculite.

2.8.2

Application

1

While insulating material shall be continuous over pipes and fittings, it shall be finished in such a manner as to allow access to valves for operation.

2

Where cold water pipes pass through areas of relatively high dew point, e.g. habitable areas, they shall be insulated to prevent condensation forming on them.

QCS 2014

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Section 19: Plumbing Work Part 02: Water Distribution

Page 14

Pipes in hot water supply systems that exceed the maximum lengths given in Table 2.6 shall be thermally insulated in accordance with BS 5422. Table 2.6 Maximum Permissible Lengths of Uninsulated Hot Water Pipes Maximum length

(mm)

(m)

12

20

Over 12 up to and including 22

12

Over 22 up to and including 28

8

Over 28

3

.

Outside diameter of pipes

MISCELLANEOUS

2.9.1

Electrical Work Related to Plumbing Works

1

Electrical works related to plumbing works shall be done in accordance with the relevant provisions of BS 7671 and the requirements of QGEWC.

2.9.2

Water Meter Cabinet

1

Water meter cabinets shall comply with the Rules and Regulations Guide for Plumbing Works prepared by QGEWC.

2

Water meter cabinets shall be located in an easily accessible place as approved by QGEWC.

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Section 19: Plumbing work Part 03: Plumbing Pipework in Trenches

Page 1

3

PLUMBING PIPEWORK IN TRENCHES ...................................................... 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2

Scope References

3.2

PIPES AND FITTINGS .................................................................................. 3

3.2.1 3.2.2

General Requirements Pipe Materials

3.3

PIPEWORK JOINTING .................................................................................. 3

3.3.1

General Requirements

3.4

PIPE LAYING ................................................................................................ 4

3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11

General Bedding Concrete Protection to Pipes Completion of Pipe Surround Backfilling Protective Coatings Pipes under Buildings Avoidance of Contamination Restraint of Pipes Testing of Pipework Surface Boxes

2 2 3 3

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Section 19: Plumbing work Part 03: Plumbing Pipework in Trenches

Page 2

PLUMBING PIPEWORK IN TRENCHES

3.1

GENERAL

3.1.1

Scope

1

This Part specifies the requirements for pipes and fittings for below ground plumbing works.

2

Related Sections and Parts are as follows:

Section 1 Section 5

General Concrete

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This Section Part 1 Part 2 Part 6

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3

References

1

The following standards are referred to in this Part:

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BS 743 ........................Materials for damp-proof courses. BS 864 .......................Capillary and compression fittings for copper tubes and copper alloy.

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BS 882 ........................Aggregates from natural sources for concrete

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BS 1142 ......................Fibre building boards BS 2494Specification for elastomeric joint rings for pipework and pipeline.

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BS 2871 ......................Specification for copper and alloy tubes.

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BS 3505 ......................Specification for unplasticized polyvinyl chloride (PVC-U) pressure pipes for cold potable water.

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BS 4127 ......................Specification for light gauge stainless steel tubes. BS 4346 ......................Joints and fittings for use with unplasticized PVC pressure pipes.

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BS 4772 ......................Ductile iron pipes and fittings. BS 4991 ......................Propylene copolymer pressure pipe. BS 5114 ......................Specification for performance requirements for joints and compression fittings of use with polyethylene pipes. BS 6076 ......................Tubular polythene film for use as a protective sleeving for buried iron pipes and fittings. BS 6572 ......................Specification for blue polyethylene pipes up to nominal size 63 for bellow ground use for potable water. BS 6700 ......................Specification for design, installation, testing and maintenance of services supplying water supplying water for domestic use within buildings and their curtilages.

QCS 2014

Section 19: Plumbing work Part 03: Plumbing Pipework in Trenches

Page 3

PIPES AND FITTINGS

3.2.1

General Requirements

1

Pipes shall have adequate strength to meet the loading requirements, be sufficiently robust to withstand site handling and be sufficiently durable to remain watertight for the anticipated life of the system. Pipes and joints should remain sufficiently water tight to prevent the ingress of ground water.

2

Every pipe, pipe joint and connected fitting shall be capable of withstanding, without damage or deterioration, sustained temperatures of up to 65C when operating under normal working pressures.

3

Pipe materials, fittings, linings and jointing materials shall impart no taste, colour, odour or toxicity to the water nor promote or foster the microbial growth under the conditions where they are going to be installed.

4

If pipes, pipe joints or fittings are of dissimilar metals, measures shall be taken to prevent corrosion. Contact between pipework components of dissimilar metals shall be avoided in below ground installations.

3.2.2

Pipe Materials

1

Copper pipework shall comply with the relevant provisions of BS 2871: Part 1, Table Y, coated with seamless continuous PVC sheeting. Copper and copper alloy tube fittings should comply with the relevant provisions of BS 864: Part 2.

2

The use and installation of polyethylene pipework shall comply with the relevant provisions of BS 6572. Copper alloy tube fittings for polyethylene pipes shall comply with the relevant provisions of BS 864: Part 3, Joints for polyethylene pipes shall comply with the relevant provisions of BS 5114 and BS 3505.

3

The use and installation of polypropylene pipework shall be in accordance with the relevant provisions of BS 4991 and shall be Series 1.

4

The use and installation of unplasticized PVC pipework shall comply with the relevant provisions of BS 3505. Solvent welded joints and fittings for PVC-U pipes shall comply with the relevant provisions of BS 4346: Part 1. Mechanical joints and fittings for PVC-U pipes shall comply with the relevant provisions of BS 4346: Part 2.

5

Ductile iron pipework shall comply with the relevant provisions of BS 4772.

6

Stainless steel pipework shall comply with the relevant provisions of BS 4127.

3.3

PIPEWORK JOINTING

3.3.1

General Requirements

1

Jointing of pipes shall be in accordance with the relevant provisions of BS 6700.

2

All proprietary joints shall be made in accordance with the manufacturer’s instructions.

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QCS 2014

Section 19: Plumbing work Part 03: Plumbing Pipework in Trenches

Page 4

Care shall be taken to establish satisfactory jointing techniques for all water service pipework. All burrs shall be removed from the ends of the pipes and any jointing materials used shall be prevented from entering the water system

4

All piping and fittings shall be cleaned internally and be free from particles of sand, soil metal filings and chips etc.

5

Jointing systems using elastomeric sealing rings shall be Type W, complying with the relevant provisions of BS 2494, and shall be obtained from the pipe manufacturer.

3.4

PIPE LAYING

3.4.1

General

1

Where socketed pipes are required to be laid on a granular or sand bed, or directly on a trench bottom, joint holes shall be formed in the bedding material or final excavated surface to ensure that each pipe is uniformly supported throughout the length of its barrel and to enable the joint to made.

2

Pipes shall be laid on setting blocks only where a concrete bed or cradle is used.

3

Where pipes are required to be bedded directly on the trench bottom, the final excavated surface shall be trimmed and levelled to provide even bedding of the pipeline and shall be free from all extraneous matter that may damage the pipe, pipe coating, or sleeving. Where rock is encountered, the trench shall be cut at least 150 mm deeper than other ground and made up with well compacted selected fill material.

4

No protective cap, disc or other appliance on the end of a pipe or fitting shall be removed permanently until the pipe or fitting which it protects is about to be jointed. Pipes and fittings, including any lining or sheathing, shall be examined for damage and the joint surfaces and components shall be cleaned immediately before laying.

5

Suitable measures shall be taken to prevent soil or other material from entering pipes, and to anchor each pipe to prevent flotation or other movement before the Works are complete.

6

Where pipeline marker tape is specified, it shall be laid between 100 mm and 300 mm above the pipe.

3.4.2

Bedding

1

Bedding for pipes shall be constructed by spreading and compacting granular bedding material over the whole width of the pipe trench. After the pipes have been laid, additional material shall, if required, be placed and compacted equally on each side of the pipe, and where practicable, this shall be done in sequence with the removal of the trench supports.

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2

Section 19: Plumbing work Part 03: Plumbing Pipework in Trenches

Page 5

Unless otherwise detailed in the Project Documentation, bedding material shall be in accordance with Table 3.1 Table 3.1 Bedding Material Pipe Diameter

Bedding Sand

65 - 100 mm

10 mm single sized aggregate

100 - 200 mm

10 or 14 mm single sized or 14-15 mm graded aggregate

Over 200 mm

10, 14 or 20 mm single sized or 155 or 20-5 mm graded aggregate.

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up to 65 mm

Nominal single sized aggregate and graded aggregate shall comply with Table No. 4 of BS 882.

4

Sand for bedding material shall comply with the relevant provisions of BS 882.

5

Bedding systems other than those specified above may be allowed upon approval of the Engineer or as recommended by the pipe manufacturer.

3.4.3

Concrete Protection to Pipes

1

Pipes to be bedded on or cradled with concrete shall be supported on precast concrete setting blocks. The top face of each block shall be covered with two layers of compressible packing complying with BS 743.

2

Concrete provided as a protection to pipes shall be Grade C20, placed to the required depth in one operation.

3

Where pipes with flexible joints are used, concrete protection shall be interrupted over its full cross-section at each pipe joint by a shaped compressible filler of bitumen impregnated insulating board to BS 1142 or equally compressible material. The thickness of the compressible filler shall be in accordance with Table 3.2.

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Table 3.2 Thickness of Compressible Filler Nominal bore of pipe (mm)

Thickness of compressible filler (mm)

up to 300

13

Over 300 and up to 600

25

Over 600 and up to 1200

38

4

Rapid hardening cement shall not be used in concrete for the protection of plastics pipe.

5

Plastics pipes shall be wrapped with a layer of plastic sheeting complying with a composition in accordance with Clause 3 of BS 6076 and a nominal thickness of 125 microns before being surrounded by concrete.

QCS 2014

Section 19: Plumbing work Part 03: Plumbing Pipework in Trenches

Page 6

Concrete work shall comply with the relevant provisions of Section 5, Concrete.

3.4.4

Completion of Pipe Surround

1

Fill material shall, where required, be placed and compacted over the full width of the trench in layers not exceeding 150 mm before compaction, to a finished thickness of 250 mm above the crown of the pipes.

3.4.5

Backfilling

1

Backfilling shall, wherever practicable, be undertaken immediately the specified operations preceding it have been completed. Backfilling shall not, however, be commenced until the parts of the Works to be covered have achieved a strength sufficient to withstand all loading imposed thereon.

2

Backfilling around existing structures shall be undertaken in such manner as to avoid uneven loading or damage.

3

Filling material to excavations shall be deposited in layers not exceeding 250 mm unconsolidated thickness and compacted to 95% modified proctor.

4

Where the excavations have been supported and the supports are to be removed, these, where practicable, shall be withdrawn progressively as backfilling proceeds in such a manner as to minimise the danger of collapse. All voids formed behind the supports shall be carefully filled and compacted

3.4.6

Protective Coatings

1

Coatings, sheathings or wrappings shall be examined for damage, repaired where necessary, and made continuous before trench excavations are backfilled.

3.4.7

Pipes under Buildings

1

Where a pipe has less than 300 mm of cover under a load bearing slab, it should be surrounded with concrete as an integral part of the slab. Where possible, the concrete surround shall be poured at the same time as the slab. The surround shall be tied to the slab with nominal steel reinforcement placed vertically with turned over ends.

2

No provision for pipe flexibility along the concrete surround shall be made, unless an expansion joint is included in the slab. A construction joint should be included in the surround at that point which must also coincide with a pipe joint.

3

In normal, stable ground conditions, and with 300 mm or more of cover to the pipeline beneath the slab, a total granular surround can be used as a pipe bedding. Refer to Clause 3.4.2 for bedding specification.

4

Flexibility shall be incorporated into the pipeline as it leaves any concrete surround.

5

Where plastic pipes are to be surrounded in concrete, Clause 3.4.3 of this Part shall be complied with.

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Section 19: Plumbing work Part 03: Plumbing Pipework in Trenches

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Avoidance of Contamination

1

No pipe shall be laid or installed near a sanitary manhole, cesspool, septic tank, soakaway, refuse pit or other feature likely to cause the water to become contaminated and/or cause deterioration to the pipe material.

2

Any pipe that crosses over a sewer shall be laid so that there is at least 600 mm clearance between the pipe barrels. Any pipe that lies adjacent to a sewer shall be laid so that there is at least 3m between the barrels. Plumbing pipes shall not be laid below sewers.

3

Where the above criteria cannot be met, and with the approval of the Engineer in writing, the pipe shall be encased in concrete. The limit of the concrete encasement shall be determined on site by the Engineer. No breaks in the concrete encasement shall be made at joints. If the concrete encasement extends over one or more joints it shall be treated as a beam and reinforced appropriately; in such cases, the Contractor shall prepare reinforcement details with supporting calculations and submit them to the Engineer for approval.

4

Where it is necessary to determine the extent of contamination, the Contractor shall arrange for soil samples to be taken and tested. The locations at which soil samples are taken and the number of samples to be taken shall be determined by the Engineer.

3.4.9

Restraint of Pipes

1

Except where the method of jointing and normal trench backfill are adequate to prevent longitudinal movement, Grade C20 concrete thrust blocks cast in contact with undisturbed ground shall be constructed at changes in direction, junctions and blank ends.

2

Any additional excavation required to accommodate thrust blocks shall be carried out after the bend or branch is in position and the thrust face shall be trimmed back to remove all loose or weathered material immediately prior to concreting.

3

Thrust blocks shall be required to develop adequate strength before any internal pressure is applied to the pipeline.

4

Where plastic pipes are to be surrounded in concrete, Clause 3.4.3. of this Part shall be complied with.

3.4.10

Testing of Pipework

1

Pressure tests shall be carried out on below ground plumbing pipes. Test procedures are detailed in Part 6 of this Section.

3.4.11

Surface Boxes

1

Surface boxes shall be provided to give access to operate valves.

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3.4.8

END OF PART

QCS 2014

Section 19: Plumbing Work Part 04: Cold Water Storage

Page 1

4

COLD WATER STORAGE............................................................................. 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2 4.1.3 4.1.4

Scope System Description Submittals Quality Assurance

4.2

TANK CONSTRUCTION ............................................................................... 4

4.2.1

General Requirements

4.3

FILTERS ........................................................................................................ 4

4.3.1

General Requirements

2 2 3 3

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Section 19: Plumbing Work Part 04: Cold Water Storage

Page 2

4

COLD WATER STORAGE

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the requirements for cold water storage systems.

General Water Distribution Commissioning of Systems

Section 1

General

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Related Sections and Parts are as follows:

System Description

1

Cold water storage tanks shall impart no taste, colour, odour or toxicity to the water nor promote or foster microbial growth under the conditions where the tank is going to be installed.

2

The tank shall be supported on a firm level base capable of withstanding the weight of the tank when filled with water to the rim.

3

Where possible and practicable, tanks shall be positioned in locations where they can be easily accessed for inspection, cleaning and maintenance.

4

Tanks positioned outside buildings shall be provided with a suitable shade.

5

Where two or more tanks are coupled together in series, the inlet and outlet shall be at opposite ends of the series.

6

Tanks shall not be buried or sunk in the ground without the prior approval from the Qatar General Electricity & Water Corporation (QGEWC).

7

Each tank shall be fitted with a 25 mm diameter outlet for connection to a washout pipe. The outlet shall be flush with the bottom of the tank. The floor of tank shall be laid at a slight fall towards the outlet. A washout pipe and a stop-tap shall be fitted to the outlet. The washout pipe shall be run to a point as detailed in the Documentation.

8

Every pipe supplying water to a cold water tank shall be fitted with a float operated valve or some other equally effective device, as detailed in Part 2 of this Section, to control the inflow of water and maintain it at the required level. The float valve shall be securely fixed to the tank and be installed so that the level of water in the tank when full under normal conditions is not less that 25 mm below the level of the warning or overflow pipe. A stopvalve complying with the relevant provisions of Part 2 of this Section shall be fitted to the pipework immediately upstream of the float valve to shut off supply of water to that valve.

9

Distribution pipes for tanks shall be connected so that the lowest point of the outlet is not less than 50 mm above the bottom of the tank.

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4.1.2

QCS 2014

Section 19: Plumbing Work Part 04: Cold Water Storage

Page 3

Connections to distribution pipes feeding hot water apparatus shall be set at a level of at least 25 mm above connectors to pipes feeding cold water outlets.

11

Any tank with an effective capacity of up to 4500 litres shall be fitted with a warning type overflow pipe. Tanks with an effective capacity exceeding 4500 litres shall be fitted with one or more overflow pipes. For capacities exceeding 4500 litres, either the lowest pipe will be a warning type overflow pipe, or a device shall be fitted that gives an audible or visual alarm when water in the tank reaches a level at least 50 mm below the lowest point of the lowest overflow pipe.

12

The invert level of the overflow pipe shall be not less than 75 mm below the invert level of the inlet pipe.

13

Overflow pipes shall be made of a rigid corrosion resistant material. No overflow or warning pipe shall rise in level outside the cistern.

14

Warning type overflow pipes shall discharge water immediately the water in the tank reaches the overflow level and shall discharge to a conspicuous position; these shall be outside the building where appropriate.

15

The overflow pipe or pipes should be able to convey water away from the tank at a rate equal to or greater than the rate of flow of water into the tank. Notwithstanding, warning type overflow pipes shall be not be less than 20 mm in diameter.

4.1.3

Submittals

1

The Contractor shall provide manufacturers’ specifications for all items to be supplied under this Part.

2

The Contractor shall provide design calculations and shop drawings for the fabrication and erection of sectional type storage tanks, unless otherwise detailed in the manufacturer’s data sheets.

3

The Contractor shall provide design calculations and shop drawings for the fabrication and erection of tank support assemblies unless otherwise detailed in the manufacturer’s data sheets.

4

The submittal shall include catalogue pages, erection descriptions and manufacturer data.

5

Unless the positions of the discharges for the overflow pipes are described in the Project Documentation, the Contractor shall submit his proposals for their positioning to the Engineer for approval.

4.1.4

Quality Assurance

1

Fabricated cold water storage tanks and associated equipment shall be provided by experienced and approved manufacturers and fabricators as designated in the Project Documentation and to the written approval of the Engineer.

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Section 19: Plumbing Work Part 04: Cold Water Storage

Page 4

4.2

TANK CONSTRUCTION

4.2.1

General Requirements

1

Cold water storage tanks shall be constructed in accordance with the Rules and Regulations for Plumbing Works as prepared by QGEWC.

2

The tanks shall be constructed with one of the following materials/methods:

(a) (b) (c)

fibre glassed reinforced plastic GRP sectional panel reinforced concrete (underground storage).

Tanks smaller than 6m in length shall have a removable close-fitting vermin proof cover. Tanks greater than 6m in length shall have two or more securable manhole covers.

4.3

FILTERS

4.3.1

General Requirements

1

Filters shall be of a type as detailed in the Project Documentation.

2

As a minimum, filters shall be able to remove the following:

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(b)

giardia cysts

(c)

chlorine tastes and odours

(d)

sediment to 1 micron.

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Filters shall have the following characteristics: (a)

inhibit the growth of bacteria and other micro-organisms clean and maintain.

Filters shall not unduly affect distribution rates.

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END OF PART

QCS 2014

Section 19: Plumbing Work Part 05: Hot Water Storage

Page 1

5

HOT WATER STORAGE ............................................................................... 3

5.1

GENERAL ...................................................................................................... 3

5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7

Scope References System Description Identification Plate Submittals Safety Quality Assurance

5.2

HOT WATER STORAGE TANKS .................................................................. 5

5.2.1 5.2.2

Tank Construction Pressure and Non-Pressure Hot Water Storage Tanks

5.3

LOW CAPACITY ELECTRIC IMMERSION HEATER SYSTEMS .................. 5

5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7 5.3.8

System Description Immersion Heaters Heating Element Pressure Relief Pipework Temperature and Temperature Control Electric Control Pilot Light

5.4

CALORIFIER SYSTEMS ............................................................................... 6

5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 5.4.10 5.4.11

System Description Storage Tank Construction Heat transfer System Tube Batteries Electric Heating Elements Calorifier Mountings Thermometers Altitude or Pressure Gauges Pressure Relief Valve Combined Pressure and Vacuum Gauges Vacuum Breaker

5.5

CISTERN TYPE WATER HEATERS ............................................................. 9

5.5.1

General Requirements

5.6

PRESSURE CONTROL ................................................................................. 9

5.6.1

General Requirements

5 5

5 5 6 6 6 6 6 6

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6 7 7 7 8 8 8 8 8 9 9

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Section 19: Plumbing Work Part 05: Hot Water Storage

Page 2

5.7

VENTILATION ............................................................................................. 10

5.7.1 5.7.2

Storage Tanks Indirect Calorifier Systems

5.8

EXPANSION VESSEL ................................................................................. 10

5.8.1

General Requirements

5.9

INSULATION ............................................................................................... 11

5.9.1

General

10 10

10

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Section 19: Plumbing Work Part 05: Hot Water Storage

Page 3

5

HOT WATER STORAGE

5.1

GENERAL

5.1.1

Scope

1

This Part specifies the requirements for hot water storage systems.

2

Related Sections and Parts are as follows: This Section:

Section 1

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Part 1 Part 2 Part 3

General

References

1

The following standards are referred to in this Part:

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BS 21.......................... Pipe threads for tubes and fittings where pressure tight joints are made on threads (metric dimensions)

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BS 417........................Galvanized mild steel cisterns and covers, tanks and cylinders BS 699........................Specification for copper direct cylinders for domestic purposes

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BS 759........................Valves, gauges and other safety fittings for applications to boilers and to piping installations for and in connection with boilers

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BS 853........................Calorifiers and storage vessels for central heating and hot water supply

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BS 1566......................Copper indirect cylinders

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BS 1780......................Bourdon tube pressure and vacuum gauges BS 1894......................Design and construction of electric boilers of welded construction

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BS 2871......................Copper and copper alloy. Tubes BS 3198......................Specification for copper hot water storage combination units for domestic purposes BS 3274......................Tubular heat exchangers for general purposes BS 3456......................Specification for safety of household and similar electrical appliances BS 3599......................Electrical controls for domestic appliances BS 4213......................Cold water storage and combined feed and expansion cisterns (polyolefin of olefin copolymer) up to 500 litres capacity for domestic purposes BS 4504......................Circular flanges for pipes, valves and fittings (PN designated) BS 4814......................Expansion vessels using an internal diaphragm, for sealed hot water systems BS 6144......................Expansion vessels using an internal diaphragm, for hot water unvented supply systems

QCS 2014

Section 19: Plumbing Work Part 05: Hot Water Storage

Page 4

BS 6282......................Devices with moving parts for the prevention of contamination of water by backflow BS 6283......................Safety devices for use in hot water systems System Description

1

Storage-type water heaters shall be used for the provision of hot water services.

2

The hot water storage tank shall be constructed so that water delivered is not liable to become contaminated to the extent that it is hazardous to health or unfit for its intended use.

3

The capacity of the storage tank shall be as stated in the Project Documentation.

5.1.4

Identification Plate

1

All hot water storage tanks shall have an engraved or cast-metal identification plate clearly showing the following: manufacturer’s name and address

(b)

date of manufacture

(c)

hydraulic test pressures

(d)

maximum working pressure

(e)

rated capacity and output

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5.1.3

Submittals

1

The Contractor shall provide manufacturers’ specifications for all items to be supplied under this Part.

2

The Contractor shall provide design calculations and shop drawings for the fabrication and erection of tank support assemblies (free standing or wall mounted), unless otherwise detailed in manufacturer’s data sheets.

3

The submittal shall include catalogue pages, erection descriptions and manufacturer’s data.

5.1.6

Safety

1

All safety requirements specified by the Qatar General Electricity & Water Corporation, the standard to which the hot water storage tank is constructed and the manufacturer shall be strictly adhered to. If the requirements specified by any of these three parties differ or conflict in any respect, the most stringent requirement, as defined by the Engineer, shall be followed.

5.1.7

Quality Assurance

1

Fabricated hot water storage tanks and associated equipment shall be provided by experienced and approved manufacturers and fabricators as designated in the Project Documentation and to the written approval of the Engineer.

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5.1.5

QCS 2014

Section 19: Plumbing Work Part 05: Hot Water Storage

Page 5

HOT WATER STORAGE TANKS

5.2.1

Tank Construction

1

Hot water storage tanks constructed of copper shall comply with the relevant provisions of BS 699, BS 853, BS 1566 and BS 3198, as applicable.

2

Hot water storage tanks may be constructed of materials other than copper provided that they are corrosion resistant, glass lined or porcelain lined and provided that they are approved by the Qatar General Electricity & Water Corporation. Appropriate British Standards, or equivalent, specifying the construction of storage tanks covered in this paragraph shall be supplied by the Contractor to support the required approval.

3

Tanks shall incorporate replaceable, sacrificial magnesium anodes for cathodic protection if directed in the Project Documentation.

5.2.2

Pressure and Non-Pressure Hot Water Storage Tanks

1

The hot water tanks shall be non-pressure or pressure as directed in the Project Documentation.

2

Non-pressure hot water storage tanks shall have ventilation systems as described in Clause 5.7 of this Part.

3

For non-pressure hot water storage tanks, no hose or other connection shall be made to the outlet of a non-pressure, storage type, water heater and under no circumstances shall the outlet be controlled by a tap or valve.

4

For pressure systems it shall be verified that the heater is suitable for the proposed supply pressure.

5

Suitable arrangements to accommodate expansion of the heated water shall be made for pressure hot water storage tanks. See Clause 5.8.

5.3

LOW CAPACITY ELECTRIC IMMERSION HEATER SYSTEMS

5.3.1

System Description

1

A low capacity (domestic) electrical immersion heater system involves an electric heating element placed within a hot water storage tank. Such heaters shall be used for the provision of hot water services for applications where the demand for hot water is small (i.e. kitchens and bathrooms, etc.).

2

Electric immersion heaters shall be of the vented or unvented type, as directed in the Project Documentation.

3

Tank construction shall be in accordance with Clause 5.2 of this Part.

5.3.2

Immersion Heaters

1

Electric immersion heaters shall comply with the relevant provision of BS 3456.

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5.2

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Section 19: Plumbing Work Part 05: Hot Water Storage

Page 6

Heating Element

1

The material of the heating element shall be a high-grade stainless steel. Other materials with high corrosion resistance may be used if approved by the Engineer.

5.3.4

Pressure Relief

1

An expansion relief valve shall be fitted in the cold feed to the hot water storage tank and no valves (other than a drainage tap) shall be fitted between the expansion relief valve and the storage tank. The expansion or pressure relief valve setting shall be the maximum working pressure plus 0.5 to 1.5 bar.

5.3.5

Pipework

1

For tanks with a capacity of 25 litres or greater, the size of the hot water outlet pipe shall be smaller than the cold water inlet pipe.

5.3.6

Temperature and Temperature Control

1

Unless otherwise detailed in the Project Specification, the temperature of the stored water shall never exceed 65°C.

2

Every hot water storage tank shall be fitted with a thermostat acting on the heat input. In addition, every hot water storage tank of capacity greater than 150 litres shall be fitted with an automatic control capable of stopping and starting the heat input to the stored water at pre-set times.

5.3.7

Electric Control

1

All electrical controls, including thermostats, cut-outs and switches, shall comply with the relevant provisions of BS 3599.

5.3.8

Pilot Light

1

The heater shall incorporate a clearly visible pilot light.

5.4

CALORIFIER SYSTEMS

5.4.1

System Description

1

Calorifier systems shall be used for hot water applications with a high hot water demand (hospitals, schools, etc.).

2

Calorifier systems shall be storage type systems and shall be the direct or indirect type.

3

Direct systems involve directly heating the water that will enter the hot water distribution system. This is done by circulating the water in the hot water storage tank through a heat transfer system (boiler). When inside the boiler, the water is directly exposed to the heat source.

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5.3.3

QCS 2014

Section 19: Plumbing Work Part 05: Hot Water Storage

Page 7

Direct type systems shall be designed for gravity circulation. Flow and return pipes between the boiler and the storage tank shall run as directly as possible and shall be not less than 25 mm diameter. The storage tank shall be located at a sufficient height above the boiler to give adequate circulation.

5

Indirect systems involve heating water by means of routing steam or hot water through the hot water storage tank via a tube battery. A heat transfer system (boiler) heats up the water or generates the steam that is conveyed through the tube battery that runs through the water storage tank. On exiting the hot water storage tank, the tube returns to the boiler. The hot water/steam does not come into contact with the water that will enter the hot water distribution system.

6

Indirect systems shall incorporate a sealed or vented primary circuit as directed in the Project Documentation. Primary circuits comprise the boiler, the primary heat exchanger in the hot water storage tank and the interconnecting and associated pipework.

7

Calorifiers shall incorporate electrical immersion heaters if required by the Project Documentation.

5.4.2

Storage Tank Construction

1

Storage tank construction shall be in accordance with Clause 5.2 of this Part and shall be horizontal or vertical type.

2

The storage tanks shall comply with the relevant provisions of BS 853 Grade B for shell operating pressures not exceeding 4.5 bar and temperatures not exceeding 90 oC.

3

They shall be supported on fabricated feet attached to the shell or on separate cradles or frames. Sheet lead pads shall be fitted between shell bearing surfaces and any separate supports.

4

They shall have screwed and/or flanged connections complying with the relevant provisions of BS 21 and BS 4504.

5

They shall be delivered with all connections capped or blanked-off.

5.4.3

Heat transfer System

1

Boilers shall comply with the relevant provisions of BS 1894 unless otherwise specified in the Project Documentation.

5.4.4

Tube Batteries

1

Tube battery shall be design shall comply with the relevant provisions of BS 3274 Type 2.

2

Tubes batteries shall be of solid drawn copper to BS 2871 Part 3.

3

Tube batteries shall be fixed or removable, as stated in the Project Documentation. If fixed type tube batteries are to be used, the storage tank shall include an access opening for battery maintenance purposes.

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QCS 2014

Section 19: Plumbing Work Part 05: Hot Water Storage

Page 8

Electric Heating Elements

1

Electric immersion heaters shall be complete with an integral thermostatic controller.

2

A minimum of two heating elements shall be provided in each calorifier. The first shall be at low level and the second one approximately two thirds from the base. The ratings of the elements shall be such that the lower heating element shall provide a minimum heat-up time of two (2) hours. The higher heating element shall be equivalently rated for a heat up time of four (4) hours.

3

The material of the heating element shall be a high-grade stainless steel. Other materials with high corrosion resistance may be used if approved by the Engineer.

5.4.6

Calorifier Mountings

1

The calorifiers shall have connections for hot water system controls and for open systems, a vent pipe connection.

2

The calorifiers shall also have an emptying/drain cock of the bronze gland pattern with hose union connection and malleable iron lever handle. The cock shall be fitted to the calorifier shell lowest point to ensure complete removal of water content and shall be of adequate size (25 mm diameter minimum).

5.4.7

Thermometers

1

The calorifier shall incorporate a stainless steel dial type mercury thermometer. The dial shall be 100 mm diameter (minimum), white faced with a black figured scale calibrated from 0 oC to 120 oC with divisions at 1 oC intervals and numbered at 10 oC intervals with bold figures. The thermometer shall be complete with an integral vertical or centre stem and separate pocket to suit the immersion position.

5.4.8

Altitude or Pressure Gauges

1

The calorifier shall incorporate a stainless steel dial type altitude or pressure gauges. The dial shall be 100 mm diameter (minimum), white faced with a black figured scale, calibrated both in bar and metre head, to approximately twice the working pressure, complete with lever handle gauge cock and adjustable red dial pointer set at normal working pressure or head of the system. The gauge shall generally to comply with the relevant provisions of BS 1780 Part 2.

5.4.9

Pressure Relief Valve

1

The calorifier shall incorporate an enclosed spring loaded pattern pressure relief valve fitted with a padlock. The valve shall incorporate a copper discharge pipe running clear of any insulation and terminating 150 mm from floor level adjacent to a drain gully position. The pressure relief valve shall comply with the relevant provisions of BS 759.

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5.4.5

QCS 2014

Section 19: Plumbing Work Part 05: Hot Water Storage

Page 9

Combined Pressure and Vacuum Gauges

1

The calorifier shall incorporate a stainless steel dial type combined pressure and vacuum gauge. The dial shall be 100 mm diameter (minimum), white faced with a black figure scale, calibrated to suit steam chest pressure, complete with U pattern siphon and lever handle gauge cock. The gauge shall generally to comply with the relevant provisions of BS 1780 Part 2.

5.4.11

Vacuum Breaker

1

Vacuum breakers shall comply with the relevant provisions of BS 6282 Part 2 or 3.

2

Every vacuum breaker valve shall be of the same nominal size as the pipe on which it is connected.

3

Each vacuum breaker shall be installed at a height of not less than 150 mm above the overflowing level of the receiving cistern tank or appliance, when the later is fixed or not less than 300 mm above the outlet of the fitting in all other cases.

5.5

CISTERN TYPE WATER HEATERS

5.5.1

General Requirements

1

Cistern type water heaters shall comply with BS 417, BS 4213 and BS 4814, as appropriate.

2

The cistern shall comply with all the requirements for a cold water storage cistern.

3

The feed cisterns shall have a capacity at least equal to that of the hot water storage tank.

4

The feed cistern shall be situated at a height that will ensure a satisfactory flow of water at the highest point of discharge.

5.6

PRESSURE CONTROL

5.6.1

General Requirements

1

Whether hot or cold water is involved, it shall be ensured that no part of the system bursts due to the hydraulic pressures to which it is subjected. The pressures in the system shall never exceed the safe working pressures of the component parts. The maximum working pressure in a sealed primary circuit shall not exceed 3 bar but it shall be capable of passing a test at 1.5 times the working pressure at the working temperature. The maximum working pressure in an unvented hot water storage tank or secondary circuit shall not exceed 6 bar.

2

Where necessary the supply pressure shall be controlled by using break cisterns or by pressure reducing valves. If the supply to a storage type water heater is through a pressure reducing a valve of the type that permits backflow, the working pressure in the system shall be assumed to be the maximum pressure upstream of the valve. Where reliance is placed on pressure reducing valves to limit the maximum working pressure, these shall comply with BS 6283, Part 4.

3

Where unvented storage type water heaters are used, an expansion relief valve shall be fitted in the cold feed to the heater or hot water cylinder and no valves (other than a draining tap) shall be fitted between the expansion relief valve and the heater or hot water cylinder.

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5.4.10

QCS 2014

Section 19: Plumbing Work Part 05: Hot Water Storage

Page 10

In every case, including sealed primary circuits, the expansion or pressure relief valve setting shall be maximum working pressure plus 0.5 bar to 1.5 bar. This also applies to combined temperature and pressure relief valves.

5.7

VENTILATION

5.7.1

Storage Tanks

1

With ventilated hot water storage tanks, an open vent pipe shall run from the top of the hot water storage tank to a point above the cold water storage tank, into which it shall discharge. No valves shall be fitted to any vent pipe. The vent pipe shall rise continuously from its point of connection to the hot water storage tank to its point of discharge. The vent pipe shall be 19mm diameter or greater.

5.7.2

Indirect Calorifier Systems

1

Indirect calorifier systems incorporating vented primary circuits shall have vent route connecting the flow connection on the calorifier to the vent pipe above the expansion cistern and a feed water route from a point near the bottom of the expansion cistern to the return connection on the calorifier. These routes shall be independent.

5.8

EXPANSION VESSEL

5.8.1

General Requirements

1

An expansion vessel shall be connected to the cold feed supply pipe to unvented hot water storage vessels. There shall be no valve on the pipe between the expansion vessel and the storage vessel.

2

On indirect systems incorporating sealed primary circuits, an expansion vessel shall be connected to the section of pipework routing the water from the storage tank and boiler.

3

Provision shall be made to accommodate expansion water by one of the following alternative methods. allow the expansion water to travel back along cold feed pipe, provided that heated water cannot reach any communication pipe or branch feeding a cold water outlet.

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where reverse flow along the cold feed is prevented by a stopvalve with a loose jumper, replace this valve by one with a fixed jumper.

(c)

where reverse flow along the cold feed is prevented, e.g. by a check valve, some types of pressure reducing valve or a stopvalve with a loose jumper, provide an expansion vessel in accordance with BS 6144 to accommodate expansion water. This vessel shall be sized in accordance with the volume of water heated and the water temperature rise so as to limit the pressure to the maximum working pressure for the system. The expansion vessel shall accommodate expansion equal to 4% of the total volume of water heated. Any discharge from relief valves shall be readily visible and disposed of safely.

QCS 2014

Section 19: Plumbing Work Part 05: Hot Water Storage

Page 11

5.9

INSULATION

5.9.1

General

1

The storage tank shall be supplied complete with a factory applied layer of high density, CFC free polyurethane foam insulation. The dimensions and properties of the polyurethane insulation shall be sufficient to ensure that heat loss under normal operating conditions does not exceed 90 watts per square metre of surface area.

2

The polyurethane shall be protected against mechanical damage and moist atmosphere by an outer shell.

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END OF PART

QCS 2014

Section 19: Plumbing Part 06: Commissioning of Systems

Page 1

6

COMMISSIONING OF SYSTEMS ................................................................. 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2 6.1.3 6.1.4

Scope System Description Submittals Connection to Water Supply System

6.2

PIPELINE IDENTIFICATION ......................................................................... 3

6.2.1

Tags and Colour Coding System

6.3

TESTING AND INSPECTION ........................................................................ 3

6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7

General Requirements Timing of Tests Inspection Leakage Test for Underground Pipelines Testing of Installation Within Buildings Back-Siphonage Mechanical and Electrical Equipment

6.4

DISINFECTION.............................................................................................. 6

6.4.1 6.4.2 6.4.3

General Requirements Installations Outside buildings Installation Inside Buildings

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QCS 2014

Section 19: Plumbing Part 06: Commissioning of Systems

Page 2

COMMISSIONING OF SYSTEMS

6.1

GENERAL

6.1.1

Scope

1

This Part specifies the requirements for identification markings for components of plumbing installations, testing of plumbing installations and disinfection of plumbing installations.

2

Related Sections and parts are as follows:

Section 1

General

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System Description

1

Where possible and practicable, the parts of all Works covered in this Section shall be split into sections for interim testing purposes. Final testing shall be done when the installation is complete.

2

Disinfection shall not be undertaken until all tests and inspections have been completed to the satisfaction of the Engineer.

6.1.3

Submittals

1

The Contractor shall prepare a detailed testing and inspection programme, including method statements, and submit it to the Engineer for approval. This programme shall identify each item to be tested, the type of test to be performed and the date and time of the test.

2

The Contractor shall prepare test record sheets for all tests undertaken. The format of the test record sheet shall be to the approval of the Engineer. On successful completion of a test, the test record sheet shall be signed and stamped by all parties. The Engineer shall retain the original test record sheet.

3

The Contractor shall prepare a detailed disinfection programme, including method statements, and shall submit it to the Engineer for approval. This programme shall identify the date and time at which each item is to be disinfected.

4

The Contractor shall prepare disinfection record sheets for all disinfections undertaken. The format of the disinfection record sheet shall be to the approval of the Engineer. On completion of disinfection, the disinfection record sheet shall be signed and stamped by all parties. The Engineer shall retain the original disinfection record sheet.

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6.1.2

QCS 2014

Section 19: Plumbing Part 06: Commissioning of Systems

Page 3

Connection to Water Supply System

1

Connection to the Qatar General Electricity & Water Corporation (QGEWC) water supply system shall not take place until all tests and inspections have been successfully completed and the system has been disinfected.

2

The Contractor shall comply with all the requirements of the QGEWC with respect to making the connection to the water supply system.

6.2

PIPELINE IDENTIFICATION

6.2.1

Tags and Colour Coding System

1

Marker tape shall be laid above all underground water mains. The marker tape shall be blue PVC or polyethylene mesh or ribbon at least 50 mm wide, incorporating a corrosion resistant tracing system. The tape shall be clearly marked “WATER” in both English and Arabic in black print.

2

Where aesthetically acceptable, above ground piping shall be clearly and indelibly marked “WATER” in both English and Arabic. Pipes solely for the use of fire fighting purposes shall be distinguishable from other water pipes.

3

Every valve in hot and cold water service pipework installed above ground shall be provided with an identification label. The label shall be secured by either non-corroding, incombustible means to the valve or fixed to a permanent structure near the valve. Labels secured to valves shall be of a non-corroding and incombustible material and clearly marked, by stamping or engraving, with a reference number for the valve. The reference numbers for the valves shall be as stated in the Project Documents. Labels fixed near valves shall comply with the requirements for labels secured to valves except that they need not be incombustible.

4

Surface boxes shall have “WATER” in both English and Arabic cast on. They shall be painted blue with a durable epoxy paint.

6.3

TESTING AND INSPECTION

6.3.1

General Requirements

1

The Contractor shall notify the Engineer at least two clear working days before hand of his intention to test any section of the Works.

2

Unless otherwise agreed by the Engineer, both interim and final tests shall be undertaken on each section of the Works.

3

The Contractor shall also carry out any further testing or inspections specifically requested by QGEWC.

4

Unless otherwise provided in the Project Documentation, the Contractor shall be responsible for providing all equipment and materials for testing purposes and for their removal and proper disposal on completion of testing.

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6.1.4

QCS 2014

Section 19: Plumbing Part 06: Commissioning of Systems

6.3.2

Timing of Tests

1

The timing of tests shall be arranged as follows:

Page 4

(a)

interim test shall be undertaken as soon as practicable after completion of a particular section; particular attention shall be made to work which will be concealed

(a)

final tests shall be carried out on completion of all work on items included in this Section and prior to handing over

(b)

items failing any test shall be corrected immediately and re-tested before further work proceeds.

The Contractor shall note that satisfactory completion at an interim test does not constitute a final test.

6.3.3

Inspection

1

Visual inspection shall be carried out at both interim and final testing in order to detect faults in construction or materials not shown up under testing but which could lead to premature failure. A careful record shall be kept of such inspections.

2

On external pipelines, the following shall be visually inspected:

(b)

pipe line and level

(c)

joints

(d)

air valves

(e)

washout valves

(f)

gate valves

(g)

thrust blocks

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3

Trenches shall be inspected to ensure that excavation is to the correct depth to guard against mechanical damage due to traffic loading.

4

No part of the pipe trench shall be backfilled until the above are satisfactory completed and approved by the Engineer.

5

All internal pipework shall be inspected to ensure that it has been securely fixed.

6

Before testing takes place, all cisterns, tanks, hot water cylinders and water heaters shall be inspected to ensure that they are properly supported and secured, that they are clean and that cisterns are provided with correctly fitting covers.

7

Before testing takes place, all electrical and mechanical items shall be inspected in accordance with Section 9, Mechanical and Electrical Equipment.

QCS 2014

Section 19: Plumbing Part 06: Commissioning of Systems

Page 5

6.3.4

Leakage Test for Underground Pipelines

1

After satisfactory visual inspections have been completed, hydraulic pressure testing shall be carried out on the installation. The testing procedure shall be as follows: gauges used for testing pressure pipelines shall either be of the conventional circular type, not less than 200 mm diameter, calibrated in metres head of water, or shall have a digital indicator capable of reading increments of 0.1m head. Before any gauge is used, the Contractor shall arrange for it to be checked independently and a dated certificate of its accuracy shall be provided

(b)

before testing, valves shall be checked and sealed, the sections of pipe filled with water and the air released. After having been filled, pipelines shall be left under operating pressure for the period described in the Project Documentation or as directed by the Engineer, so as to achieve conditions as stable as possible for testing

(c)

the pressure in the pipeline shall then be raised steadily by pumping in water until the specified test pressure, as given in the Project Documentation or as directed by the Engineer, is reached in the lowest part of the section. The pressure shall be maintained at this level, by pumping if necessary, for a period of one hour. The pumps shall then be disconnected, and no further water shall be permitted to enter the pipeline for a further period of one hour. After the one hour test period, the pressure in the pipe shall be recorded. At the end of this period the original test pressure shall be restored by pumping in water and the loss measured by drawing off water form the pipeline until the pressure as recorded at the end of the one hour test period is again reached

(d)

the permissible loss shall not exceed 2 litres per metre nominal bore per kilometre length per metre head (calculated as the average head applied to the section) per 24 hours. This relationship in equation format, with the leakage measured in litres, can be written as follows:

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Permissible leakage = (2 x D x P x L) / 24 Where: D = pipe diameter (m) P = test pressure (m) L = length of test section (km)

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(e)

in addition to the tests on separate sections, the whole pipeline shall be tested on completion to the same pressure and by the same procedures as that outlined for individual sections

(f)

where a new pipeline is to connect to an operational pipeline the final connection shall be inspected visually under normal operating pressure and there shall be no visible leakage.

To avoid the risk of contamination, water used for testing shall be obtained from a potable supply.

QCS 2014

Section 19: Plumbing Part 06: Commissioning of Systems

Page 6

3

Before accepting a pipeline, a check shall be made that valve boxes are properly aligned, that suitable operating keys are provided which can be easily fitted to the valves and in the case of deep valves, that adequate extension spindles are installed.

6.3.5

Testing of Installation Within Buildings

1

When the installation is complete and visual inspection has been satisfactorily completed, it shall be slowly filled with water, with the highest draw-off point open to allow air to be expelled from the system. The installation, including all cisterns, tanks cylinders and water heaters, shall then be inspected for leaks.

2

The system shall be hydraulically tested in the following way: subject the pipes, pipe fittings and connected appliances to a test pressure at least 1.5 times the maximum working pressure for a period of at least 24 hours

(b)

check the installation for leaks; including all cisterns, tanks, cylinders and water heaters.

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Each draw-off tap, shower fitting and float-operated valve shall be checked for flow against specified requirements. Performance tests shall also be carried out on any specialist items to show that they meet the requirements detailed in the Project Documentation.

6.3.6

Back-Siphonage

1

It shall be verified that the appropriate back-flow prevention devices have been selected and that they have been installed correctly.

6.3.7

Mechanical and Electrical Equipment

1

Mechanical and electrical equipment shall be tested and commissioned in accordance with Section 9, Mechanical and Electrical Equipment.

6.4

DISINFECTION

6.4.1

General Requirements

1

All hot water systems and cold water systems installed shall be disinfected before being taken into use.

2

Where chlorinated water that has been used to disinfect an installation is to be discharged into a sewer, the Drainage Department shall be informed.

3

Unless otherwise stated in the Project Documentation, the Contractor is responsible for providing water for disinfection purposes.

6.4.2

Installations Outside buildings

1

At the time of laying, large bore pipes shall be brushed clean and sprayed internally with a strong solution of sodium hypochlorite.

2

At the time of laying, small bore pipes shall be swabbed with a polyurethane foam plug soaked in a strong solution of sodium hypochlorite. A water jet may be used to push the plug along the pipe.

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QCS 2014

Section 19: Plumbing Part 06: Commissioning of Systems

Page 7

Following the disinfection process, the pipe shall be regarded as operational and the Contractor shall not open or close any valves or take any other action which might interfere with the use of the pipe.

6.4.3

Installation Inside Buildings

1

All visible dirt and debris shall be removed from the cistern.

2

The cistern and distributing pipework shall be filled with clean water and then drained until empty of all water. The cistern shall be filled again and the supply closed.

3

A measured quantity of sodium hypochlorite solution of known strength shall be added to the water in the cistern to give a free residual chlorine concentration of 50 mg/litre in the water.

4

The cistern shall be left to stand for 1 hour. Then each draw-off fitting shall be successively opened working progressively away from the cistern. Each tap or draw-off fitting shall be closed when the water discharged begins to smell of chlorine. The cistern shall not be allowed to become empty during the operation; if necessary it shall be refilled and chlorinated as detailed above. Should refilling be necessary, the cistern and pipes shall be left for a further hour before continuing the disinfection procedure.

5

The tap furthest from the cistern shall be opened and the level of free residual chlorine in the water discharged from the tap shall be measured. If the concentration of free residual chlorine is less than 30 mg/l the disinfecting process shall be repeated.

6

Finally, the cistern and pipes shall remain charged with chlorinated water for at least 16 hours and then thoroughly flushed out with clean water until the chlorine concentration at the taps is no greater than that present in the clean water from the QGEWC supply main.

7

For installation with more than one cistern, all cisterns shall be cleaned and chlorinated, in accordance with paragraph 1 to 4 above, simultaneously.

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END OF PART

QCS 2014

Section 19: Plumbing Work Part 07: Plumbing For Gases

Page 1

7

PLUMBING FOR GASES .............................................................................. 2

7.1

GENERAL ...................................................................................................... 2

7.1.1 7.1.2 7.1.3 7.1.4

Scope References Compliance Quality Assurance

7.2

MATERIALS .................................................................................................. 3

7.2.1 7.2.2

Gas System Accessories Compressed Air System Accessories

7.3

EXECUTION .................................................................................................. 5

7.3.1 7.3.2

Hangers and Supports Execution Requirements

2 2 2 2

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QCS 2014

Section 19: Plumbing Work Part 07: Plumbing For Gases

Page 2

7

PLUMBING FOR GASES

7.1

GENERAL

7.1.1

Scope

1

The work covered in this Part consists of providing all plant, labour and materials and performing all operations in connection with gas and compressed air supply in buildings.

7.1.2

References

1

The following standards are referred to in this Part:

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1

Installation and testing of gas system shall be in accordance with NFPA 99.

2

Gas pressure vessels and relief valves shall be in accordance with the relevant ASME codes.

3

Fabrication and installation of gas systems shall be in accordance ASME B 31.9.

4

Electrical components for compressed air systems shall be listed and labelled by Underwritten Laboratories.

7.1.4

Quality Assurance

1

Manufacturers of gas and compressed air system products shall have been regularly engaged in the manufacture of such products, of the type and size specified in the Project Documentation, that have been in satisfactory use in similar service conditions for not less than five years.

2

Installation of gas and compressed air system shall be carried out by specialists with at least three years of successful installation experience of gas and compressed air systems similar to the type specified in the Project Documentation.

3

Upon completion and prior to acceptance of the installation, the contractor shall carry out operating and pressure tests at not less than 1.5 times the operating pressure, checked at half hour intervals to demonstrate satisfactory functional and operational efficiency. Such operating tests shall take place over a continuous period of not less than 8 hours for each system and shall include the following information in a report with a conclusion as to the adequacy of the system:

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7.1.3

(a)

a description of the test method including references to standard testing procedures if appropriate

(b)

time, date and duration of the test

(c)

compressed air pressure readings of the compressor at each outlet.

QCS 2014

Section 19: Plumbing Work Part 07: Plumbing For Gases

Page 3

MATERIALS

7.2.1

Gas System Accessories

1

Gas cocks shall be bronze with a square head and shall have distinctly marked ON-OFF indications. They shall be pressure rated for 900 kPa (9.0 bar). The units shall conform with SSA 119 and shall be provided with an identification label. Labels shall be visible after installation. Where quick-type couplers are furnished, they shall be of the noninterchangeable type. The connector shall lock firmly into position and shall have a fingertype quick release.

2

A wrench shall be provided and attached to each cock.

3

Pressure regulators shall be in accordance with SSA 121 and shall have an adjustable diaphragm actuated by a spring-loaded pressure reducing valve, designed for liquid petroleum gas (LPG) systems. Pressure regulators shall be provided with a relief valve, and the diaphragm chamber shall be piped to the outside of the building. Pressure regulators shall be approved and marked by authorised officials recognised by a Qatari authority.

4

Shut-off valves shall be wafer type ball valves with bronze body, ball and stem, non-stick seats, seals, O-ring packing and lever handle. Shut-off valves shall have socket ends or threaded socket adapters.

5

Check valves shall be of the threaded bronze spring type with composition disc and bronze spring or of the silent double-centre guided conical spring type.

6

Safety relief valves shall have a spring-loaded shuttle with a pressure adjustment corresponding to the highest permissible working pressure of the cylinder.

7

Pipe failure valves shall have a spring-loaded shuttle suitable to shut off the flow of the gas if the rate of flow is too high.

8

Pressure gauges shall be a black enamel cast iron or cast aluminium case, chromium plated brass ring with a heavy glass, phosphor bronze bushed rotary precision movement, and a dial with a suitable pressure range.

7.2.2

Compressed Air System Accessories

1

Air compressors shall be of the reciprocating air cooled type.

2

Compressors shall consist of replaceable finned cast iron cylinders, flanged cast iron or cast aluminium heads, cast iron or cast aluminium pistons with rings made of carbon or non-stick and forged steel, bronze or aluminium connecting rods. Crank cases shall be made of cast iron. Each compressor shall have an automatic unloader system for no-load start up, a positive pressure lubricating system and stainless steel strip valves

3

Compressors and motors shall be direct-connected or operated by means of a V-belt drive, and provided with guard for flywheel and belts.

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7.2

QCS 2014

Section 19: Plumbing Work Part 07: Plumbing For Gases

Page 4

Motors shall be of the single-phase type or the three-phase type. Motors shall be standard open frame, drip proof, ball bearing 40ºC rise NEMA standard design “B” induction type. Single-phase motors shall have grease lubricated ball bearings and built-in overload. Threephase motors shall have rigid base mounting with slide rails for belt adjustment. Motor voltage shall be as given in the Project Specification.

5

Air receivers shall be suitable for the specified system working pressure, designed and constructed in accordance with the relevant ISO Standards.

6

Air receivers shall be provided with condensate drain trap, relief valve, pressure gauge, and welded steel supporting feet.

7

The outside of air receivers shall either be galvanised or supplied with a commercial enamel finish.

8

Air dryer units shall be of the package assembled type with a cabinet enclosing refrigeration unit, hot bye-pass valve, heat exchanger, moisture separator, chiller section with replaceable type cartridge filter, temperature and pressure gauges, controls and condensate drain trap.

9

Refrigeration units shall be of the hermetically sealed compressor type with air cooled condenser.

10

The cabinets shall be made of steel and finished with commercial enamel, and provided with top-hinged access door and front panel for easy access.

11

Control valves shall be of the top entry or wafer type ball valve with bronze body, ball and stem, non-stick seats, and lever handles with socket ends or threaded socket adapters.

12

Check valves shall be of the threaded bronze spring type with composition disc and bronze spring or of the silent double-centre guided conical spring type.

13

Pressure regulating valves shall be of the adjustable, direct-acting, single-seat, springactuated diaphragm type, or of the double-seated valve plug type, the body shall be made of cast iron, die cast zinc or bronze.

14

The regulator shall be provided with an adjustment device for adjusting pressure differential, and shall be of the same size as the pipe.

15

The filter regulator units shall consist of a bronze or die cast zinc body, actuated by an adjustable direct-acting single-seat spring diaphragm type regulator.

16

The filter regulator units shall be provided with filter units, suitable to filter the supply air of particles down to fine micron size, and pressure gauges.

17

Pressure gauges shall have a black enamel cast iron or cast aluminium case, a chromium plated brass ring with a heavy duty glass cover, a phosphor bronze bushed rotary precision movement, and a dial with a suitable pressure range.

18

Drains shall be the brass pre-cock type in low points of the compressed air system, or the automatic drain type.

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QCS 2014

Section 19: Plumbing Work Part 07: Plumbing For Gases

Page 5

EXECUTION

7.3.1

Hangers and Supports

1

Hangers in contact with copper tubing shall be electrolytically coated and shall be sized to suit the outside diameter of the pipe.

7.3.2

Execution Requirements

1

For gas systems only copper tubing shall be used. Joints shall be made either by soldering or welding. Jointing material shall be suitable for soldering and welding gas pipes.

2

No gas piping shall be installed under any building or structure and all exposed gas piping shall be kept at least 150 mm above the ground.

3

When stand-by gas is connected to the gas piping system, an approved three-way, two-part valve or other adequate safeguard shall be installed to prevent backflow into either supply system.

4

An accessible shut-off valve shall be installed in the gas piping system near each appliance and the head of the union connection thereto, and in addition to any valve on the appliance. Shut-off valves shall be within 1.0 m of the appliance. Shut-off valves may be located immediately adjacent to and inside or under an appliance when placed in an accessible and protected location and when such appliance may be removed without removal of the valve.

5

Appliance connections shall, at no time, have a diameter less than that of the inlet connection to the appliance as provided by the manufacturer.

6

Compressed air piping shall be copper steel, installed free of traps and graded to low points with condensate drain pet-cocks, or automatic condensate drain traps, as required in the Project Specification or shown on the Project Drawings.

7

Compressors shall start unloaded and shall start and stop automatically by means of an enclosed diaphragm-type pressure switch mounted on the unit.

8

Guards shall be provided for all exposed moving parts.

9

After cooler and moisture separator shall be installed between the compressor and the air receiver to remove moisture and oil condensate before the air enters the receiver, except where air dryers are installed.

10

Vacuum cleaning piping shall be made of plastic or steel and shall slope to the separator free of traps. Changes in the direction of piping shall be made by using 45 degree bends or long turn tees or bends, and shall be slip jointed.

11

Drop lines shall be connected from side or top of horizontal lines only.

12

Cleanout plugs shall be provided at all changes in direction and/or as indicated in the Project Specification or shown on the Project Drawings.

13

Floor mounted vacuum inlet valves shall be flush with floor finish.

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QCS 2014

Page 6

The vacuum producer unit shall be provided with rubber inlet sleeve and stainless steel clamps for connecting unit to piping.

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END OF PART

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Section 19: Plumbing Work Part 07: Plumbing For Gases

QCS 2014

Section 20: Drainage Works for Buildings Part 01: General

Page 1

1

GENERAL ...................................................................................................... 2

1.1

INTRODUCTION ........................................................................................... 2

1.1.1 1.1.2

Scope References

1.2

REGULATIONS AND STANDARDS .............................................................. 2

1.2.1

Public Works Authority

1.3

CONTRACTOR’S RESPONSIBILITY ............................................................ 2

1.3.1 1.3.2 1.3.3

General Existing Services Maintenance Period Requirements

1.4

CRAFTSMEN................................................................................................. 2

1.4.1 1.4.2

Workmanship Qualifications

1.5

MATERIALS................................................................................................... 3

1.5.1

General

1.6

DRAWINGS ................................................................................................... 3

1.6.1 1.6.2 1.6.3

Shop Drawings Co-ordination Drawings As-Built Record Drawings and Survey Drawings

1.7

SITE WORKS ................................................................................................ 4

1.7.1

Co-operation with other Trades

2 2

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QCS 2014

Section 20: Drainage Works for Buildings Part 01: General

Page 2

1

GENERAL

1.1

INTRODUCTION

1.1.1

Scope

1

This Section specifies the requirements for the construction and installation of drainage works for buildings. It does not include highway drainage.

2

Related Sections are as follows: Section 1

General

References

1

The following standards are referred to in this Part:

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BS 8000......................Workmanship on building sites

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1.1.2

REGULATIONS AND STANDARDS

1.2.1

Public Works Authority

1

The Contractor shall carry out his work in accordance with the relevant requirements of the Public Works Authority.

1.3

CONTRACTOR’S RESPONSIBILITY

1.3.1

General

1

The Contractor is responsible for obtaining all necessary approvals and permits required to complete the parts of the Works included in this Section.

1.3.2

Existing Services

1

The Contractor is responsible for locating and identifying all existing services that may affect, or be affected by, the construction of the parts of the Works included in this Section.

1.3.3

Maintenance Period Requirements

1

The Contractor is responsible for all the maintenance period requirements for all parts and components of the Works included in this Section.

1.4

CRAFTSMEN

1.4.1

Workmanship

1

Workmanship shall comply with the relevant provisions of BS 8000.

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1.2

QCS 2014

Section 20: Drainage Works for Buildings Part 01: General

Page 3

Construction of each part of the Works covered in this Section shall be undertaken by experienced craftsmen capable of performing the tasks allocated to them in a professional and competent manner.

3

If required by the Engineer, the Contractor shall instruct craftsmen to demonstrate their ability to perform tasks allocated to him.

1.4.2

Qualifications

1

Where the Project Documentation specifies that specialist craftsmen are required to undertake a specific work task, the Contractor shall furnish the Engineer with copies of qualifications pertinent to performing such work tasks for those craftsmen who will be undertaking the work.

1.5

MATERIALS

1.5.1

General

1

All materials, components and products shall comply with the relevant provisions of Section 1, General.

2

All materials, components and products shall be supplied by experienced manufacturers as designated in the Project Documentation or to the written approval of the Engineer.

1.6

DRAWINGS

1.6.1

Shop Drawings

1

The Contractor shall prepare shop drawings for all parts of the Works to be installed or constructed under this Section and submit them to the Engineer in accordance with the relevant provisions of Section 1, General. The shop drawings shall include diagrams, illustrations, schedules, general arrangements of equipment and appurtenances in relation to buildings and structures, method statements and details of specialised installation and construction work.

1.6.2

Co-ordination Drawings

1

These shall be prepared by the Contractor to show how interdisciplinary work will be coordinated. The location, size and details of fixings, box-outs, ducts, holes, pipe chases and plinths shall be shown on the detailed layout drawings which shall be fully co-ordinated with all other work disciplines.

1.6.3

As-Built Record Drawings and Survey Drawings

1

The Contractor shall prepare Record Drawings of all works constructed or installed under this Section in accordance with the relevant provisions of Section 1, General. These shall be prepared as work proceeds. They shall provide a record of any modification to materials and equipment, and to the layout, arrangement and installation of the Works.

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QCS 2014

Section 20: Drainage Works for Buildings Part 01: General

Page 4

1.7

SITE WORKS

1.7.1

Co-operation with other Trades

1

The Contractor shall so organise work progress to harmonise with the work of all trades so that work may proceed as expeditiously as possible. The Contractor shall be responsible for the correct placing of the Works and the connection thereof to the work of all related trades.

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END OF PART

QCS 2014

Section 20: Drainage Works for Buildings Part 02: Internal Drainage Works

Page 1

2

INTERNAL DRAINAGE WORKS ................................................................... 2

2.1

GENERAL ...................................................................................................... 2

2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8

Scope Reference Contractor’s Responsibility System Description Site Work Fixing Sealants Inspection

2.2

INTERNAL DRAINAGE PIPEWORK ............................................................. 4

2.2.1 2.2.2

General Materials

2.3

LABORATORY DRAINAGE SYSTEMS ......................................................... 4

2.3.1

General

2.4

GULLIES ........................................................................................................ 5

2.4.1

Floor Gullies

2.5

ACCESS TO DRAINS .................................................................................... 5

2.5.1

General

2.6

ROOF TERMINATION ................................................................................... 5

2.6.1

Ventilating Pipes and Stack Vents

2.7

PUMPING FACILITIES .................................................................................. 6

2.7.1

Sump Pumps

2.8

SANITARYWARE INSTALLATIONS ............................................................. 6

2.8.1 2.8.2 2.8.3 2.8.4 2.8.5 2.8.6 2.8.7 2.8.8 2.8.9 2.8.10 2.8.11

General Pedestal WC Pans Squat Type Toilet Flushing Cisterns for Toilets Slab Urinals Bowl Urinals Wash-basins Sinks Showers Taps Traps

4 4

4

5

5

5

6

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QCS 2014

Section 20: Drainage Works for Buildings Part 02: Internal Drainage Works

Page 2

INTERNAL DRAINAGE WORKS

2.1

GENERAL

2.1.1

Scope

1

This Part specifies the requirements for internal drainage pipework, internal drainage systems and sanitary appliances.

2

Related Sections and Parts are as follows:

General Sewerage Mechanical and Electrical

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Section 1 Section 8 Section 9

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General Commissioning of Systems

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This Section Part 1 Part 7

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2

Reference

1

The following standards are referred to in this Part:

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BS 416........................Discharge and ventilating pipes and fittings, sand-cast or spun in cast iron BS 437........................Specification for cast iron spigot and socket drain pipes and fittings

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BS 539........................Dimensions of fittings for use with clay drains and sewer pipes

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BS 1010......................Specification for draw-off taps and stopvalves for water services (screw-down patterns) BS 1125......................WC flushing cisterns

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BS 1184......................Specification copper and copper alloy traps

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BS 1188......................Ceramic wash basins and pedestals BS 1206......................Fireclay sinks. Dimensions and workmanship

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BS 1212......................Float operated valves BS 1244......................Metal sinks for domestic purposes BS 1254......................Specification for WC seats (plastics) BS 1255......................WC seats (plastics) BS 2456......................Specification for floats (plastics) for ballvalves for hot and cold water BS 3402......................Quality of vitreous china sanitary appliances BS 4514......................Unplasticized PVC soil and ventilation pipes, fittings and accessories BS 5254......................Polypropylene waste pipe and fittings (external diameter 34.6 mm, 41.0 mm and 54.1 mm) BS 5255......................Thermoplastics waste pipe and fittings BS 5503......................Specification for vitreous china washdown WC pans with horizontal outlet BS 5572......................Sanitary Pipework BS 5889......................One-part gun grade silicone-based sealants

QCS 2014

Section 20: Drainage Works for Buildings Part 02: Internal Drainage Works

Page 3

BS 8313......................Code of Practice for accommodation of building services in ducts Contractor’s Responsibility

1

The Contractor is responsible for checking the dimensions of all internal drainage works to be installed against the availability of space at their intended installation location.

2.1.4

System Description

1

Internal drainage systems shall generally conform to the relevant provisions of BS 5572.

2

Internal drainage systems shall comprise the minimum pipework necessary to carry away the discharges from sanitary appliances in buildings quickly and quietly.

3

Drainage pipework installations shall be such that there is no leakage of contaminated water or foul air into the building.

4

Drainage systems, including materials, joints, supports and fixings shall be durable under the expected operating conditions.

5

Pipework and fittings in drainage systems shall be installed so that defective parts can be replaced without undue difficulty.

2.1.5

Site Work

1

A check should be made to ensure that all holes, chases and ducts required for pipework have been properly provided in accordance with the relevant provisions of BS 8313.

2

Where several pipes pass through floors in close proximity, the Contractor may provide a single framed opening in lieu of individual sleeves. Framed openings shall be to the approval of the Engineer and shall be provided with 100 mm high curbs, on all sides.

2.1.6

Fixing

1

Water supply and discharge pipes should be installed before sanitary appliances are fixed. Before fixing an appliance into position, the Contractor shall ensure that the discharge pipe is clear of obstruction. Joints between appliances and traps and/or pipes should be of the union or detachable type.

2

Sinks and baths should be installed so that they drain to the outlet by gravity.

3

Cistern overflow pipes should be arranged to give a visible warning of discharge.

2.1.7

Sealants

1

Sealants shall comply with the relevant provisions of BS 5889, type B (high modulus sealant) with a fungicide incorporated. The sealant should be applied using a purpose made gun or devise.

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2.1.3

QCS 2014

Section 20: Drainage Works for Buildings Part 02: Internal Drainage Works

Page 4

Inspection

1

Upon completion of the work, all appliances, materials and workmanship should be carefully examined for defects and for faults in installation. Any defects or faults shall be corrected before the appliances are handed over for use.

2.2

INTERNAL DRAINAGE PIPEWORK

2.2.1

General

1

Pipes and fittings used shall be suitable for their purpose.

2

If pipes, pipe joints and pipe fittings are of dissimilar metals, measures shall be taken to prevent electrolytic corrosion.

3

The Contractor shall comply with all the recommendations of manufacturers when jointing pipes of different materials.

2.2.2

Materials

1

Soil, waste and ventilating pipes, fittings and accessories for above ground drainage systems shall comply with the relevant provisions of the appropriate standard, as set out in Table 2.1.

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2.1.8

Material

Standard

Cast Iron

BS 416, Parts 1 and 2

PVC-U (soil and ventilating)

BS 4514

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Table 2.1 Standards for pipes, fittings and accessories for above ground drainage systems

BS 5254

Plastic (waste)

BS 5255

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Polypropylene (waste)

2

Internal drainage pipes and fittings for below ground applications shall comply with the relevant provisions of Section 8, Sewerage.

2.3

LABORATORY DRAINAGE SYSTEMS

2.3.1

General

1

The chemical resistance properties of pipes, fittings, jointing systems and any other drainage accessory shall be suitable for conveying all solutions expected to be discharged to the drainage system. Where possible, technical advisory services provided by manufacturers shall be used to ascertain the suitability of products to be used in the drainage system. A full list of the solutions expected to be discharged to the drainage system is given in the Project Documentation.

QCS 2014

Section 20: Drainage Works for Buildings Part 02: Internal Drainage Works

Page 5

Drainage systems for the collection of solutions which are not permitted to be discharged to existing drainage facilities shall be kept totally separate form other drainage systems.

3

Drainage systems to which grit, gravel, sand or other granular material shall be discharged shall have sufficient abrasion resistance properties and be fitted with suitable traps and catch basins.

2.4

GULLIES

2.4.1

Floor Gullies

1

Floor gullies shall comply with the requirements of the following paragraphs unless otherwise detailed in the Project Documentation.

2

Floor gullies shall be coated cast iron and comply with the relevant provisions of BS 539. They shall have a 90 mm diameter trapped outlet and be fitted with a galvanised flat grating of an approved type.

3

Floor drains shall be selected with sufficient grate free area to pass the anticipated flow. The grate free area is defined as the total area of the drainage openings in the grate and shall be not less than 1.5 times greater than the pipe to which the grate is draining.

4

With the exception of those located in toilets, all floor drains fitted with traps shall incorporate a removable bucket.

5

The gully should be installed on a firm base and located relative to the floor finish. The method of fixing shall be as detailed in the Project Documentation.

2.5

ACCESS TO DRAINS

2.5.1

General

1

Sufficient and suitable access should be provided to enable all pipework to be tested and maintained effectively. Access covers, plugs or caps should be sited so as to facilitate the insertion of testing apparatus and the use of equipment for cleaning and/or for the removal of blockages. The use of apparatus or equipment should not be impeded by the structure or other services.

2

Access points should not be located where their use may give rise to nuisance or danger if spillage occurs.

2.6

ROOF TERMINATION

2.6.1

Ventilating Pipes and Stack Vents

1

Ventilating pipes and stack vents shall terminate with a domical cage or other cover that does not restrict air flow. They shall be positioned so that foul air does not cause a nuisance or health hazard.

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QCS 2014

Section 20: Drainage Works for Buildings Part 02: Internal Drainage Works

Page 6

PUMPING FACILITIES

2.7.1

Sump Pumps

1

Sump pumps shall comply with the relevant provisions of Section 9, Mechanical and Electrical Equipment.

2.8

SANITARYWARE INSTALLATIONS

2.8.1

General

1

Sanitary fittings shall, unless otherwise stated in the Project Documentation, be as described in the following Clauses.

2

Where screws are used to fix sanitary appliances to concrete, blockwork or brickwork they shall be rust-proofed steel and plugged.

2.8.2

Pedestal WC Pans

1

Pedestal WC pans shall be of white glazed fireclay and shall comply with the relevant provisions of BS 5503. They shall have P, Q or S traps as required. WC seats shall be black plastic and shall comply with the relevant provisions of BS 1254. The traps shall be provided with antisyphonage outlets, where required

2

Where pans are fixed to timber floors they shall be jointed to the drain pipe with hemp gaskin and red lead putty. Where pans are fixed to concrete floors, they shall be jointed to the drain pipe with cement/sand mortar mixed in a 1:2 ratio. The pans shall be screwed to the floor.

2.8.3

Squat Type Toilet

1

Squat type toilets shall comprise a closet of white vitreous china complying with the relevant provisions of BS 3402 for sinking into the floors and integral or separate tread plates in a matching material. They shall have P, Q or S trap as required. The traps shall be provided with antisyphonage outlets, where required.

2

The closets and tread plates shall be set into a concrete bed with the top surface level with the floor finish.

2.8.4

Flushing Cisterns for Toilets

1

Flushing cisterns shall be black plastic or white vitreous china complying with the relevant provisions of BS 1125 and shall be the single flushing type. They shall be fitted with a nylon or brass ball valve complying with the relevant provisions of BS 1212 with a plastic float complying with the relevant provisions of BS 2456. They shall have connections for 12 mm diameter supply and 20 mm diameter overflow pipes. Flush pipes complying with the relevant provisions of BS 1125 shall be provided and shall be of galvanised mild steel.

2

Flush pipes shall be jointed to the bottom of the cisterns by means of watertight unions which allow for easy removal and shall be jointed to WC pans by means of approved rubber cone connectors. The cisterns shall be fixed to walls with screws.

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2.7

QCS 2014

Section 20: Drainage Works for Buildings Part 02: Internal Drainage Works

Page 7

High level cisterns shall be provided with chromium plated chains with rubber pull handles. They shall be fixed a height of 1500 mm from finished floor level to the underside of the cistern. Flush pipes shall be 30 mm diameter and shall be fixed with pipe clips which shall be screwed to walls.

4

Low level cisterns shall be provided with chromium plated lever flushing handles. They shall be fixed at a height of 600 mm from finished floor level to the underside of the cistern. Flush pipes shall be 35 mm diameter.

2.8.5

Slab Urinals

1

Urinal slabs shall be white glazed fireclay and shall have end screens. All urinals shall have a white glazed fireclay floor channel and white glazed fireclay fluted treads set flush with the floor finish. The channel shall have a 40 mm diameter chromium plated brass outlet with hinged grating.

2

The urinal slabs, channel and floor treads shall be bedded in cement mortar and jointed and painted with white cement. The flushing cistern shall be a white glazed fireclay automatic flushing cistern, complete with cover, and shall be fixed on white porcelain enamelled cast iron brackets which shall be screwed to the wall.

3

Flush pipes and spreaders shall be chromium plated and shall be fixed to walls with chromium plated holderbats. A 40 mm diameter trap with 40 mm or 75 mm deep seal as necessary shall be provided.

2.8.6

Bowl Urinals

1

Urinals bowls shall be white glazed fireclay with lipped basin and flushing rim. Urinal bowls shall be screwed to the wall. Flushing cisterns, flushing pipes and spreaders shall be as described for slab urinals. The bowl urinals shall be complete with chromium plated brass outlet and trap.

2.8.7

Wash-basins

1

Wash-basins shall be white glazed fireclay size 625 mm x 450 mm overall and shall comply with the relevant provisions of BS 1188. Each basin shall be provided with a 30 mm diameter chromium plated waste outlet and rubber plug with a chromium plated chain and stay.

2

A 30 mm diameter trap shall be fixed to each basin having a 40 mm deep seal and one or two 12 mm pillar taps shall be fixed as required. Where only one tap only is required, the basin shall be provided with a tap hole stopper to match the basin. Unless otherwise specified, each wash-basin shall be fixed on two cast iron brackets complying with the relevant provisions of BS 1255 which shall be screwed to the wall. If required the pedestal WC pan shall match the basin.

2.8.8

Sinks

1

Ceramic sinks shall be white glazed fireclay size 600 mm x 450 mm x 250 mm deep and shall comply with the relevant provisions of BS 1206.

2

Metal sinks shall be stainless steel or aluminium to the sizes stated in the Project Documentation and shall comply with the relevant provisions of BS 1244.

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QCS 2014

Section 20: Drainage Works for Buildings Part 02: Internal Drainage Works

Page 8

Each sink shall be provided with a 40 mm chromium plated brass waste outlet, outlet grating, overflow and rubber plug with chromium plated chain and stay. A 40 mm diameter trap shall be fixed to each sink having a 40 mm or 75 mm deep seal as necessary. Each sink shall have one or two 12 mm diameter pillar or bib taps, as required. Where only one tap is required, a tap hole stopper to match the sink shall be provided. Pillar taps shall have 150 mm raising pieces and bib taps shall have extension pieces of adequate length.

4

Sinks shall be supported and fixed on brackets or legs unless otherwise specified in the Project Documentation. Two cast iron brackets shall be used for sinks supported and fixed on brackets. The brackets shall comply with the relevant provisions of BS 1255 and shall be screwed to the wall. Legs for supporting sinks shall be of cast iron or galvanised steel with a painted finish. Sinks shall be fixed at a height of 550 mm from the outlet grating to finished floor level.

2.8.9

Showers

1

Shower fittings shall comprise a 100 mm diameter adjustable chromium plated brass inclined shower head with rose and 12 mm diameter supply pipe(s) with 12 mm diameter stop valve(s) to control the water supply.

2

The shower head shall be fixed a height of 1800 mm above the finished floor level. All exposed pipework and fittings serving the showers within the shower area shall be chromium plated and fixed with chromium plated holderbats.

2.8.10

Taps

1

All taps shall comply with the relevant provisions of BS 1010. Taps shall be of the following type as appropriate and, where necessary, shall be provided with extension pieces.

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pillar taps shall be 12 mm diameter chromium plated brass with cross heads. bib taps, unless otherwise stated, shall be 12 mm diameter chromium plated brass with cross heads, complete with backplate elbow or wall flange. Bib taps to stand pipes shall be 12 mm diameter unplated brass, and shall have an extended nozzle suitable for hose connections.

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3

Traps

1

Traps shall be of the following types:-

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2.8.11

(a)

(b)

(c)

traps for sinks, lavatory basins and baths shall be copper, brass, or aluminium complying with the relevant provisions of BS 1184, complete with cleaning eye. Traps to sinks, baths shall have an overflow connection. traps for urinals with suspended drains shall be 75 mm diameter cast iron complying with the relevant provisions of BS 416, Table 14. They shall be fitted with cast iron connectors and threaded to receive the outlet from the urinal. traps for urinals with buried drainage shall be 75 mm diameter cast iron complying with the relevant provisions of BS 437. They shall be fitted with cast iron connectors and threaded to receive the outlet from the urinal. END OF PART

QCS 2014

Section 20: Drainage Works for Buildings Part 03: External Drainage Works

Page 1

3

EXTERNAL DRAINAGE WORKS .................................................................. 2

3.1

GENERAL ...................................................................................................... 2

3.1.1 3.1.2 3.1.3

Scope References System Description

3.2

PIPEWORK.................................................................................................... 3

3.2.1 3.2.2 3.2.3 3.2.4

General Vitrified Clay Pipework Unplasticized Polyvinyl Chloride (PVC-U) Pipework Testing of Pipework

3.3

ACCESSORIES ............................................................................................. 3

3.3.1

Gullies and Gully Gratings

3.4

CONNECTION TO EXISTING PIPELINES .................................................... 4

3.4.1

Connections to Existing Government Mains

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3

4

QCS 2014

Section 20: Drainage Works for Buildings Part 03: External Drainage Works

Page 2

EXTERNAL DRAINAGE WORKS

3.1

GENERAL

3.1.1

Scope

1

This Part specifies the requirements for pipework and accessories for external drainage works in building areas. External drainage works includes foul water sewerage and surface water sewerage.

2

Related Sections and Parts are as follows:

Section 1 Section 5 Section 6 Section 8

General Concrete Roadworks Sewerage

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General Commissioning of Systems

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This Section Part 1 Part 6

.

3

References

1

The following standards are referred to in this Part:

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BS 2494......................Elastomeric seals for joints in pipework and pipeline BS 4346 .....................Joints and fittings for use with unplasticized PVC pressure pipes.

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BS 4660......................unplasticized polyvinyl chloride (PVC-U) pipes and plastic fittings of nominal sizes 110 and 160 for below ground drainage and sewage

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BS 5481......................Unplasticized PVC pipe and fittings for gravity sewers BS 6209 .....................Solvent cement for non-pressure thermoplastic pipe systems

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BS EN 295 .................Vitrified clay pipes and fittings and pipe joints for drains and sewers

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ISO 4633 ....................Rubber Seals -Joints rings for supply, drainage System Description

1

Pipes and fittings to be used for foul sewerage shall be suitable for carrying sewage at temperatures of up to 45C with hydrogen sulphide concentrations up to 400 mg/l.

2

Pipes shall be suitable for immersion in corrosive groundwater conditions typically exhibiting the following characteristics unless otherwise specified:

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3.1.3

SO3 Content CI Content pH Conductivity 3

: : : :

1.7 g/l 1.07 g/l 8.6 4000 s/cm

The Contractor shall be responsible for providing a jointing system as recommended by the pipe manufacturer that enables the installation and use of the designated pipeline systems.

QCS 2014

Section 20: Drainage Works for Buildings Part 03: External Drainage Works

Page 3

PIPEWORK

3.2.1

General

1

Pipes shall have adequate strength to meet the loading requirements, be sufficiently robust to withstand site handling and be sufficiently durable to remain watertight for the anticipated life of the system.

2

Pipes and joints should remain sufficiently water tight to prevent the ingress of ground water and the ingress of effluent when subject to ground movement and settlement.

3.2.2

Vitrified Clay Pipework

1

Vitrified clay pipes and fittings for drains and sewers shall comply with the relevant provisions of BS EN 295.

2

Pipes shall have spigot and socket joints complying with the relevant provisions of BS EN 295. Joints shall have elastomeric joint seals. Complying with the relevant provision of ISO 4633 or, BS 2494 (Type D) and shall be obtained from the pipe manufacturer. For pipes up to 150 mm diameter, push-fit (sleeve type) polypropylene flexible couplings may be used in place of spigot and socket joints.

3

All other requirements related to the manufacture, inspection and testing of vitrified clay pipes shall be in accordance with the relevant provision of Section 8, Sewerage.

3.2.3

Unplasticized Polyvinyl Chloride (PVC-U) Pipework

1

PVC-U pipe joints and fittings for gravity drains and sewers shall comply with the relevant provisions of BS 4660 or 5481.

2

Joints shall have elastomeric joint seals complying with the relevant provisions of ISO 4633 or BS 2949 (Type D) and shall be obtained from the pipe manufacturer.

3

Solvent cements for jointing PVC-U pipes shall comply with BS 4346. For pipes and fittings complying with BS 4660, solvent cement may alternatively comply with BS 6209.

4

All other requirements related to the manufacture, inspection and testing of PVC-U pipes shall be in accordance with the relevant provisions of Section 8, Sewerage.

3.2.4

Testing of Pipework

1

Internal and external pressure tests shall be carried out on external drainage pipes. Test procedures are detailed in Part 6 of this Section.

3.3

ACCESSORIES

3.3.1

Gullies and Gully Gratings

1

Gullies and gully gratings shall comply with the relevant provisions of Section 6, Roadworks.

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QCS 2014

Section 20: Drainage Works for Buildings Part 03: External Drainage Works

Page 4

CONNECTION TO EXISTING PIPELINES

3.4.1

Connections to Existing Government Mains

1

Connections to existing Government mains shall comply with the relevant provisions of Section 8, Sewerage, and the following clauses.

2

Where possible and practicable, connections shall be made to future connection ports in existing Government manholes. The caps on future connection ports to which connections are made shall be cleaned and delivered to the government stores in accordance with he relevant provisions of Section 1, General.

3

Where it is not possible of practicable to utilise future connection ports in existing manholes, connections shall be made by either breaking into existing manholes or constructing new manholes on existing mains.

4

If it is necessary to break into an existing manhole, the Contractor shall break into the manhole wall, insert pipework, break out the existing benching, construct benching to suit new connection and make good. If necessary, the Contractor shall relocate the access ladder and the cover slab to suit the new benching layout.

5

Manholes built on an existing Government mains shall be constructed in accordance with Clause 6 of this Part. On completion, such manholes shall become the property of the government.

6

The Contractor shall be responsible for all over-pumping operations associated with making connections to Government mains.

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END OF PART

QCS 2014

Section 20: Drainage Works for Buildings Part 04: Drainage Pipes in Trenches

Page 1

4

DRAINAGE PIPES IN TRENCHES ............................................................... 2

4.1

GENERAL ...................................................................................................... 2

4.1.1 4.1.2

Scope References

4.2

LAYING OF DRAINAGE PIPES IN TRENCHES ........................................... 2

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9

System Description General Bedding Protective Coatings Concrete Protection to Pipes Completion of Pipe Surround Backfilling Protective Coatings Pipes under Buildings

4.3

ACCESS TO DRAINAGE PIPES IN TRENCHES .......................................... 5

4.3.1 4.3.2 4.3.3

General Rodding Eyes Provision of Access to Drains

4.4

TESTING ....................................................................................................... 6

4.4.1

Testing of Pipework

2 2 3 3 4 4 4 5 5

5 5 5

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QCS 2014

Section 20: Drainage Works for Buildings Part 04: Drainage Pipes in Trenches

Page 2

DRAINAGE PIPES IN TRENCHES

4.1

GENERAL

4.1.1

Scope

1

This Part specifies the requirements for trenches and bedding for drainage pipes constructed internally and externally.

2

Related Sections and Parts are as follows:

Section 1 Section 5 Section 8

General Concrete Sewerage

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General Internal Drainage Works External Drainage Works Commissioning of Systems

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This Section Part 1 Part 2 Part 3 Part 6

.

4

References

1

The following standards are referred to in this Part:

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4.1.2

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BS 743........................Materials for damp-proof courses. BS 882 Aggregates from natural sources for concrete

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BS 1142......................Fibre building boards BS 2494 Specification for elastomeric joint rings for pipework and pipeline

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BS 6076......................Tubular polythene film for use as a protective sleeving for buried iron pipes and fittings

LAYING OF DRAINAGE PIPES IN TRENCHES

4.2.1

System Description

1

The laying of drainage pipes in trenches shall generally be in accordance with the relevant provisions of Section 8, Sewerage.

4.2.2

General

1

Where socketed pipes are required to be laid on a granular or sand bed, or directly on a trench bottom, joint holes shall be formed in the bedding material or final excavated surface to ensure that each pipe is uniformly supported throughout the length of its barrel and to enable the joint to made.

2

Pipes shall be laid on setting blocks only where a concrete bed or cradle is used.

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QCS 2014

Section 20: Drainage Works for Buildings Part 04: Drainage Pipes in Trenches

Page 3

Where pipes are required to be bedded directly on the trench bottom, the final excavated surface shall be trimmed and levelled to provide even bedding for the pipeline and shall be free from all extraneous matter that may damage the pipe, pipe coating, or sleeving. Where rock is encountered, the trench shall be cut at least 150 mm deeper than other ground and made up with well compacted selected fill material.

4

No protective cap, disc or other appliance on the end of a pipe or fitting shall be removed permanently until the pipe or fitting which it protects is about to be jointed. Pipes and fittings, including any lining or sheathing, shall be examined for damage and the joint surfaces and components shall be cleaned immediately before laying.

5

Suitable measures shall be taken to prevent soil or other material from entering pipes, and to anchor each pipe to prevent flotation or other movement before the Works are complete.

6

Where pipeline marker tape is specified, it shall be laid between 100 mm and 300 mm above the pipe.

4.2.3

Bedding

1

Bedding for pipes shall be constructed by spreading and compacting granular bedding material over the whole width of the pipe trench. After the pipes have been laid, additional material shall, if required, be placed and compacted equally on each side of the pipe, and where practicable, this shall be done in sequence with the removal of the trench supports.

2

Bedding material shall be in accordance with Table 4.1 unless otherwise specified in the Project Documentation.

3

Nominal single sized aggregate and graded aggregate shall comply with Table No. 4 of BS 882.

4

Sand for bedding material shall comply with the relevant provisions of BS 882.

5

Bedding systems other than those specified in this Clause may be allowed upon approval of the Engineer or as recommended by the pipe manufacturer.

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Table 4.1 Bedding Material

Pipe Diameter

Bedding

up to 65 mm

Sand

65 - 100 mm

10 mm single sized aggregate

100 - 200 mm

10 or 14 mm single sized or 14-15 mm graded aggregate

Over 200 mm

10,14 or 20 mm single sized or 15-5 or 20-5 mm graded aggregate.

4.2.4

Protective Coatings

1

Coatings, sheathings or wrappings shall be examined for damage, repaired where necessary, and made continuos before trench excavations are backfilled.

QCS 2014

Section 20: Drainage Works for Buildings Part 04: Drainage Pipes in Trenches

Page 4

Concrete Protection to Pipes

1

Pipes to be bedded on or cradled with concrete shall be supported on precast concrete setting blocks. The top face of each block shall be covered with two layers of compressible packing complying with BS 743.

2

Concrete provided as a protection to pipes shall be Grade C20, placed to the required depth in one operation.

3

Where pipes with flexible joints are used, the concrete protection shall be interrupted over its full cross-section at each pipe joint by a shaped compressible filler of bitumen impregnated insulating board to BS 1142 or equally compressible material. The thickness of the compressible filler shall be in accordance with Table 4.2.

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Table 4.2 Thickness of Compressible Filler

.

4.2.5

Thickness of Compressible Filler (mm)

Up to 300

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Nominal Bore of Pipe (mm)

Over 300 and up to 600

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Over 600 and up to 1200

25 38

Rapid hardening cement shall not be used in concrete for the protection of plastics pipe.

5

Plastics pipes shall be wrapped with a layer of plastic sheeting complying with a composition in accordance with Clause 3 of BS 6076 and a nominal thickness of 125 microns before being surrounded by concrete.

6

Concrete work shall comply with the relevant provisions of Section 5, Concrete.

4.2.6

Completion of Pipe Surround

1

Fill material shall, where required, be placed and compacted over the full width of the trench in layers not exceeding 150 mm before compaction, to a finished thickness of 250 mm above the crown of the pipes.

4.2.7

Backfilling

1

Backfilling shall, wherever practicable, be undertaken immediately the specified operations preceding it have been completed. Backfilling shall not, however, be commenced until the parts of the Works to be covered have achieved a strength sufficient to withstand all loading imposed thereon.

2

Backfilling around existing structures shall be undertaken in such manner as to avoid uneven loading or damage.

3

Filling material to excavations shall be deposited in layers not exceeding 250 mm unconsolidated thickness and compacted to 95% modified proctor.

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QCS 2014

Section 20: Drainage Works for Buildings Part 04: Drainage Pipes in Trenches

Page 5

Where the excavations have been supported and the supports are to be removed, these, where practicable, shall be withdrawn progressively as backfilling proceeds in such a manner as to minimise the danger of collapse. All voids formed behind the supports shall be carefully filled and compacted

4.2.8

Protective Coatings

1

Coatings, sheathings or wrappings shall be examined for damage, repaired where necessary, and made continuos before trench excavations are backfilled.

4.2.9

Pipes under Buildings

1

Where a pipe has less than 300 mm of cover under a load bearing slab, it should be surrounded with concrete as an integral part of the slab. Where possible, the concrete surround shall be poured at the same time as the slab. The surround shall be tied to the slab with nominal steel reinforcement placed vertically with turned over ends.

2

No provision for pipe flexibility along the concrete surround shall be made, unless an expansion joint is included in the slab. A construction joint should be included in the surround at that point which must also coincide with a pipe joint.

3

In normal, stable ground conditions, and with 300 mm or more of cover to the pipeline beneath the slab, a total granular surround can be used as a pipe bedding. Refer to Clause 4.2.3 of this Part for the bedding specification.

4

Flexibility shall be incorporated into the pipeline as it leaves any concrete surround.

5

Where plastic pipes are to be surrounded in concrete, Clause 4.2.5 of this Part shall apply.

4.3

ACCESS TO DRAINAGE PIPES IN TRENCHES

4.3.1

General

1

Access is required to drainage installations for testing, inspection, maintenance and removal of debris.

4.3.2

Rodding Eyes

1

Rodding eyes shall be constructed in pipework of the same diameter as the drains it serves and should connect to the drain at an angle not steeper than 45 from the horizontal.

4.3.3

Provision of Access to Drains

1

Every drain length should be accessible for maintenance and rodding without the need to enter buildings. Access should be provided at the head of each run of a drain and at changes in direction, gradient or pipe diameter.

2

Table 4.3 indicates the recommended maximum distance between rodding eyes, inspection chambers and manholes.

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QCS 2014

3

Section 20: Drainage Works for Buildings Part 04: Drainage Pipes in Trenches

Page 6

Where a branch drain joins another drain without the provision of an inspection chamber or manhole at the junction, access should be provided on the branch drains within 12 m of the junction. Table 4.3 Maximum Spacings of Access Points from Junction or Branch

from Inspection Chamber

from Manhole

-

22 m

45 m

rodding eye

22 m

45 m

45 m

inspection chamber

22 m

45 m

45 m

manhole

45 m

45 m

90 m

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start of external drain

.

Distance to

TESTING

4.4.1

Testing of Pipework

1

Pressure tests shall be carried out on below ground plumbing pipes. Test procedures are detailed in Part 6 of this Section.

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END OF PART

QCS 2014

Section 20: Drainage Works for Buildings Part 05: Structures Related to Drainage Work

Page 1

5

STRUCTURES RELATED TO DRAINAGE WORK ....................................... 2

5.1

GENERAL ...................................................................................................... 2

5.1.1 5.1.2 5.1.3 5.1.4

Scope References Concrete Work Pipes built into structures

5.2

CONSTRUCTION OF MANHOLES, CHAMBERS AND SOAKAWAYS ........ 2

5.2.1 5.2.2

General Soakaways

5.3

PRECAST CONCRETE MANHOLES ............................................................ 3

5.3.1 5.3.2

General Jointing of Precast Manholes

5.4

TESTING OF STRUCTURES RELATED TO DRAINAGE WORK ................. 3

5.4.1

General

2 2 2 2

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QCS 2014

Section 20: Drainage Works for Buildings Part 05: Structures Related to Drainage Work

Page 2

5

STRUCTURES RELATED TO DRAINAGE WORK

5.1

GENERAL

5.1.1

Scope

1

This Part specifies the requirements for the construction of manholes, chambers and soakaways for drainage works.

2

Related Section and Parts are as follows: This Section

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Concrete Roadworks Sewerage

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Section 5 Section 6 Section 8

General External Drainage Works Commissioning of Systems

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Part 1 Part 3 Part 6

References

1

The following standards are referred to in this Part:

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PWA Developer’s Drainage Guide

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5.1.2

Concrete Work

1

Concrete for manholes, chambers and soakaways shall comply with the relevant provisions of Section 5, Concrete.

5.1.4

Pipes built into structures

1

Where pipes are built into concrete, they shall be rigidly secured in position to prevent movement and shall be free from external coatings which might adversely affect the bond.

5.2

CONSTRUCTION OF MANHOLES, CHAMBERS AND SOAKAWAYS

5.2.1

General

1

The construction of manholes and chambers for drainage works for foul sewage and surface water sewage shall comply with the relevant provisions of the following:

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5.1.3

(a)

Section 8 of this Specification, Sewerage

(b)

PWA - Developer’s Drainage Guide

5.2.2

Soakaways

1

Soakaways for surface water sewage shall comply with the relevant provisions of Section 6, Roadworks, except as amended in this Part.

QCS 2014

Section 20: Drainage Works for Buildings Part 05: Structures Related to Drainage Work

Page 3

Soakaways shall not be constructed closer than 5 m from a building or in a position where the ground below foundations is likely to be affected.

3

Precast concrete soakaways shall be dry jointed.

5.3

PRECAST CONCRETE MANHOLES

5.3.1

General

1

Precast concrete manholes shall comply with the relevant provisions of the PWA, except as amended in this Part.

5.3.2

Jointing of Precast Manholes

1

The jointing material for precast manholes shall be mortar or a proprietary bitumen or resin mastic sealant, with the concrete surfaces primed with an appropriate sealant. The jointing material which is extruded inside the manhole shall be trimmed off and joints pointed on completion.

2

Units which bed onto bases shall be manufactured so that imposed vertical loads are transmitted directly via the full wall thickness of the unit.

3

For joints between units and the underside of slabs, joint profiles shall be capable of withstanding applied loadings from such slabs. Spigot ended sections shall only be used where the soffit of the slab is recessed to receive them.

5.4

TESTING OF STRUCTURES RELATED TO DRAINAGE WORK

5.4.1

General

1

Testing of structures related to drainage work shall be done in accordance with the relevant provisions of Part 6 of this Section.

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END OF PART

Section 20: Drainage Works for Buildings Part 06: Surface Water Drainage

Page 1

6

SURFACE WATER DRAINAGE .................................................................... 2

6.1

GENERAL ...................................................................................................... 2

6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6

Scope References Submittals Pipe Marking Handling and Storage Quality Assurance

6.2

PIPEWORK.................................................................................................... 4

6.2.1 6.2.2 6.2.3 6.2.4 6.2.5

General Vitrified Clay Pipework Unplasticized Polyvinyl Chloride (PVC-U) Pipework Reinforced Concrete Pipes Testing of Pipework

6.3

PIPE LAYING................................................................................................. 5

6.3.1 6.1.1 6.3.2 6.3.3 6.3.4

General Pipe Bedding Concrete Protection to Pipes Completion of Pipe Surround Backfilling

6.4

GULLIES AND DRAINAGE CHANNELS ....................................................... 7

6.4.1 6.4.2 6.4.3

Gullies Pre-formed Gullies Drainage Channels

6.5

SOAKAWAYS ................................................................................................ 8

6.5.1

General Requirements

8

6.6

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QCS 2014

MANHOLES AND CATCH PITS .................................................................... 8

6.6.1

General Requirements

8

6.7

CONNECTION TO GOVERNMENT MAIN .................................................... 9

6.7.1

General Requirements

4 4 5 5 5 5 6 6 6 6 7 7 8

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QCS 2013

9

QCS 2014

Section 20: Drainage Works for Buildings Part 06: Surface Water Drainage

Page 2

SURFACE WATER DRAINAGE

6.1

GENERAL

6.1.1

Scope

1

This Part specifies the requirement for pipework, gullies, manholes, catch pits, soakaways and other items related to surface water drainage.

2

Related Sections and Parts are as follows:

Section 5

Concrete

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General Commissioning of Systems

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References

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The following standards are referred to in this Part:

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BS 65.......................... Vitrified clay pipes, fittings and ducts, also flexible mechanical joints for use solely with surface water pipes and fittings BS 497........................Manhole covers, road gully grating and frames for drainage purposes

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BS 743........................Materials for damp-proof courses

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BS 1142......................Fibre building boards BS 1247......................Manhole steps

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BS 2494......................Elastomeric seals for joints in pipework and pipelines

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BS 4660......................unplasticized polyvinyl chloride (PVC-U) pipes and plastic fittings of nominal sizes 110 and 160 for below ground gravity drainage and sewerage BS 6076......................Tubular polythene film for use as protective sleeving for buried iron .................................. pipes and fittings

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This Section Part 1 Part 6

.

6

BS 5481......................unplasticized PVC pipe and fittings for gravity sewers BS 5911......................Precast concrete pipes, fittings and ancillary products BS EN 124 .................Gully tops and manhole tops for vehicular and pedestrian areas BS EN 295 .................Vitrified clay pipes and fittings and pipe joints for drains and sewers.

QCS 2013

QCS 2014

Section 20: Drainage Works for Buildings Part 06: Surface Water Drainage

Page 3

6.1.3

Submittals

1

The Contractor shall order materials to suit the construction programme and obtain the Engineer’s approval of submittals before placing orders. The Contractor shall submit two copies of the following documents for the approval of the Engineer.

originals of catalogues and engineering data sheets for manufactured items; each item and option to be provided shall be clearly marked and each item not to be provided shall be deleted

(ii)

literature to show that products provided meet the requirements for material, construction, operation, and testing

(iii)

information on the following items as a minimum: pipes; pipe jointing systems, manhole covers and frames and gully covers, gratings and frames.

(iv)

manufacturer’s installation instructions for all items

(v)

certified reports for all tests and inspections designated herein, signed and sealed, showing full compliance with referenced standards

(vi)

maintenance requirements and procedures

(vii)

period of guarantee for products.

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Shop Drawings showing the following:

profiles of each pipe system including chainage, ground levels, invert levels, critical clearances and position of pipework structures.

(ii)

material, class, grade, joint type, pressure rating, dimension, location and identification number of each pipe and pipe fitting to be furnished and installed.

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(b)

Product Data

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(a)

procedures for building pipes into concrete structures.

(iv)

procedures for encasing pipes in concrete.

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(iii)

(v)

class, dimensions, location and identification of each manhole cover and frame to be furnished and installed.

(vi)

procedures for placing and fixing manhole covers and frames.

(vii)

class, dimensions, location and identification of each gully cover, grating and frame to be furnished and installed.

(viii) procedures for placing and fixing gully covers, gratings and frames. (ix)

details for handling and storage of pipes, manhole covers and frames and gully covers, gratings and frames.

(x)

all other miscellaneous details required for complete installation.

QCS 2013

QCS 2014

Section 20: Drainage Works for Buildings Part 06: Surface Water Drainage

6.1.4

Pipe Marking

1

Each pipe and pipe fitting shall be marked with the following: (a)

serial number

(b)

class of pipe

(c)

nominal diameter

(d)

name or trademark for manufacturer

(e)

date of manufacture.

Page 4

Handling and Storage

1

Each item to be provided under this Part shall be stored and handled in accordance with the recommendations of the manufacturer of the item.

2

Products susceptible to ultra violet degradation shall be stored under cover and out of direct sunlight.

3

Pipes and fittings shall be subject to visual inspections after off-loading at the site and before installation.

6.1.6

Quality Assurance

1

Pipes, pipe fittings, manhole covers and frames and gully covers, gratings and frames shall be supplied by approved manufacturers as designated in the Project Specification. Production facilities shall be quality assessed in accordance with ISO 9000 or equivalent.

6.2

PIPEWORK

6.2.1

General

1

Pipes shall have adequate strength to meet the loading requirements, be sufficiently robust to withstand site handling and be sufficiently durable to remain watertight for the anticipated life of the system. Pipes and joints should remain sufficiently water tight to prevent the ingress of ground water.

6.2.2

Vitrified Clay Pipework

1

Vitrified clay pipes and fittings for surface water drainage shall comply with the relevant provisions of BS EN 295.

2

Pipes and pipe fittings shall be extra strength class.

3

All pipes and pipe fittings shall have flexible mechanical joints. Pipes with diameters larger than 150 mm shall have spigot and socket joints complying with the relevant provisions of BS EN 295. Spigot and socket joints shall have elastomeric joint seals, Type D, complying with the relevant provisions of BS 2494, and shall be obtained from the pipe manufacturer. Push-fit (sleeve type) polypropylene flexible couplings may be used in place of spigot and socket joints for pipes up to 150 mm diameter.

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6.1.5

QCS 2013

QCS 2014

Section 20: Drainage Works for Buildings Part 06: Surface Water Drainage

Page 5

Unplasticized Polyvinyl Chloride (PVC-U) Pipework

1

PVC-U pipes and fittings for surface water drainage shall comply with the relevant provisions of BS 4660 and BS 5481.

2

All pipes and pipe fittings shall have spigot and socket joints complying with the relevant provisions of BS 4660 and BS 5481. Spigot and socket joints shall incorporate Type D elastomeric joint seals complying with the relevant provisions for BS 2494 and shall be obtained from the pipe manufacturer.

6.2.4

Reinforced Concrete Pipes

1

Reinforced concrete pipes and fittings and flexible or ogee joints shall comply with the relevant provisions of BS 5911: Parts 100 and 110 respectively.

2

All pipes and fittings shall have gasket type joints of spigot and socket or rebated form, unless otherwise described in the Project Specification or shown on the Project Drawings.

6.2.5

Testing of Pipework

1

Pressure tests shall be carried out on surface water drainage pipes. Test procedures are detailed in Part 6 of this Section.

6.3

PIPE LAYING

6.3.1

General

1

Where socketed pipes are required to be laid on a granular or sand bed, or directly on a trench bottom, joint holes shall be formed in the bedding material or final excavated surface to ensure that each pipe is uniformly supported throughout the length of its barrel and to enable the joint to made.

2

Pipes shall be laid on setting blocks only where a concrete bed or cradle is used.

3

Where pipes are required to be bedded directly on the trench bottom, the final excavated surface shall be trimmed and levelled to provide even bedding of the pipeline and shall be free from all extraneous matter that may damage the pipe, pipe coating, or sleeving.

4

No protective cap, disc or other appliance on the end of a pipe or fitting shall be removed permanently until the pipe or fitting which it protects is about to be jointed. Pipes and fittings, including any lining or sheathing, shall be examined for damage and the joint surfaces and components shall be cleaned immediately before laying.

5

Suitable measures shall be taken to prevent soil or other material from entering pipes, and to anchor each pipe to prevent flotation or other movement before the Works are complete.

6

Where pipeline marker tape is specified, it shall be laid between 100 mm and 300 mm above the pipe.

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6.2.3

QCS 2013

QCS 2014

Section 20: Drainage Works for Buildings Part 06: Surface Water Drainage

Page 6

Pipe Bedding

7

Bedding for pipes shall be constructed by spreading and compacting granular bedding material over the full width of the pipe trench. After the pipes have been laid, additional material shall, if required, be placed and compacted equally on each side of the pipes, and where practicable, this shall be done in sequence with the removal of the trench supports.

6.3.2

Concrete Protection to Pipes

1

Pipes to be bedded on or cradled with concrete shall be supported on precast concrete setting blocks. The top face of each block shall be covered with two layers of compressible packing complying with BS 743.

2

Concrete provided as a protection to pipes shall be Grade C20, placed to the required depth in one operation.

3

Where pipes with flexible joints are used, concrete protection shall be interrupted over its full cross-section at each pipe joint by a shaped compressible filler of bitumen impregnated insulating board to BS 1142 or equally compressible material. The thickness of the compressible filler shall be in accordance with Table 6.1.

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Table 6.1 Thickness of Compressible Filler

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Nominal bore of pipe (mm)

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Less than 450

Thickness of compressible filler (mm) 18 36

Exceeding 1200

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450 to 1200

Rapid hardening cement shall not be used in concrete for the protection of plastics pipe.

5

Plastics pipes shall be wrapped with a layer of plastic sheeting complying with a composition in accordance with Clause 3 of BS 6076 and a nominal thickness of 125 microns before being surrounded by concrete.

6.3.3

Completion of Pipe Surround

1

Fill material shall, where required, be placed and compacted over the full width of the trench in layers not exceeding 150 mm before compaction, to a finished thickness of 250 mm above the crown of the pipes.

6.3.4

Backfilling

1

Backfilling shall, wherever practicable, be undertaken immediately the specified operations preceding it have been completed. Backfilling shall not, however, be commenced until the works to be covered have achieved a strength sufficient to withstand all loading imposed thereon.

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Page 7

Backfilling around existing structures shall be undertaken in such manner as to avoid uneven loading or damage.

3

Filling material to excavations shall be deposited in layers not exceeding 250mm unconsolidated thickness and compacted to 95% modified proctor.

4

Where the excavations have been supported and the supports are to be removed, these, where practicable, shall be withdrawn progressively as backfilling proceeds in such a manner as to minimise the danger of collapse. All voids formed behind the supports shall be carefully filled and compacted

6.4

GULLIES AND DRAINAGE CHANNELS

6.4.1

Gullies

1

Gullies shall incorporate rodding eyes. Rodding eyes shall be fitted with rubber stoppers during normal operation.

2

All gullies shall be trapped to prevent unwanted odours escaping from the drain.

3

All gullies shall incorporate aluminium silt buckets.

4

The Contractor shall ensure that the gully outlet and the outlet pipework are compatible.

5

Gully covers, gratings and frames shall comply with the relevant provisions of BS 497: Part 1 or BS EN 124.

6

The class of gullies covers, gratings and frames shall be as described in the Project Specification or as shown on the Project Drawings.

6.4.2

Pre-formed Gullies

1

Precast concrete gullies shall comply with the relevant provisions of BS 5911: Part 2 and Section 5 - Concrete.

2

Vitrified clay gullies shall comply with the relevant provisions at BS EN 295: Part 1 or BS 65.

3

Polypropylene gullies shall be of a type detailed in the Project Specification or shown on the Project Drawings and shall be obtained from a reputable manufacturer as approved by the Engineer.

4

Cast iron gullies shall be of a type detailed in the Project Specification or shown on the Project Drawings and shall be obtained from a reputable manufacturer as approved by the Engineer.

5

Pre-formed gullies shall be bedded and surrounded with Grade C20 concrete to the thickness described in the Contract Documentation.

6

Frames shall be bedded in mortar on two courses of Class B engineering brickwork or precast concrete gully cover slabs. Precast concrete gully cover slabs shall comply with the relevant provisions of BS 5911: Part 2 and Section.

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Section 20: Drainage Works for Buildings Part 06: Surface Water Drainage

Page 8

Drainage Channels

1

Precast concrete drainage channels shall comply with the relevant provisions of BS 5911: Part 2 and Section 5 - Concrete.

2

Drainage channel gratings and frames shall comply with the relevant provisions of BS EN 124.

6.5

SOAKAWAYS

6.5.1

General Requirements

1

Soakaways shall not be constructed closer than 10 m from a building or in a position where the ground below foundations is likely to be adversely affected.

2

Excavation round the soakaway shall be backfilled with a band of 40mm nominal single size stone to provide a permeable surround to the soakaway. The permeable surround shall be fully wrapped in a geotextile fabric. The dimensions of the band shall be as shown on the Project Drawings.

6.6

MANHOLES AND CATCH PITS

6.6.1

General Requirements

1

Bases and walls to manholes and catch pits shall be cast in situ using Grade C30 concrete.

2

Cover slabs to manholes shall be precast using Grade C40 concrete and shall incorporate an integral GRP liner with a minimum thickness of 3.5 mm. The vertical sides of the

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6.4.3

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openings of cover slabs shall be formed of filament would GRP pipe and soffits shall be formed of GRP sheet. The Contractor shall provide the Engineer with a seven year unconditional guarantee against failure of all GRP linings whether caused by defective materials or workmanship. The guarantee shall be valid from the date of completion of the installation and must be handed over to the Engineer before the issue of the Final Completion Certificate.

4

Unless otherwise stated in the Project Specification or shown on the Project Drawings, manhole inverts and benching shall be formed in Grade C20 concrete. Where there is no change of diameter, the invert of the benching shall follow the same gradient as the outgoing pipe.

5

Where a high strength concrete topping (granolithic finish) is required, the invert and benching shall be formed in Grade C20 concrete, and the topping shall be applied as soon as practicable thereafter.

6

All concrete works, including benching, shall comply with the relevant provisions of Section 5 - Concrete.

7

Step irons shall comply with the relevant provisions of BS 1247:Parts 1, 2 and 3.

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Page 9

Covers and frames shall comply with the relevant provisions of BS 497:Part 1 and have a minimum clear opening of 600 mm diameter if circular or 600 x 750 mm if rectangular. All covers shall have closed keyways.

9

The Contractor shall prepare a standard record sheet for every manhole and catch pit to the approval of the Engineer.

10

Testing of manholes and catch pit chambers shall be as detailed in Part 6 of this Section.

6.7

CONNECTION TO GOVERNMENT MAIN

6.7.1

General Requirements

1

Connection to government mains shall be done at manholes. Pipe saddles and oblique junctions will not be permitted.

2

Where possible and practicable, connections shall be made to future connection ports in existing Government manholes. The caps on future connection ports to which connections are made shall be cleaned and delivered to the government stores on completion of the work.

3

Where it is not possible or practicable to utilise future connection ports in existing manholes, connections shall be made by either breaking into existing manholes or constructing new manholes on existing mains.

4

If it is necessary to break into an existing manhole, the Contractor shall break into the manhole wall, insert pipework, break out the existing benching, construct benching to suit new connection and make good. If necessary, the Contractor shall relocate the access ladder and the cover slab to suit the new benching layout.

5

Manholes built on an existing Government mains shall be constructed in accordance with Clause 6 of this Part. On completion, such manholes shall become the property of the government.

6

The Contractor shall be responsible for all over-pumping operations associated with making connections to Government mains:

7

When a connection is made to an existing manhole in an area with high groundwater levels, the Contractor shall undertake the following if instructed to by the Engineer.

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(a)

undertake a CCTV survey and deflection test between the manhole immediately upstream and the manhole immediately downstream of the manhole to which the connection is to be made before commencing dewatering operations.

(b)

construct two mass concrete stanks round the base of the manhole to prevent groundwater from flowing into the excavation. The stanks shall be positioned each side of the proposed connection and shall extend across the full width of the excavation. The stanks shall be in place before any dewatering takes place.

(c)

undertake a CCTV survey and deflection test between the manhole immediately upstream and the manhole downstream of the manhole to which the connection has been made when work is complete and groundwater levels have returned to their natural levels.

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Section 20: Drainage Works for Buildings Part 06: Surface Water Drainage

Page 10

(d)

the Contractor shall submit all CCTV survey data and deflection test data to the Engineer. Such data shall be used to determine whether any damage has been caused to the existing main by the Contractor while carrying out his work.

(e)

the Contractor shall be responsible for rectifying any damage caused as a result of his work.

(f)

the Contractor shall submit his proposals for carrying out remedial works to the Engineer for approval prior to starting such work, should it be necessary.

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END OF PART

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QCS 2014

Section 20: Drainage Works for Buildings Part 07: Commissioning of Systems

Page 1

7

COMMISSIONING OF SYSTEMS ................................................................. 2

7.1

GENERAL ...................................................................................................... 2

7.1.1 7.1.2 7.1.3 7.1.4

Scope System Description Submittals Connection to Existing Mains

7.2

CLEANSING OF PIPES, MANHOLES AND CHAMBERS ............................. 2

7.2.1

General

7.3

TESTING ....................................................................................................... 3

7.3.1

General

7.4

TESTING AND INSPECTION EXTERNAL DRAINAGE PIPELINES ............. 3

7.4.1 7.4.2 7.4.3 7.4.4 7.4.5 7.4.6

General Inspection Water Test Air Test CCTV Inspection Infiltration

7.5

TESTING AND INSPECTION INTERNAL DRAINAGE PIPELINES .............. 5

7.5.1 7.5.2 7.5.3

Air Test Leak Location Water test

7.6

TESTING OF SANITARY APPLIANCES ....................................................... 6

7.6.1 7.6.2 7.6.3

General Self-Siphonage and Induced Siphonage in Branch Discharge Pipes Induced Siphonage and Back Pressure in Discharge Stacks

7.7

TESTING OF DRAINAGE STRUCTURES .................................................... 7

7.7.1

Manholes and Chambers

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Section 20: Drainage Works for Buildings Part 07: Commissioning of Systems

Page 2

COMMISSIONING OF SYSTEMS

7.1

GENERAL

7.1.1

Scope

1

This Part specifies the requirements for the testing and cleaning of drainage installations.

2

Related Sections and parts are as follows:

Section 1

General

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General Internal Drainage Works External Drainage Works Trenches for Drainage Pipework Surface Water drainage

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This Section Part 1 Part 2 Part 3 Part 4 Part 6

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System Description

1

Inspections and tests should be made during the installation of the discharge system as the work proceeds, to ensure that the pipework is properly secured and clear of obstructing debris and superfluous matter and that all work which is to be concealed is free from defects before it is finally enclosed.

2

Prefabricated units should be tested at the works or place of fabrication, and inspected on delivery at the Site.

7.1.3

Submittals

1

The Contractor shall prepare a detailed testing and inspection programme and submit it to the Engineer for approval. This programme shall identify each item to be tested, the type of test to be performed and the date and time of the test.

2

The Contractor shall prepare test and inspection record sheets for all tests and inspections undertaken. The format of the test record sheets shall be to the approval of the Engineer. On successful completion of a test/inspection, the test record sheet shall be signed and stamped by all the Contractor and the Engineer. The Engineer shall retain the original test record sheet.

7.1.4

Connection to Existing Mains

1

Connection to existing mains shall not take place until all tests and inspections have been successfully completed and the system has been cleaned.

7.2

CLEANSING OF PIPES, MANHOLES AND CHAMBERS

7.2.1

General

1

On completion, the discharge system should be meticulously inspected to ensure that the requirements of the Contract Documentation have been observed.

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7.1.2

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Section 20: Drainage Works for Buildings Part 07: Commissioning of Systems

Page 3

The Contractor shall ensure that no cement droppings, rubble or other objects are left in or on the pipes and that no jointing material projects into the pipe bore.

3

Manholes and chambers shall be thoroughly cleansed to remove all deleterious matter, without such matter being passed forward to existing mains.

4

Sanitary appliances shall be thoroughly cleansed. Any chromium plated or other metallic surfaces forming part sanitary appliances that exposed to view shall be polished.

5

All parts of the Works included in this Section shall be maintained in a clean and serviceable condition by the Contractor until completion of the Contract.

7.3

TESTING

7.3.1

General

1

The Contractor shall notify the Engineer at least two clear working days prior to his intention to test a section of pipeline.

2

Items failing any test shall be corrected immediately and re-tested before further work proceeds.

3

Unless otherwise stated in the Project Documentation, the Contractor is responsible for providing materials and apparatus required for testing purposes and for their removal and proper disposal on completion at testing.

7.4

TESTING AND INSPECTION EXTERNAL DRAINAGE PIPELINES

7.4.1

General

1

Unless otherwise agreed by the Engineer, both interim and final test shall be undertaken on each section of the Works. The Contractor shall note that the satisfactory completion of an interim test does not constitute a final test.

2

Non-pressure pipelines laid in trenches shall be tested after they are jointed and before any concreting or backfilling is commenced, other than such as may be necessary for structural stability whilst under test.

3

The pipelines shall be tested by means of an air or water test or by a visual or closed circuit television (CCTV) examination, in lengths determined by the course of construction.

4

A further test shall be carried out after the backfilling is complete.

7.4.2

Inspection

1

Visual inspection shall be carried out before backfilling in order to detect faults in construction or material not shown up under test but which could lead to premature failure. A careful record shall be kept of such inspections.

2

On external pipelines, the following shall be visually inspected:

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(a)

pipe bed

(b)

pipe line and level

QCS 2014

Section 20: Drainage Works for Buildings Part 07: Commissioning of Systems

(c)

joints

(d)

pipe protective coating

(e)

any pipeline appurtenance.

Page 4

Trenches shall be inspected to ensure that the excavation is to the correct depth to guard against mechanical damage due to traffic loading.

4

No part of the pipe trench shall be backfilled until the above are performed to the satisfaction of the Engineer.

7.4.3

Water Test

1

The test pressure for external drainage pipelines up to and including 750 mm nominal bore shall be not less than 1.2m head of water above the pipe soffit or groundwater level, whichever is the higher at the highest point, and not greater than 6m head at the lowest point of the section. Steeply graded pipelines shall be tested in stages in cases where the maximum head, as stated above, would be exceeded if the whole section where tested in one length.

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The pipeline shall be filled with water and a minimum period of 2 hours shall be allowed for absorption after which water shall be added from a measuring vessel at intervals of 5 minutes and the quantity required to maintain the original water level noted. Unless otherwise specified, the length of pipeline shall be accepted if the quantity of water added over a 30 minute period is less than 0.5 litre per linear metre per metre of nominal bore. This relationship in equation format, with water added measured in litres, can be written as follows:

L = pipe diameter (m) D = Length of test section (m)

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Where:

ov

Maximum volume of water added over a 30 minute period = 0.5 x L x D

Air Test

1

Non-pressure pipelines to be air tested shall have air pumped in by suitable means until a pressure of 100 mm head of water is indicated in a U-tube connected to the system. The pipeline shall be accepted if the air pressure remains above 75 mm head of water after a period of 5 minutes without further pumping following a period for stabilisation. Failure to pass the test shall not preclude acceptance of the pipeline if a successful water test, ordered by the Engineer, can subsequently be carried out in accordance with Clause 7.3.3.

7.4.5

CCTV Inspection

1

Where internal inspection of pipelines by CCTV is required, the Contractor shall provide all necessary equipment, including suitable covered accommodation for viewing the monitor screen, together with personnel experienced in the operation of the equipment and interpretation of results.

2

The intensity of illumination within the pipe and the rate of draw of the camera shall be such as to allow a proper examination of the inside of the pipe. Provision shall be made for the movement of the camera to be stopped and its position recorded and for permanent photographs to be taken at any point requested by the Engineer.

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Section 20: Drainage Works for Buildings Part 07: Commissioning of Systems

Page 5

7.4.6

Infiltration

1

External drainage pipelines shall be tested for infiltration after backfilling. All inlets to the system shall be effectively closed, and any residual flow shall be deemed to be infiltration.

2

The pipeline shall be accepted as satisfactory if the infiltration, including infiltration into manholes, in 30 minutes does not exceed 0.5 litre per linear metre per metre of nominal bore. This relationship in equation format, with water infiltration measured in litres, can be written as follows: Maximum volume of infiltration over a 30 minute period = 0.5 x L x D L = pipe diameter (m) D = Length of test section (m)

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Where:

Notwithstanding the satisfactory completion of the above test, if there is any discernible flow of water entering the pipeline at a point which can be located either by visual or CCTV inspection, the Contractor shall take such measures as are necessary to stop such infiltration.

7.5

TESTING AND INSPECTION INTERNAL DRAINAGE PIPELINES

7.5.1

Air Test

1

The water seals of all sanitary appliances should be fully charged and test plugs or bags inserted into the open ends of the pipework to be tested.

2

To ensure that there is a satisfactory air seal at the base of the stack, or at the lowest plug or bag in the stack if only a section of the pipework is to be tested, a small quantity of water sufficient to cover the plug or bag can be allowed to enter the system.

3

One of the remaining test plugs should be fitted with a tee piece, with a cock on each branch, one branch being connected by means of a flexible tube to a manometer. Alternatively, a flexible tube from a tee piece fitted with cocks on its other tow branches can be passed through the water seal of a sanitary appliance. Any water trapped in this tube should be removed and then a manometer can be connected to one of the branches as described above.

4

Air shall be pumped into the system through the other branch of the tee piece until a pressure equal to 38 mm water gauge is obtained. The air inlet cock is then closed and pressure in the system should remain constant for a period of not less than 3 min.

7.5.2

Leak Location

1

The use of smoke to detect leaks shall only be permitted if approved in writing by the Engineer. A smoke producing machine may be used which will introduce smoke under pressure into the defective pipework. Leakage may be observed as the smoke escapes. Smoke cartridges containing special chemicals should be used with caution, taking care that the ignited cartridge is not in direct contact with the pipework and that the products of combustion do not have a harmful effect upon the materials used for the drainage system. Smoke testing of plastics pipework or systems with rubber jointing components is not permitted.

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Section 20: Drainage Works for Buildings Part 07: Commissioning of Systems

Page 6

With the pipework subjected to an internal pressure using the smoke machine or air test method, a soap solution can be applied to the pipes and joints. Leakage can be detected by the formation of bubbles.

7.5.3

Water test

1

There is not justification for a water test to be applied to the whole of the plumbing system. The part of the system mainly at risk is that below the lowest sanitary appliance and this may be tested by inserting a test plug in the lower end of the pipe and filling the pipe with water up to the flood level of the lowest sanitary appliance, provided that the static head does not exceed 6 m.

7.6

TESTING OF SANITARY APPLIANCES

7.6.1

General

1

To ensure that adequate water seals are retained during peak working conditions the tests described below should be carried out. After each test a minimum of 25 mm of water seal should be retained in every trap.

2

Each test should be repeated at least three times, the trap or traps being recharged before each test. The maximum loss of seal in any one test, measured by a dip stick or small diameter transparent tube, should be taken as the significant result.

7.6.2

Self-Siphonage and Induced Siphonage in Branch Discharge Pipes

1

To test for the effect of self-siphonage the appliance should be filled to overflowing level and discharged by removing the plug; WC pans should be flushed. The seal remaining in the trap should be measured when the discharge has finished.

2

Ranges of appliances, connected to a common discharge pipe, should also be tested for induced siphonage in a similar way. The number of appliances which should be discharged together is given in Table 6.1. The seal remaining in all the traps should be measured at the end of the discharge. Only those appliances included in Table 6.1 shall be tested under simultaneous discharge conditions.

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Table 6.1 Number of Sanitary Appliances to be Discharged for Performance Testing

Number of appliances of each kind on the stack

Number of appliances to be discharged simultaneously WC

Wash Basin

1 to 9

1

1

10 to 18

1

2

19 to 26

2

2

27 to 52

2

3

53 to 78

3

4

79 to 100

3

5

QCS 2014

Section 20: Drainage Works for Buildings Part 07: Commissioning of Systems

Page 7

Induced Siphonage and Back Pressure in Discharge Stacks

1

A selection of appliances connected to the stack should be discharged simultaneously and the trap and seal losses due to positive or negative pressures in the stack should be noted. These selected appliances should normally be close to the top of the stack and on adjacent floors, as this gives the worst pressure conditions. Table 6.1 shows the number of appliances which should be discharged simultaneously. Only those appliances included in Table 6.1 shall be tested under simultaneous discharge conditions.

7.7

TESTING OF DRAINAGE STRUCTURES

7.7.1

Manholes and Chambers

1

Manholes and chambers shall be tested for infiltration after backfilling. Where appropriate, they shall be inspected for water tightness before placing cover slabs.

2

Manholes and chambers shall be substantially water tight, with no identifiable flow of water penetrating the structure. Manholes and chambers which are not substantially water tight shall be corrected immediately.

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END OF PART

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QCS 2014

Section 21: Electrical Works Part 01: General Provisions for Electrical Installation

Page 1

GENERAL PROVISIONS FOR ELECTRICAL INSTALLATION .................... 2

1.1

GENERAL ...................................................................................................... 2

1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.13 1.1.14 1.1.15 1.1.16 1.1.17 1.1.18 1.1.19 1.1.20 1.1.21 1.1.22 1.1.23 1.1.24 1.1.25 1.1.26 1.1.27

Scope Regulations Existing Services Contract Drawings Shop Drawings Progress Drawings As built drawings Builders Work Programme Equipment and Materials Approval Fire and Safety Precautions Protection Quality of Staff/Personnel Climatic Conditions Samples Quality of Materials Equipment Duties and Ratings Workmanship Labels/Circuit Lists/Cable Identification Segregation of Services Electricity Supply Polarity Safety Interlocks Spare Parts Protection of Excavation Supply of materials Special Requirements

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2 2 3 3 4 5 5 6 6 6 7 8 8 9 9 9 10 10 11 12 13 14 14 14 16 16 16

QCS 2014

Section 21: Electrical Works Part 01: General Provisions for Electrical Installation

Page 2

1

GENERAL PROVISIONS FOR ELECTRICAL INSTALLATION

1.1

GENERAL

1.1.1

Scope

1

The Electrical Installation Contractor, herein referred to as the 'Contractor' within this part and all other Section 21 parts of this specifications shall carry out all electrical works complete in accordance with the requirements of the Project Documentation.

2

The scope of work shall include but not be limited to: (The supply and installation of all services, equipment, components, accessories and fittings required for the operation of the facility to the extent specified and detailed on the Drawings and Specifications including 400 days maintenance or as stipulated in the contract specification and all extended warranties after provisional handover

(b)

Builder's work in connection with the Electrical Installations, including supply, necessary inserts sleeves and making good.

(c)

Any work which can be reasonably inferred as necessary for the safe, satisfactory operation of each system, whether such work is specified or shown on drawings or not

(d)

The supply and installation of cables, conduits, boxes and termination points, for the motors, starters, controls and the like for the Process Equipment, Heating, Ventilation and Air-conditioning and Plumbing services

(e)

(Arranging for installation of permanent Electrical supply by the Qatar General Electricity and Water Corporation (QGEWC), including submission of all necessary documents to the QGEWC, and carrying all necessary approvals and obtaining consumption meters Moreover, the Contractor shall allow in his tender and be responsible for the payment of all charges by way of examination, certification, depositing or connection fee to any Statutory Authority. (I.e. Electricity, Water, Drainage, Telephone, Fire, etc).

(f)

Supply and installation of permanent electrical supply equipment and cables in compliance with QGEWC requirements and approvals. The electrical equipment is required for the implementation of the of the new facilities as well for the supply of new loads,. The supply includes EHV cables, HV/MV substations, HV and MV cables and accessories, consumption meters, and all related civil works, and including submission of all necessary documents to QGEWC, and carrying all necessary approvals Coordinating with QGEWC regarding outage schedule, attending upon the Supply Authority installing mains power supply and carrying out primary and secondary injection tests and any other tests as directed by QGEWC.

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(a)

(h)

Arranging and carrying out all necessary approvals with Telecom Provider for the Telephone System

(i)

Arranging and carrying out all necessary approvals with the Qatar Civil Defence Department for the Fire Alarm System, extinguishing and protection systems.

1.1.2

Regulations

1

All supplies and services offered in response to this specification shall conform to the latest standards.

2

The design, equipment and installation requirements shall comply with the standards and recommendations laid down by the following : (a)

Regulations for Electrical Installations as issued by the Qatar General Electricity and Water Corporation (QGEWC) Qatar

QCS 2014

Section 21: Electrical Works Part 01: General Provisions for Electrical Installation

Page 3

(b)

Regulations for Electrical Installations as issued by the Institution of Electrical Engineers (I.E.E.), London (for points not included in QGEWC Regulations)

(c)

Recommendations for Lighting Installations as issued by QGEWC and the Chartered Institute of Building Services, London

(d)

Standards relating to Electrical Installations and equipment as issued by International Electrotechnical Commission (I.E.C.) and British Standards Institute (BSI)

(e)

Regulations for telephone system installation as issued by Q-TEL

(f)

National Electrical Code issued by National Fire Protection Association (NFPA), Boston, U.S.A

(g)

Rules of the Qatar Civil Defence Department for Fire Alarm Installations.

Where two or more applicable standards and/or the Specifications are in conflict, the most stringent shall apply.

1.1.3

Existing Services

1

The Contractor is deemed to have visited and inspected the site to familiarise himself with the existing site conditions and services at tender stage.

2

The Contractor shall obtain the existing services record drawings from QGEWC and various utility services departments (i.e. Q-TEL, CDD etc).

3

Co-ordination between shop drawings, work on site and existing services shall be carried out by the Contractor.

4

The Contractor shall be fully responsible for any damages to the existing services including repairs, and penalties imposed by the concerned parties etc and for removing any site obstacles such as underground cables, pipes, civil works etc. which is obstructing his work on site.

5

The Contractor shall also be responsible for liaison with QGEWC, Q-TEL and all other government utility departments to disconnect or divert the existing services supply to the existing site prior to demolishing.

1.1.4

Contract Drawings

1

The indication and/or description in any of the Contracts documents, unless otherwise specifically stated, implies an instruction to supply and fix such items.

2

Notes on Drawings referring to individual items of work take precedence over the Specification.

3

Drawings show the general run of cables, raceways, etc. and the approximate location of equipment and utilities; symbols and schematic diagrams are of no dimensional significance. Obtain from the Engineer dimensions not shown on, or which cannot be determined from Drawings. Do not scale drawings to obtain locations.

4

Notify the Engineer of conflicting requirements. Where departures from the drawings are deemed necessary, details of such departure and reasons thereupon shall be submitted to the Engineer for approval.

5

No such departure shall be made without prior written approval of the Engineer.

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QCS 2014

Section 21: Electrical Works Part 01: General Provisions for Electrical Installation

Page 4

The design specifications and criteria shall not relieve the Contractor from continuously following up with the respective authorities to obtain up-to-date requirements and instructions.

1.1.5

Shop Drawings

1

The term 'shop drawings' includes fabrication, erection, layout and setting out drawings; manufacturer's standard drawings, schedules; descriptive literature, illustrations, catalogues and brochures; performance and test data; wiring and control diagrams and other drawings and descriptive data pertaining to materials, equipment, raceway systems, control systems and methods of construction as required to show that materials, equipment and systems and position thereof, conform to the Contract Documents. The term 'manufactured' applies to standard units usually mass produced. The term 'fabricated' means items specifically assembled or made out of selected materials to meet individual design requirements.

2

Shop drawings shall establish actual detail of all manufactured or fabricated items, indicate proper relation to adjoining work, amplify design details of electrical equipment in proper relation to physical spaces in the structure, and incorporate minor changes of design or construction to suit actual conditions.

3

The Contractor shall submit for approval, and obtain in due time to conform to the Contract Program, all shop and installation drawings based on the design drawings approved by the QGEWC and all other relevant Municipality and Government Authorities.

4

The Contractor, immediately after being awarded the said Contract, shall prepare and submit shop drawings. Shop drawings shall be submitted with such promptness as to cause no delay in his own work nor to any other Contractor. No extensions of time will be granted because of failure to have shop drawings submitted in ample time to allow for processing, in accordance with the submittals schedule outlined in Section 9, Part 1, Clause 1.1.4.

5

Provide shop drawings, to a scale not smaller than the corresponding layout drawings, showing the following and obtain approval before commencing work:

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exact runs and sizes of conduits, ducts, cables, cable trays and trunking

(b)

layout drawings for each separate electrical installation showing the actual locations of points, suitably identified, the locations of switchgears, switchboards, motor control centres and distribution boards, details and types of fittings plans showing the equipment assembly, space requirements, clearances and locations for cable entrances and anchor bolts

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(d)

elevations showing all parts, devices, components and nameplates, positions and arrangements of the equipment. Show as many elevations as necessary to clearly depict component and device arrangements

(e)

schedules of points, indicating how the various outlets are connected to the distribution boards, size of circuit wiring, the rating of the protective device and the type and size of appliance of fitting

(f)

schematic diagram of connections of distribution boards, and equipment to main switchboards showing sizes of feeders, etc

(g)

schematic and elementary wiring diagrams, of each unit of each equipment, showing numbered terminal points, numbered wires and numbered interconnections to other equipment and remote devices

(h)

connection wiring diagrams, of each unit of each equipment, showing numbered terminal points, numbered wires and numbered interconnections to other equipment and remote devices

(i)

complete catalogue information of all parts and components of electrical equipment

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(j)

all cable routings and layouts for the different electrical services, feeders and branch circuits showing routes, sizes and types of cables

(k)

any other data necessary for the proper maintenance of the installations.

Drawings shall be ISO standard size A1. Lettering shall be stencilled. Shop drawings and samples shall be properly identified with the name of the Project, the Contractor, the SubContractor and the date, and signed by Contractors Authorised Engineers.

7

Final co-ordination of electrical works with mechanical, structural and architectural work shall be carried out from complete shop drawings and sufficient time shall be allowed for coordination and checking of shop drawings and calculations after shop drawings are submitted.

8

Individual shop drawings shall be submitted following the distribution of the co-ordination drawings and shall bear a stamp indicating that the work has been co-ordinated with other trades.

9

The Engineer's review and approval of shop drawings submitted by and approved by the Contractor is for general conformance with the design concept and information given in the Contract Documents and shall not relieve the Contractor from responsibility for any deviations from the requirements of the Contract Documents. The Engineer's review and approval shall not be construed as a complete check nor shall it relieve the Contractor from responsibility for error of any sort in shop drawings or schedules, or from the necessity of furnishing any work required by the Contract Documents which may have been omitted on the shop drawings. The Engineer's review and approval of a component item shall not indicate review and approval of the complete assembly in which it functions.

10

The Engineer or the supervising consultant shall forward electrical drawings and specifications which are to be submitted for approval to QGEWC, when appropriate. However, it shall be the Contractors responsibility to obtain written approval from QGEWC for all such drawings and specifications appertaining to the work carried out under the contract. QGEWC approvals may take a considerable time to obtain and the Contractor should make allowance for this and be available for liaising with and pursuing approvals with QGEWC.

1.1.6

Progress Drawings

1

Provide and keep on the job at all times, one complete and separate set of blackline prints of the electrical work on which shall be clearly, neatly and accurately noted, promptly as the work progresses, all architectural and electrical changes, revisions and additions to the work. Whatever work is installed otherwise than as shown on the Contract Drawings, such changes shall be noted.

2

Indicate daily progress on these prints by colouring in the various conduit, ducts, trunking, cable trays, fixtures, apparatus and associated installation works erected.

1.1.7

As built drawings

1

The Contractor shall provide the as built drawings, as approved by the Engineer, in DXF format or AutoCAD DWG format, either in floppy diskettes or in CD-ROM, as per the Project Documentation requirement. The drawings shall be submitted not later than 2 months after completion of the Project, or putting into operation, whichever is earlier. An addition, 3 sets of hard copy of all relevant drawings, which will be required for operation and maintenance, shall be supplied in bound book forms immediately after the commissioning of the Project. The quality of these drawings shall be consistent with the standard of QGEWC. Diary sheets for Work completed shall not be authorised until such records have been presented to the Engineer and accepted.

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The Contractor shall supply, 3 sets of all operation and maintenance manuals in original, from the manufacturer in bound book forms, at least 2 weeks prior to commissioning of the equipment. These shall also be supplied, in computer diskettes, based on popular Microsoft window based publishing software programmes, along with the as built drawings as mentioned above, as specified in the Project Documentation or as directed by the Engineer.

1.1.8

Builders Work

1

Lay electrical works in advance of pouring concrete slabs and construction of walls. Obtain Engineer's approval before commencing builder's work in connection with electrical installation. Related co-ordinated shop-drawings shall be submitted for approval as per the related clause 1.1.5 of this section. Materials approval shall be obtained as per procedure detailed in clause 1.1.9 below. The Contractor shall make it certain that drawings properly coordinated with other works are submitted immediately after signing of the contract and approval of drawings and the materials are obtained at least one month prior to the commencement date of the construction.

2

Check with other trades to ensure equipment and material can be installed in space provided.

3

Provide other trades with information necessary for them to execute their work.

4

Details on drawings which are specific regarding dimensions and locations, are for information purposes. Co-ordinate with other trades to ensure work can be installed as indicated.

1.1.9

Programme

1

The Contractor shall produce a work programme based on CPM or Bar-chart form or as directed by the Engineer indicating the time required for various operations to complete the Project in time. The following points shall be highlighted in the programme:

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mobilisation

(b)

drawings/submittals

(c)

approvals

(d)

equipment deliveries including delivery periods from supply sources external to the State of Qatar

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cabling

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(g)

main/sub-main distribution equipment

(h)

second fix

(i)

fixing of light fittings

(j)

testing

(k)

commissioning and handing over.

2

The Contractor is responsible for all liaison with QGEWC in respect of programming the installation and commissioning of complete electrical system. The Contractor shall ensure that QGEWC are at all times kept informed of the current progress of the electrical works on site and that his approved electricity supply subcontractor programs the cable laying works in the specified sequence in accordance with the approved programme.

1.1.10

Equipment and Materials Approval

1

Approval of materials and equipment shall be based on latest manufacturer's published data.

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Complete and detailed information of all materials and equipment to be incorporated in the work shall be submitted. Submit detailed description and specifications, catalogues cuts, installation data, diagrams, dimensions, controls and any other data required to demonstrate compliance with the Contract Documents. Each item submitted shall be referenced to the applicable paragraph in the Specification.

3

At the request of the Engineer, submit a sample of any equipment or material for further study before approval. Where samples are required by the Engineer, the period required to obtain the sample will be taken into account when scheduling approvals.

4

Only approved materials shall be employed at the site. All materials installed which are not approved shall be removed and reinstated by approved ones.

5

Time periods for equipment and materials approvals shall be as outlined in Section 9, Part 1, Clause 1.1.4.

1.1.11

Fire and Safety Precautions

1

Establish from Architectural Drawings where fire and smoke barriers exist, and make adequate provision of fire and smoke barriers in and around trunking, conduits, cables, etc., where they pass through floors and fire rated walls, and where protection systems are installed pack space between wiring and sleeve full with Fire Retardant Material and seal with caulking.

2

The Contractor shall ensure that this work is carried out such that the integrity of any such fire barrier is properly maintained where pierced by electrical services.

3

For each switchboard the Contractor shall supply the following equipment:

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1 no. electrical grade rubber mat to BS 921 1000 mm wide extending the full length of the switchboard

(b)

1 no. pair of electrical grade rubber gloves to BS 697. The hand glove should have the date of test stamped on it.

(c)

1 no. notice in English and Arabic advising treatment for a person suffering from electrical shock.

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The Contractor shall put the notice for electrical shock treatment in details with sketches and instructions as per standard procedures. The notice shall comply with the requirement of the QGEWC in content and format. However, this should include the following as a minimum,

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(a)

(b)

ACT IMMEDIATELY (i)

Safeguard Yourself

(ii)

Switch off current or break electric circuit

(iii)

Use or stand on some dry non-conducting material to remove the CASUALTY from cable or source of electricity.

(iv)

Start artificial respiration and call for Medical Aid

TREATMENT FOR ELECTRIC SHOCK ARTIFICIAL RESPIRATION (KISS OF LIFE, MOUTH TO MOUTH METHOD) (i)

Lay the casualty on back and if possible on a table

(ii)

Kneel or stand near to the casualty‟s head

(iii)

Remove any obstruction from the mouth

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(iv)

Support the nape of the neck and press top of the head so that it is tilted backwards

(v)

Open your mouth and take a deep breath, pinch the casualty‟s nostrils with your fingers. Seal your lips round his mouth and blow into his lungs until the chest rises.

(vi)

Remove your mouth and watch the chest falls

(vii)

Repeat and continue inflation at your natural rate of breathing. Continue to give artificial respiration until natural breathing is restored or until the medical aid arrives

(viii)

When the casualty is breathing, place in recovery position, lying and resting on the side. Remain with and watch casualty closely.

Protection

1

The Contractor shall be responsible for his work and equipment until finally inspected, tested, accepted and handed over. Materials and equipment which are not immediately installed after delivery to site shall be stored carefully. Close open ends of work with temporary covers or plugs during construction to prevent entry of obstructing material.

2

Protect work and material of other trades from damage that might be caused by his work or workmen and make good damage thus caused.

3

Protect exposed live equipment during construction for personnel safety.

4

Shield and mark live parts "LIVE 240 VOLTS" or with appropriate voltage in English and Arabic.

5

Arrange for installation of temporary doors for room containing electrical distribution equipment. Keep these doors locked except when under direct supervision of an electrician.

1.1.13

Quality of Staff/Personnel

1

The electrical services installation shall be carried out in a professional manner by experienced and qualified personnel.

2

Electrical Contractor shall be to the classifications required by QGEWC and shall carry a valid licence.

3

Prior to the commencement of works the Contractor shall notify the Engineer of his intended site staffing levels.

4

The Contractor shall appoint one graduate Electrical Engineer full time with 5 years experience in similar works and qualified staff/personnel for the supervision of the Electrical Installation Works.

5

The name, qualifications and experience of the nominated engineers shall be submitted to the Engineer for approval within 15 days of the receipt of the order to commence the works.

6

An Electrical Foreman of 10 years experience in similar projects should be full time available on site for direct follow up and implementation of the electrical works.

7

Qualified and Experienced Electricians shall be available on site to carry out the works in accordance with the programme.

8

The Engineer reserves the right to require the Contractor to provide information and documentation as may be necessary to establish the validity of any individual persons proficiency and effect their removal from site should they prove to be unsatisfactory.

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1.1.12

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1.1.14

Climatic Conditions

1

The climate in Qatar in the summer months is hot and humid and a humidity of 100 % at 30 °C has been recorded. (a)

violent sand and dust storms of several hours duration occur and even on comparatively still days, fine dust is carried in suspension in the atmosphere.

(b)

all apparatus and equipment shall, therefore, be so designed and constructed that they operate satisfactorily and without any deleterious effect for prolonged and continuous periods in the conditions stated above and at the following ambient temperature conditions: maximum sun radiation temperature in summer

-

84 °C

(ii)

maximum ambient temperature in summer

-

52 °C

(iii)

average max. ambient temperature in summer

-

(iv)

minimum ambient temperature in winter

(v)

the altitude of Qatar may be taken as sea level.

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0 °C

The temperatures quoted above make no allowance for heat generated from equipment itself or from any other equipment in the vicinity

3

The capacity and ratings of all electrical equipment and materials given are, unless otherwise indicated, for Qatar climatic conditions. Provide the basis of the derating factors applied in each case

4

Where specific sizes are indicated e.g. cable sizes, due allowances have been made in the design for the climatic conditions of Qatar and derating has been applied

5

Where no ratings or sizes are indicated for components and other accessories, supply equipment which will give trouble free service in the ambient conditions stated above.

1.1.15

Samples

1

The term „samples‟ includes natural materials, fabricated items, equipment, devices, appliances, or parts thereof as specified and other samples as may be required to determine whether kind, quality, construction, workmanship, finish, colour and other characteristics of materials conform to requirements of the Contract Documents.

2

Samples shall establish kind, quality and other required characteristics of various parts of the work. Indicate details of construction, dimensions, capacities, weights and electrical performance characteristic of equipment or material.

3

Samples and sample board should be prepared and identified by the manufacturer and stamped/engraved with make, type, Cat No. and size marking should be indelible and legible.

1.1.16

Quality of Materials

1

Manufacturers shall provide their standard guarantees for products furnished under this Contract. However, such guarantees shall be in addition to and not in lieu of all other liabilities which manufacturers and the Contractor may have by law or by other provisions of the Contract Documents.

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All materials, items of equipment and workmanship furnished under this Contract shall carry standard warranty against all defects in materials and workmanship. Any faults due to defective or improper material, equipment, workmanship or Contractor's design which develop shall be made good, forthwith, by and at the expense of the Contractor, including all other damage done to areas, materials and other systems resulting from this failure.

3

Guarantee that all elements of the systems are of sufficient capacity to meet the specified performance requirements as set forth herein or as indicated.

4

Upon receipt of notice from the Engineer, of failure of any part of system or equipment during the period of maintenance, the affected parts shall be replaced.

1.1.17

Equipment Duties and Ratings

1

Power ratings shown for the proposed equipment are in accordance with the best information available to the Engineer and are to be considered as minimum ratings. In the event equipment items proposed by the Contractor should require motors with different power rating than shown, it shall be the Contractor‟s responsibility to furnish circuit breaker, starting equipment, feeder and branch circuits, conduits, and accessories etc. as required to comply with the electrical code and prevent excessive voltage drop without added cost to the Client.

2

Where equipment to be furnished is installed in an existing enclosure or adjacent to existing equipment, the Contractor shall field check the dimensions of existing equipment, location of conduits, etc., and shall familiarise himself with all existing conditions and difficulties to be encountered in performing such work.

3

Degree of protection for all electrical equipment shall be as follows:

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IP 54, for indoor equipment IP 55, for outdoor equipment IP 68, for submersible equipment

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All external equipment to be of metallic construction.

5

The equipment shall be located generally as indicated on the drawings and the Contractor shall ensure that the equipment is suitably constructed to permit installation as shown. The equipment shall where necessary be constructed in modular form to permit access into the buildings and facilitate ease of erection at site.

6

The equipment arrangements and single line diagram are for guidance only and show a practical arrangement that would be acceptable. The Contractor may propose an alternative arrangement which meets the requirements of the specification.

7

All equipment performing similar duties shall be of a single type and make and be fully interchangeable in order to limit the stock of spare parts required. This is to apply particularly to such items as motors, switchgear, instruments, controls, relays, etc.

1.1.18

Workmanship

1

The entire work provided in this specification shall be constructed and finished in every respect in a workmanlike and substantial manner. The Contractor shall provide the system in accordance with the best trade practice and to the satisfaction of the Engineer.

2

Keep others fully informed as to the shape, size and position of all openings required for apparatus and give full information sufficiently in advance of the work so that all openings may be built in advance. Provide and install all sleeves, supports, etc., hereinafter specified or required.

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Obtain detailed information from the manufacturers of apparatus as to the proper method of installing and connecting same. Obtain all information from others which may be necessary to facilitate work and the completion of the whole Project.

4

Provide the services of an experienced foreman, who shall be continuously in charge of the erection of the electrical work, together with all necessary skilled workmen, helpers and labourers, required to properly unload, transfer, erect and connect up, adjust, start, operate and test the system.

5

Before installing any work, verify that it does not interfere with clearance required for other work. Notice of adverse conditions shall be forwarded in writing to the Engineer before any work in question is installed. If notification is not made, and work installed causes interference with the contemplated design, make such changes in his work as directed by the Engineer to permit the installation of all work of the Project, at no additional cost to the Client.

6

Raceways shall be run as straight and direct as possible in general forming right angles with or parallel with walls or piping and neatly spaced, with risers erected plumb and true, maintain a clearance of at least 25 mm between finished coverings and adjoining work. Approved ceiling height shall be obtained from Architectural Drawings.

7

All equipment and accessories shall operate without objectionable noise or vibration. Should operation of any of the equipment or systems produce noise or vibration which is, in the opinion of the Engineer objectionable, make change in equipment and do all work necessary to eliminate the objectionable noise or vibration at no additional cost to the Client.

8

Wherever possible services shall not cross expansion joints. Where this is unavoidable the services shall accommodate the design movement without damage, by use of approved expansion couplings/flexible conduit arrangement.

9

All MV, HV and EHV works shall be carried out by a contractor or sub-contractor pre-qualified and approved by QGEWC. Proof of such approval shall be required in writing prior to the works commencing on site and the name of any sub–contractor to be used shall be entered in the relevant form of tender when the tender is submitted. All cable jointers to be used on the Contract shall be required to undertake and pass a trade test conducted by QGEWC at the Contractor‟s expense.

1.1.19

Labels/Circuit Lists/Cable Identification

1

For substations, switchgears, switchboards, motor control centres and panel boards:

2

engraved lamacoid name plates, black with minimum 10 mm high white lettering.

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For Distribution Boards and Circuit Breakers: (a)

where individually enclosed or in substations, switchgears, switchboards, motor control centres and panel boards without doors : engraved lamacoid nameplates, black with minimum 8 mm high white lettering.

(b) 3

in panel boards with doors : directories mounted inside transparent plastic covers in metal frames.

Wiring Identification: (a)

identify wiring with permanent indelible, identifying markings, either numbered or coloured, heat shrinkable tube or ferrules, on both ends of phase conductors of feeders and branch circuit wiring.

(b)

maintain phase sequence and colour coding throughout

(c)

colour code to standards above as specified elsewhere

(d)

use colour coded wires in communication cables, matched throughout system.

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Conduit and Cable Identification: (a)

colour code conduits and metallic sheathed cables

(b)

code with plastic sleeve or paint end points where conduit or cable enters wall, ceiling or floor and also at 15 m intervals along its length.

(c)

colours to be 25 mm wide prime colour and 20 mm wide auxiliary colour to standards above

(d)

number code, per Circuit Schedule, all feeder and branch circuit cables at both connection points and in manholes, handholes, pull-boxes and junction boxes with fibre or non-ferrous metal tags, fastened with non-ferrous wire.

Device Plates: for Device Plates of local toggle switches, toggle switch type motor starters, pilot lights and the like, whose junction is not readily apparent : plates to be engraved with 3 mm high letters describing equipment controlled or indicated.

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phase identification letters shall be stamped into the metal of the busbars of each phase of the main buses in each substation, switchgear, switchboards, motor control centre and panel board in addition to colour identification

(b)

Letters shall be visible without disassembling current carrying supporting elements.

(c)

busbars shall be sleeved for phase identification by using high temperature grade heat shrinkable coloured PVC sleeving throughout its length. In no circumstances will any kind of wrapping tape be accepted on busbars.

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For Busbars:

For Doors:

where switchboard rooms, cable chambers, metal screened spaces and the like contain electric power cables, bus bars or equipment operating at voltages exceeding 600 V : enamelled sheet metal, red on white, reading "Danger - High Voltage".

For Rooms:

Languages:

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to switchboard rooms, electric closets, metal screened spaces assigned to electrical equipment, and the like : enamelled sheet metal, red on white, reading "Electrical Equipment Room - No Storage Permitted".

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(a)

nameplates with directional, operational or warning labels shall be in Arabic and English.

1.1.20

Segregation of Services

1

Electrical services shall be segregated as specified throughout the installation to obviate the following; (a)

electrical interference from one circuit to another

(b)

a fault on one circuit affecting another

(c)

unnecessary fire damage

(d)

difficulties in circuit identification

(e)

voltage limits for general safety

(f)

difficulties in removal and/or maintenance.

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2

All raceways shall be kept clear of other services except where intentionally earthed or bonded. Generally, raceways shall be kept 150 mm away from and above hot water and 75 mm away from other services.

3

Unless specifically indicated otherwise, normal, emergency, low voltage cables and wiring shall be segregated throughout the installation generally in the following manner:

(b)

insulated conductors: Insulated conductor circuits shall, where possible, be segregated throughout by enclosing in separate conduits, trunking or trunking compartments.

.

armoured and sheathed cables: Where more than one tray has been specified or is necessary to accommodate the number of cables on a run, where practical, segregation shall be achieved by dedicating each tray to either normal or emergency services. Where normal and emergency cables have to run together in trays, ducts or trenches, they shall be formed in two groups, one normal and one emergency

(a)

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Fire Alarms:

fire alarm cables shall be segregated from other services throughout and be either armoured and sheathed cable, or insulated conductors enclosed in conduit or trunking, as indicated on the drawings.

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(a)

Electricity Supply

1

The Supply Authority will make available, at the incoming terminals of each Main Switchboard (Medium Voltage Panel) a 3 phase + Neutral, 4 wire, 415 V, 50 Hz supply of adequate capacity and having the following tolerances:

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1.1.21

voltage

415 6 %

(b)

frequency seconds)

50Hz± 0.1 Hz (short term ± 0.15 Hz for a duration of only a few

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(a)

Phase rotation of supply to BS 158.

3

Neutral: Solidly earthed at transformer location

4

Earthing system: TNS

5

Obtain fault level and fault duration time from the Supply Authority (QGEWC).

6

Obtain confirmation from the Supply Authority of the size and number of cables they will provide to Main Switchboards. Allow for adequate and appropriate cable glands, lugs and boxes.

7

After inspection and approval of the Contractor‟s installation, QGEWC will permit energisation of the feeder cables to the installation.

8

QGEWC will only inspect the Contractor's installation and permit energisation of the power supply after receiving a written request to do so from the Contractor.

9

The Contractor will be responsible for any delay caused by omission to make the request in good time.

10

The Contractor shall provide a generator of adequate capacity to carry out all precommissioning tests. Per-commissioning tests may be carried out using mains electricity if this is available.

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1.1.22

Polarity

1

The polarity of all apparatus used for the Works specified shall be arranged as follows when apparatus is viewed from the front: (a)

for two pole apparatus the phase or “live” pole at the top (or left hand side) and the '“neutral or earthed” pole at the bottom (or right hand side). On plug and socket outlets the polarity shall conform to BS 196, BS 546, or BS 1363 as appropriate

(b)

for three or four pole apparatus the phases in order red, yellow, blue and neutral reading from top to bottom or left to right in the case of vertical and horizontal layouts respectively.

All cables shall be so connected between main switchboards, distribution boards, plant and accessories so that the correct sequence of phase colours is preserved throughout the system.

3

All cable cores shall be identified with phase colours. Where more than one phase is incorporated on a common system in one room then the live cores shall be red, yellow, blue, as appropriate, and fittings and switch accessories shall be permanently labelled and segregated in accordance with I.E.E. Regulations.

1.1.23

Safety Interlocks

1

A complete system of interlocks and safety devices shall be provided as necessary for the safe and continuous operation of the plant in order to provide for the following:

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safety of personnel engaged on operation and maintenance of the plant

(b)

correct sequence of operation of the plant during start up and shut down

(c)

safety of the plant when operating under normal or emergency conditions.

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Interlocks shall be preventive and not corrective

3

The Contractor shall be responsible for the preparation of interlocking schemes for the approval of the Engineer.

4

Locks for interlocking purposes shall be of the figure lock type.

5

No spare or master key shall be provided, unless specified.

6

Device items are to be arranged to ensure that there is no danger of interchange with existing locks on other units.

1.1.24

Spare Parts

1

General:

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(a)

provide sufficient spare parts for all the electrical items included within the scope of works. Submit to the Engineer a list of all spare parts to be required for a further two years operation from the date of issue of the Maintenance Certificate

(b)

spare parts required include but not necessarily limited to those listed below, provided specified in the Project Documentation or where quantities for each item or equipment is recommended by the manufacturer

(c)

spare parts to be delivered to central stores.

Main Low Tension Boards: (a)

2 % spare moulded case circuit breakers of all different frame sizes, but in any case not less than 2 nos. circuit breaker of each size

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Section 21: Electrical Works Part 01: General Provisions for Electrical Installation

(b)

5 % spare indicating lamps for each indicating lamp in the switchgear

(c)

one set of tools required for switchgear maintenance

(d)

provide complete spare parts as recommended by the manufacturer for different sizes of ACB.

5 % spare combination magnetic motor starters

(b)

5 % spare circuit breakers for each rating of each MCCB

(c)

5 % spare HRC fuses for each rating

(d)

5 % spare of load break switch (isolators) of each size

(e)

5 % spare of current operated ELCB of each size

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5 % spare switch of each size.

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Circuit Accessories:

plug fuses - furnish ten percent (10%) of the number of each size and type of fuses installed, but in any case not less than six fuses of each sizes

(b)

wall switches - provide five percent (5%) of the number of each size and type of wall switch installed

(c)

socket outlets - provide five percent (5%) of the number of each size and type installed

(d)

lamps - provide five percent (5%) lamps of each size and type for indicating panels and pilot lights installed for different systems.

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Disconnecting Switches: (a)

.

(a)

Lighting Fixtures: (a)

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Switchboards, Motor Control Centres and Distribution Boards:

for lighting fixtures provide the following spare parts: 2 % of the total quantity of each type of lighting fixture. This quantity shall not be less than one fixture of each type

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(i)

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3

Page 15

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(ii)

7

(iii)

10 % spare lamps of each wattage of different type

(iv)

5 % of the total quantity of control gear (ballast) of each type and size but in no case less than (6) ballast of each size and type.

Emergency Generating Sets: (a)

8

additional diffusers for 5 % of the total quantity of each type of lighting fixture provided with acrylic, plastic or glass enclosures. Diffusers shall be identical to those of the installed fixtures. This quantity shall not be less than two diffusers of each type

complete itemised list of different spares to be included and priced by the tenderers. For emergency generator, furnish by the generator supplier to maintain it for two years.

The tenderer shall submit with his offer detail prices of the spare parts he is required to provide under the Contract indicating the quantity and the unit rate of each item.

QCS 2014

Section 21: Electrical Works Part 01: General Provisions for Electrical Installation

Page 16

Protection of Excavation

1

The Contractor shall comply with all requirements of the Police Department for marking, lighting and protecting excavations. It is the responsibility of the Contractor to ascertain the requirements of Police Department and to comply fully with these requirements. No additional payments will be authorised under any circumstances for marking, lighting or protecting excavations.

2

Where carriageway works and road crossings are performed the Contractor shall provide steel plates of sufficient size and quality to permit the safe passage of traffic and the plate shall be so placed (if necessary fixed) to permit reasonable traffic flow.

3

All doorways, gates and entrances shall be kept clear with full access. Where excavations impede pedestrian access, crossings boards shall be provided. Crossing boards shall be 1250mm wide with a hand rail on both sides 1 metre high and guard rails on both sides at vehicular access to premises etc. Ducts will not be installed at entrances to premises unless instructed by the Engineer.

4

Materials excavated shall be placed so as to prevent nuisance or damage. Where this is not possible, the material shall be removed from site and returned for backfilling on completion of cable laying at the Contractor‟s expense. In cases where the excavated material is not to be used for backfilling trenches it must be removed from site on the same day as it is excavated. Surplus material shall only be disposed of at Government approved sites. At the time of Contract award the Contractor shall contact the Ministry of Municipal Affairs and Agriculture to ascertain the approved sites and route.

1.1.26

Supply of materials

1

Where materials are to be supplied by the Contractor, the following shall apply:

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1.1.25

Materials shall be ordered in accordance with the Specifications issued by QGEWC.

(b)

Specifications and details of the proposed supplier shall be submitted to QGEWC before a firm order being placed.

(c)

On delivery of materials from outside of Qatar, QGEWC inspectors shall be given the opportunity to inspect the materials prior to their use.

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(a)

Special Requirements

1

The Contractor shall consult the public utility authorities not less than one month before it is proposed to commence work to ascertain whether any underground installations will be affected by the proposed work, in which event the Contractor shall make all necessary arrangements with the public utility authorities to safeguard the installation.

2

The Contractor shall give at least one week‟s notice in writing to the public utility authorities of the dates upon which it is intended to operate plant or equipment or carry out any work for which permission has been given in writing by the public utility authorities: such operations of work shall only be carried out in the presence of the public utility authorities unless notice has been obtained in writing from the public utility authorities that they do not require to be present.

3

The public utility authorities may require work to be executed on their installation during the period of the Contract: the Contractor shall afford all facilities to the public utility authorities‟ contractors or workmen until their diversion work is complete. The Contractor shall co ordinate the work of the public utility authorities and his own activities and when necessary shall amend his programme of working to suit all requirements of the department in connection with their diversion work and shall keep the Engineer informed of all arrangements made.

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1.1.27

QCS 2014

Page 17

The Contractor shall locate and mark with suitable posts all the public utility authorities underground installations that are within the area of the Works and shall ensure that such markers are maintained in their correct positions at all times; the Contractor shall advise the public utility authorities of any installation not found where shown on the Drawings, or found but not shown or found damaged or subsequently damaged.

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END OF PART

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Section 21: Electrical Works Part 01: General Provisions for Electrical Installation

QCS 2014

Section 21: Electrical Works Part 10: Wiring Accessories and General Power

Page 1

10

WIRING ACCESSORIES AND GENERAL POWER ..................................... 2

10.1

GENERAL ...................................................................................................... 2

10.1.1 10.1.2 10.1.3 10.1.4

General Reference References Description of Work Submittals

10.2

PRODUCTS ................................................................................................... 3

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10.2.1 General 10.2.2 Outlet Boxes 10.2.3 Switches 10.2.4 Ceiling Roses 10.2.5 Socket Outlets 10.2.6 Shaver Socket Outlets 10.2.7 Cooker Control Units 10.2.8 Disconnect Switches and Switch Fuses 10.2.9 Fused Connection Units 10.2.10 Junction, Pull and Terminal Boxes 10.2.11 Timer 10.2.12 Time clocks

.

2 2 2 2 3 3 3 4 4 5 6 6 6 7 7 7

INSTALLATION ............................................................................................. 8

10.3.1 10.3.2 10.3.3 10.3.4 10.3.5

Mounting Heights Installation of Outlet Boxes Installation of Switches Installation of Junction, Pull and Terminal Boxes Testing

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8 8 8 8 8

QCS 2014

Section 21: Electrical Works Part 10: Wiring Accessories and General Power

Page 2

WIRING ACCESSORIES AND GENERAL POWER

10.1

GENERAL

10.1.1

General Reference

1

The work of this Section is integral with the whole of the Project Documentation and is not intended to be interpreted outside that context.

2

Co-ordinate the work with all other services affecting the work of this Section.

3

Related Parts and Sections are as follows:

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General Provisions for Electrical Installation Cables and Small wiring Conduits and Conduits Boxes Trunking

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This Section Part 1 Part 6 Part 7 Part 8

.

10

References

1

The following standards are referred to in this Part:

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10.1.2

BS 88..........................HRC Fuses

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BS 546........................Specification Two pole and earthing-pin plugs, socket-outlets and socket-outlet adapters

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BS 800........................Specification for radio interference limits and measurements for household appliances, portable tools and other electrical equipment causing similar types of interference

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BS 1363......................13A Plugs, Switched and Un-switched Socket Outlets and connection units

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BS 3456......................Specifications for safety of household and similar electrical appliances

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BS 3676......................Part 1 Switches for household and similar fixed electrical installations BS 4177......................Cooker Control Units rated 30 Amp. and 45 Amp. 250 volts single phase supply

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BS 4343......................Industrial Plugs, Socket Outlets and Couplers BS 4662......................Boxes for enclosure of electrical Accessories BS 5419......................Fuse Switches and Switch Fuses BS 5733......................General requirements for electrical accessories BS 6972......................General requirements for luminaire supporting couplers 10.1.3

Description of Work

1

This Section shall include all labour, materials, equipment, appliances and accessories necessary for the complete performance of all switches, socket outlets etc. In accordance with the Specifications and Drawings.

10.1.4

Submittals

1

Submit shop drawings, equipment list, relevant samples etc. as mentioned under Section Part 1.

QCS 2014

Section 21: Electrical Works Part 10: Wiring Accessories and General Power

Page 3

10.2

PRODUCTS

10.2.1

General

1

All individual items of materials shall be of the same make throughout the Project unless specifically approved by the Engineer.

2

Unless otherwise indicated in the sections to follow, the faceplate of all devices shall be polycarbonate.

10.2.2

Outlet Boxes

1

Outlet Boxes: galvanized one piece pressed steel, sizes and designs shall suit devices to be fitted with a minimum wall thickness of 1.0 mm.

(B)

In all hazardous areas specified and/or shown on drawings: explosion proof.

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(a)

Outlet boxes mounted externally or in damp locations shall be totally sealed to ensure water tightness.

10.2.3

Switches

1

Lighting Switches

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(b)

to be rated 10, 15 or 20 amps depending on connected load, as stipulated in the QGEWC regulations

(c)

recessed with concealed conduit, surface pattern elsewhere

(d)

quick make and break type

(e)

single pole, double pole, one way, two way or intermediate as indicated

(f)

surface mounted switches to be either poly-carbonate, or metallic and as indicated in the Project Documentation

(g)

flush mounted switches to be of the grid fixing type with finish as noted in the Project document.

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switches shall be certified for AC-23A duty

Waterproof Switches: (a)

to be watertight IP 56 or as indicated in the Project Documentation

(b)

to be made of poly-carbonate for indoor application in damp and wet areas.

(c)

to be metallic suitable for AC-23A duty and have sunshades fitted where exposed to direct sunlight.

(d)

to be provided with rear entry for outdoor use to avoid the exposure of conduit/cables to the harmful effects of the sun.

Switch Plates (a)

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to BS 3676

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(a)

(h) 2

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2

where two or more switches are grouped together and connected to the same phase, multi-gang devices and common plates shall be used.

Double Pole Switches: (a)

the double pole switches shall be with neon indication lamps and shall be rated 20, 30 or 45 Amps. as indicated on the drawings

QCS 2014

(b)

the face plate shall be of matt chrome, unless specified otherwise in the Project Documentation and shall be engraved „WATER HEATER‟, „WATER COOLER‟ etc. as required.

(c)

switches shall be certified for AC-23A duty.

Push switches for lighting contactor control: push to make momentary contact switch

(b)

suitable for inductive load

(c)

surface mounted type shall be either poly-carbonate, metallic, protected to IP 56 or as indicated in the Project Documentation

(d)

where two or more switches occur in one position they shall be contained in one case and each shall be appropriately labelled to indicate its function

(e)

switches shall be certified for AC-23A duty and contactors shall be certified for AC-3 duty.

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Dimming Switches:

where indicated on the Project Drawings, dimming switches shall be provided, complying with BS1155

(b)

dimming switches shall be interference suppressed to conform with BS588

(c)

all dimmer units shall be sized to give a 40% margin above the connected load.

(d)

switches shall be certified for AC-23A duty

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(a)

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Section 21: Electrical Works Part 10: Wiring Accessories and General Power

Ceiling Roses

1

Ceiling roses shall be of the all insulated type conforming to BS76 with a white finish.

2

Ceiling roses shall be provided with insulated terminals for the switched live, neutral and protective conductors; loop-in facilities shall be provided.

3

Plug-in ceiling roses shall be used in large buildings, with extensive false ceiling systems, as detailed in the particular specification.

10.2.5

Socket Outlets

1

General purpose Socket Outlets:

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10.2.4

2

3

(a)

to BS 1363

(b)

3 rectangular pin (2P+E) shuttered, with combined switch, rated 13A, 250 V

(c)

to be supplied with plug complete with fuse

15A Socket Outlet: (a)

to BS 546

(b)

3 round pin (2 P + E) shuttered switched pattern complete with plugs.

(c)

Neon indicator lamp, unless specified otherwise in the Project Documentation.

Weather proof Sockets: (a)

13A Sockets: to BS 1363

(b)

3 rectangular pins, Un-switched type to be complete with weather proof plugs

(c)

plugs: 13 Amps

QCS 2014

Section 21: Electrical Works Part 10: Wiring Accessories and General Power

(d)

sockets: fused type with single pole cartridge fuse link of same rating as plug

(e)

sockets and plugs:

Page 5

(i)

to have minimum IP 55 grade protection

(ii)

housing parts: brass or pressure die-cast finished in grey hammered stove enamel

(iii)

plugs:

 

(f)

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Industrial Sockets:

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to be a combined unit comprising two sockets, rated 16A, 240V, 1 phase and 32A, 415V, 3 phase

(ii)

to be equipped with 16A SP and 32A TP MCBs, or as indicted in the Project Documentation

(iii)

three phase socket to be 5 pin type, single phase socket to be 3 pin type

(iv)

plugs of the same manufacturer to be provided

(v)

sockets and plugs to conform to BS 4343

(vi)

to have minimum IP 55 ingress protection.

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(i)

plugs and sockets for hazardous area:

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(b)

Combined Socket

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(a)

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socket outlet face plates shall be finished as indicated in the Project Documentation.

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(a)

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Socket Outlet Plates:

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cable grips shall have rubber compression rings there shall be rubber gasket between plug and socket to ensure weather tightness. sockets shall have screw on caps that close tight on socket when plugs are not inserted.

to be suitable for zone 0, zone 1 or zone 2 applications, as relevant, and indicated on the Project Drawings and/or Project Documentation

(ii)

to conform to IEC 309-3

(iii)

to be corrosion resistant

(iv)

ingress protection to IP 66.

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(i)

10.2.6

Shaver Socket Outlets

1

All shaver socket outlet units shall comply with BS 3456 and IEC 335.

2

Shaver units shall be flush pattern with white moulded insert in matt chrome plate engraved „Shaver Only‟ and be suitable for installation in bathrooms, incorporating a double wound isolating transformer to provide an earth free supply.

3

Units shall incorporate primary winding circuit protection in the form of a self-resetting thermal overload device.

4

Units shall incorporate an „ON/OFF‟ switch with red neon indicator together with a selector switch for 20 VA load capacity at 240 Volts and 115 Volts

QCS 2014

Section 21: Electrical Works Part 10: Wiring Accessories and General Power

Page 6

Units shall incorporate two pin shuttered outlet configuration and have terminals to accept 2.5 2 mm conductors.

6

Unit outlet boxes shall be a minimum of 45 mm deep, rustproof by galvanising of equal finish and complete with a brass earthing stud secured to the back of the box.

10.2.7

Cooker Control Units

1

Cooker control units shall incorporate a 32 Amp. double pole switch and 13A, 3 pin switched socket outlet and neon indicator lights for both cooker and socket

2

The cooker control unit shall be flush mounted.

10.2.8

Disconnect Switches and Switch Fuses

1

Generally

4

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(b)

switch shall have “ON/OFF” indication and provision for locking in “OFF” position

(c)

utilisation category AC 23A

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to be metal clad with front operated handles interlocked with switch fuse case to prevent opening switch in the “ON” position

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Fuse switch and switch fuses to BS 5419

(b)

fuses: to BS 88 bolted type, class Q1, certified for 415V and AC 80 Duty, rated as indicated

(c)

fused switch carriages: withdrawable type

(d)

fuse switches: ASTA certified to 50 KA.

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Disconnect switches

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(a)

(a)

same design as switch-fuses, with solid copper links in place of fuses

(b)

single pole and neutral, or triple pole and neutral

(c)

ratings, as indicated.

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Outdoor Equipment

equipment intended for outdoor use shall be certified by the manufacturer as being weatherproof and suitable for use outside in the prevailing conditions and shall be in compliance with the requirements of Part 28, clause 28.2.6 of this Section.

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(a)

10.2.9

Fused Connection Units

1

240 V fused connection units shall be switched, shall comply with BS1655 and shall be fitted with a fuse complying with BS5571 with a rating as specified.

2

All fused connection unit shall be fitted with a neon indicator.

3

Live contacts shall not be exposed under normal operating conditions when replacing a fuse.

4

240 V fuse connection units in plant areas, workshops etc., shall be surface mounted, metalclad and shall comply with BS5575 .

5

The type of fused connection unit, particularly relating to the flex outlet, shall be authorised by the Engineer prior to the ordering of accessories.

QCS 2014

Section 21: Electrical Works Part 10: Wiring Accessories and General Power

Page 7

10.2.10 Junction, Pull and Terminal Boxes 1

The Junction Box shall be completed with a terminal block suitable for connecting up to 10 2 mm copper conductor (phase, neutral and earth) and an all insulated moulded white cover plate with removal covers.

2

The cover plate shall be raised for connecting outgoing cable.

10.2.11 Timer Timers shall be electronic type, unless specified otherwise in the Project Documentation.

2

Timers shall be suitable for operation from supply voltage of 240V, 1-phase, 50Hz system.

3

Timer output contacts shall be suitable for both a.c. and d.c. control circuits. The contacts shall be suitable for duty of AC-2 or DC-3 utilisation category. The rating of output contacts shall be co-ordinated with the application requirements.

4

Timers shall be provided with 2 independent timing scales with sets of change-over output contacts:

(b)

0.10 ................ 20 seconds

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10 ................... 200 seconds

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(a)

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1

ON/OFF indicator shall be provided to monitor the circuit status.

6

Timers shall be either:

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delay on energisation or

(b)

delay on de-energisation type, as per the application requirements

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(a)

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Upon supply of rated voltage to the input terminals, the timer shall start, the output relay remains in rest position. After the set time, the output relay pulls in. The relay resets after the input supply has been cut-off. Timers shall be suitable for minimum 10 million operations.

8

The timer shall require a pozi-drive screw driver for changing of the settings.

9

Degree of protection shall be minimum IP 20.

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10.2.12 Time clocks 1

Time clocks to control circuits depended on time and hours of the day, may be either (a)

Synchronous motor operated, or

(b)

Quartz controlled motor operated, as per Project Documentation.

2

Time clocks shall be suitable for operation from supply voltage of 240V, 1-phase, 50Hz system.

3

Output contacts shall be suitable for both AC and DC control circuits. The contacts shall be suitable for duty of AC-2 or DC-3 utilisation category. The rating of output contacts shall be co-ordinated with the application requirements.

4

The no. of output contacts and the duration of contact closing shall be decided as per the application requirements.

QCS 2014

Section 21: Electrical Works Part 10: Wiring Accessories and General Power

Page 8

Time clocks shall be provided with a time dial setting for 24 hours and 7 days program.

6

Each time clock shall be provided with a minimum running reserve energy for 1 day.

7

Accuracy of clocks shall be better than 1 second per day.

10.3

INSTALLATION

10.3.1

Mounting Heights

1

The mounting heights of wiring accessories shall be as stipulated in the QGEWC Regulations, or as otherwise approved by the Engineer.

10.3.2

Installation of Outlet Boxes

1

Location of Boxes:

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determine exact location of boxes on site and obtain the Engineer‟s approval before commencing installation

(b)

make allowance for overhead pipes, ducts, variations in arrangement, thickness of finish, window trim, panelling and other construction when locating boxes.

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(a)

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Fixing: (a)

fix outlet boxes securely

(b)

fix exposed outlet boxes to permanent inserts or lead anchors with machine screws.

Installation of Switches

1

Lighting Switches:

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10.3.3

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located at the strike side of the door, approximately 150 mm from the edge of door frame

(b)

plates shall be installed with all four edges in continuous contact with finished wall

(c)

plates shall be installed with an alignment tolerance of 1.5 mm

(d)

all switch assembly louvered plates shall have their earthing terminal connected to 2 the earth terminal attached to the switch box by an insulated 2.5 mm protective conductor.

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(a)

10.3.4

Installation of Junction, Pull and Terminal Boxes

1

Generally:

2

(a)

fix junction, pull and terminal boxes where indicated and where required to facilities pulling of wires and cables and connection of future appliances

(b)

locate boxes as inconspicuously as possible, but accessible after work is completed.

Pull Boxes: (a)

fix at maximum 10m spacing and to limit the number of bends in conduit to not more than two 90° bends.

10.3.5

Testing

1

Test all switches, socket outlets etc. for correct polarity and continuity of conductors in the presence of and to the entire satisfaction of the Engineer.

QCS 2014

Section 21: Electrical Works Part 10: Wiring Accessories and General Power

Page 9

2

Carry out live phase to earth loop impedance tests at all switches and socket outlets with an approved earth loop impedance tester to the entire satisfaction of the Engineer. Ensure that all device plates have satisfactory earth continuity to the protective conductor system.

3

Test all socket outlets for instantaneous tripping of associated distribution board current operated earth leakage circuit breaker using testing equipment, approved by the Engineer.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 11: Light Fittings

Page 1

11

LIGHT FITTINGS ........................................................................................... 2

11.1

GENERAL ...................................................................................................... 2

11.1.1 11.1.2 11.1.3 11.1.4

General Quality Assurance References Submittals

11.2

PRODUCTS ................................................................................................... 3

11.2.1 11.2.2 11.2.3 11.2.4 11.2.5 11.2.6

Lamps Luminaires Termination/Earthing Ceiling System Noise and Interference External Lighting

11.3

INSTALLATION ............................................................................................. 7

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2 2 2 3

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11.3.1 Lighting Installation 11.3.2 Installation of Lamps

3 4 5 6 6 6 7 7

QCS 2014

Section 21: Electrical Works Part 11: Light Fittings

Page 2

11

LIGHT FITTINGS

11.1

GENERAL

11.1.1

General

1

This section includes the supply and installation of lighting fittings as shown on the drawings, and as specified.

11.1.2

Quality Assurance

1

Design Criteria: lighting fittings shall be of first class quality, made by approved manufacturers and shall be suitable for trouble free operation on the system voltage at the site

(b)

lighting fittings shall be complete with internal wiring between lamp holder and termination point. Wiring shall be in silicone rubber insulated heat resistant flexible cables

(c)

the Contractor shall be responsible for co-ordinating the light fitting installation with any other components of the ceiling systems

(d)

all lighting fittings shall be complete with accessories and fixing hardware necessary for installation whether so detailed under fixture description or not

(e)

outdoor lighting fittings shall be installed at mounting heights as specified or instructed on site by the Engineer

(f)

all outdoor lighting fittings shall be suitably constructed and protected to withstand the corrosive atmosphere and high ambient temperatures of the site, whether indicated under the fittings description or not

(g)

lighting fittings shall have power factor not less than 0.9.

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(a)

References

1

The following standards are referred to in this Part:

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11.1.3

BS 800 ........................Limits and methods of measurement of radio interference characteristics of household electrical appliances, portable tools and similar electrical apparatus BS 3677 ......................High pressure mercury vapour lamps BS 4533 ......................Luminaires BS 5225 ......................Photometric data for luminaires BS 60400 ....................Lamp holders for tubular fluorescent lamps and starter holders BS EN 60081 ..............Tubular fluorescent lamps for general lighting service BS EN 60238 ............Edison screw lamp holders BS EN 60529 ............Degrees of protection provided by enclosures BS EN 60662 ...........(IEC 662), High pressure sodium vapour lamps BS EN 60947-1 ........General rules for low voltage switch gear and control gear BS EN 61167 ............Metal halide lamps

Section 21: Electrical Works Part 11: Light Fittings

11.1.4

Submittals

1

Products Data:

full technical details of the fittings, including the control gear, indicating the type and size of materials used in construction

(ii)

relevant sheets of manufacturer’s catalogues and dimensional drawings of the fittings, clearly showing the location of the component

(iii)

wiring diagram of internal connections indicating colour, size and type of wiring

(iv)

confirmation that control gear is suitable for prolonged and continuous service in the ambient conditions described in Part 1

(v)

the power factor under operating conditions and illumination data sheets.

(vi)

type and quality of any plastic materials used in the fittings.

.

(i)

Other lighting fittings, submit:

full technical details of the fittings, with relevant manufacturer’s catalogues and illumination data sheets

(b)

type and quality of all metal finishes

(c)

size and quality of all glassware.

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(a)

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Fluorescent fittings and other electrical discharge lamp fittings, submit:

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(a)

Page 3

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QCS 2014

At least one piece of each of the lighting fixtures originally specified and quoted shall be submitted and displayed at the site office, including the alternative items for comparison in the event an alternate make is offered.

11.2

PRODUCTS

11.2.1

Lamps

1

General:

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lamps shall be furnished and installed in all luminaires covered under the Contract

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2

(b)

lamps used for temporary lighting services shall not be utilised in the final use in fixture units

(c)

lamps for permanent installation shall not be placed in the fixtures until so directed by the Engineer, and this shall be accomplished directly before the building areas are ready for occupancy by the Employer

(d)

lumen output of lamps shall be in accordance with BS EN 5225

(e)

generally, high output, low consumption, tri-phosphorus lamps shall be used, unless otherwise indicated.

Fluorescent Lamps: (a)

(tubular fluorescent lamp, to BS EN 60081. Lengths/diameters as indicated in the Project Documentation

(b)

tube colour: cool white, unless otherwise indicated

(c)

fittings shall comply with BS 800, for suppressing radio frequency interference.

QCS 2014

wattage as indicated in the Project Documentation

(b)

colour: deluxe white

(c)

lumen output of lamps shall be in accordance with BS 3677

(d)

burning position: universal.

High Pressure Sodium Lamps wattage as indicated in the schedule of luminaires

(b)

lamps with a high colour rendering index of 80 shall be used as indicated, suitable for indoor applications

(c)

lumen output of lamps shall be in accordance with BS EN 60662.

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Metal Halide Lamps (a)

wattage as indicated in the schedule of luminaires

(b)

lumen output of lamps shall be in accordance with BS EN 61167

Control Gear For Fluorescent Lamps: (a)

high frequency electronic ballast not less than 25 kHz to IEC 928, unless specified otherwise

(b)

when specified, conventional type low loss ballast with electronic starters shall be used and shall provide flicker free operation, as indicated in the Project Documentation

(c)

glow starters shall not be used

(d)

capacitors shall be supplied with discharge resistors and shall be housed in aluminium canister.

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Lamp Holders: (a)

SBC, BC GES, Bi-pin, etc. as necessitated by the lamp cap Edison screw lamp holders, to BS EN 60238, to be designed so that the lamp cap only makes electrical contact when fully screwed home, and to have means to prevent the unscrewing of the lamp due to vibration or similar cause

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(a)

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High Pressure Mercury Vapour Lamps:

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Section 21: Electrical Works Part 11: Light Fittings

(c)

Lamp holders for fluorescent lamps, shall be the spring loaded rotary type, to BS 6702.

11.2.2

Luminaires

1

Luminaires shall be manufactured to BS 4533 with an appropriate IP classification to BS EN 60529.

2

All lighting fittings shall be supplied complete with appropriate control gear where necessary, lamps, mounting and fixing accessories etc. whether explicitly mentioned in the description of each light fitting or not. All the fittings shall have the same appearance, material, technical details and approximate dimensions.

QCS 2014

Section 21: Electrical Works Part 11: Light Fittings

Page 5

Luminaires shall be connected to the main circuit wiring with heat resistant flexible cables of 2 a minimum conductor size of 1.5 mm insulated with silicon rubber.

4

Break joint rings shall be used in conjunction with batten holders, ceiling roses or back plates mounted onto a flush installation.

5

Standard fluorescent luminaires shall have two suspension or fixing points. The thickness of the luminaries body shall not be less than 0.6 mm.

6

All lamp-holders for flexible pendants shall be of the all insulated skirted pattern with code grips and for batten or wall mounting shall be of similar pattern. All lamp holders shall be of the bayonet cap pattern.

7

The point box suspensions and other parts of the lighting fittings shall be provided to be erected at festival time to suit the building programme for decoration as per the requirements of the Project Documentation.

8

The glassware diffusers, shades and lamps shall not be fitted until all building work is complete.

9

All fittings shall be easy to clean inside and outside, when mounted.

10

All fluorescent fittings shall be suitable for instant start irrespective of any catalogue or list numbers quoted.

11

Diffusers on fluorescent luminaires shall be poly-carbonate unless otherwise specified in the Project Documentation.

12

All fittings that are mounted in areas accessible to the public shall be provided with vandal proof high strength diffusers and shall be additionally provided with a galvanised steel mesh security guard.

13

All luminaires shall be certified by the manufacturer for use in an ambient temperature of 50°C.

14

All luminaires intended for use in hazardous areas shall be certified to be zone 1 or 2 as required at 50°C ambient temperature.

15

Wet well luminaries, fixtures and cabling shall conform to ingress protection IP67,shall be PTFE coated and shall be provided with tungsten halogen lamps i.e. no run up or re-strike time for safety reasons.

16

All wet well luminaries, fixtures and cabling shall conform to ingress protection IP67.

11.2.3

Termination/Earthing

1

Fused terminal blocks shall be fitted and be of sufficient capacity for the wiring involved. 2 Each terminal shall be capable of accommodating two 2.5 mm conductors.

2

Connector strip terminals shall have a current rating not less than the rating of the circuit protective device and shall be encapsulated in self-extinguishing grade polyethylene.

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QCS 2014

Section 21: Electrical Works Part 11: Light Fittings

Page 6

Where connector strips are provided in boxes behind heat producing appliances, porcelain connectors shall be used where temperatures in excess of 70 °C are likely.

4

Conductors shall be clamped between metal surfaces such that no screws make direct contact with the conductor. The metal used in construction of the connector shall be at least 85 °C copper alloy such that good conductivity and electrolytic compatibility are maintained at all times.

5

All light fittings shall be provided with an earthing terminal which shall be connected to the earth continuity lead of the final sub-circuit.

6

The earthing of all pendant or semi-pendant fittings shall be by a separate core in the connecting flex or cable securely bonding the earth terminal on the fitting to the glanded joint of interconnecting cables. In no case shall pendant chains or conduit support tubes be used as a means of earthing.

11.2.4

Ceiling System

1

In false ceilings, luminaires whether surface or recessed mounted shall not be supported by the false ceiling construction. Separate independent supporting systems shall be provided for each luminaire, comprising drop rods, chains or similar.

2

Luminaires installed in false ceilings shall be connected to the lighting circuit using mechanically coupled plug-in ceiling roses.

3

Luminaires shall be positioned to provide ease of access for maintenance, cleaning etc., while not impairing the distribution of light.

4

The Contractor shall ensure that the luminaire manufacturer has the correct details of the ceiling system, including suspension, tiles, etc. He shall ensure that the luminaires are supplied with the correct trim, suspension system and are fully compatible with the ceiling system.

11.2.5

Noise and Interference

1

The noise level from control gear, obtained from the average of sound pressure levels each measured at 2000 mm from the control gear in at least five positions (on each side and below), shall not exceed 30 dB Scale “A” (Noise Rating Number).

11.2.6

External Lighting

1

General:

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3

(a)

external lighting system shall consist of supply and installation of lighting columns, foundation and fixing of the columns, underground cabling, high pressure sodium vapour lamps or as specified, and control equipment as required

(b)

contactor units, where specified incorporating a controlling photo-cell and time switch, shall be provided within the external lighting distribution board for the control of external lighting

(c)

underground lighting cabling shall be XLPE or PVC/SWA/PVC or as detailed in in the Project Documentation.

QCS 2014

Page 7

Lighting Columns (a)

columns shall be hot-dip galvanized steel of either tapered or tubular construction complete with luminaire fixing arms or brackets, as per design.

(b)

all columns shall be externally painted with 2 coats of aluminium paints, internal surface including the studs inside the cable connecting box with red lead anticorrosive paints, the finishing shall be micaceous iron oxide paint pigmented with aluminium

(c)

the column shall be equipped with auxiliary control gear and a 15 amp. single pole and neutral cut-out (with a three phase and neutral terminal block), two cable glands and two entry slots in the base of the pole for incoming and outgoing cables

(d)

a two core and earth 2.5 mm sq. butyl rubber insulated heat resistant flexible cable shall connect the lantern to the cut-out

(e)

columns shall be provided with base plates having fixing holes and anchor bolts for foundations

(f)

unless specified otherwise, the column length shall be 5m including buried part or 4m when plinth mounted. The diameter at the bottom shall not be less than 120 mm.

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Section 21: Electrical Works Part 11: Light Fittings

All external lighting fittings shall be adequately earthed.

4

Control gear shall form an integral part of the lighting fittings except where specified, or where this is not possible, it shall be totally enclosed in a housing to suit the installation location.

5

All external fittings shall be dust-tight and waterproof to IP 65.

6

The particular requirements for road lighting and high mast floodlighting are specified in Section 6, Part 12.

11.3

INSTALLATION

11.3.1

Lighting Installation

1

Terminations:

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(a)

general fluorescent fittings mounted direct to conduit outlet boxes shall have the circuit wiring run direct to the fittings terminal position. Flexible conduit pigtail shall be provided for all fixtures to J-boxes

(b)

terminations for recessed, or semi-recessed pattern fittings fitted in false ceilings, shall have the circuit wiring terminal above the ceiling in a ceiling rose Outlets shall be mounted adjacent to the fitting.

11.3.2

Installation of Lamps

1

Generally install new lamps in all luminaires at substantial completion of work. END OF PART

QCS 2014

Section 21: Electrical Works Part 12: Emergency Lighting

Page 1

12

EMERGENCY LIGHTING .............................................................................. 2

12.1

GENERAL ...................................................................................................... 2

12.1.1 12.1.2 12.1.3 12.1.4

Scope Reference Standards Quality Assurance Warranty

12.2

PRODUCTS ................................................................................................... 3

12.2.1 12.2.2 12.2.3 12.2.4 12.2.5

General Central Battery Units Self Contained Emergency Battery Packs Luminaries and Lamps Obstruction / Beacon lights

12.3

INSTALLATION ............................................................................................. 6

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2 2 2 2

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12.3.1 Wiring 12.3.2 Installation of Batteries 12.3.3 Luminaries and Lamps

3 3 4 5 6 6 6 7

QCS 2014

Section 21: Electrical Works Part 12: Emergency Lighting

Page 2

EMERGENCY LIGHTING

12.1

GENERAL

12.1.1

Scope

1

This Part specifies the general requirements for emergency lighting and accessories both maintained and non-maintained. It shall be read in conjunction with other parts of the Specifications and the Project Drawings.

2

Related Parts and Sections are as follows:

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General Provisions for Electrical Installations Wiring Accessories and General Power Light Fittings Testing

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This Section Part 1 Part 10 Part 11 Part 24

.

12

Reference Standards

1

The following standards and documents of other organisations are referred to in this Part, and shall be complied with:

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BS 4533 .....................General requirements and tests

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BS 4533 ......................Luminaires for emergency lighting

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BS 5225 ......................Method of photometric measurement of battery operated emergency lighting luminaires BS 5266 ......................Emergency lighting

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BS EN 60529 ..............Degrees of protection provided by enclosures (IP code)

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ISO 9000 ....................Quality management and assurance standards QGEWC .....................Qatar General Electricity & Water Corporation Regulations.

12.1.3

Quality Assurance

1

The supplier‟s manufacturing facility shall be certified to ISO 9000 or equivalent.

12.1.4

Warranty

1

Battery units, luminaires and accessories shall be warranted for a minimum of 5 years by the manufacturer. The battery shall have minimum 10 years useful life.

QCS 2014

Section 21: Electrical Works Part 12: Emergency Lighting

Page 3

PRODUCTS

12.2.1

General

1

Emergency lighting installations shall be complete with emergency batteries, chargers, luminaires and wiring, all as described in Specifications and as indicated on the Project Drawings, complying with BS 5266 Part 1.All emergency lighting shall be Non-maintained type except for the EXIT lights where it shall be maintained unless otherwise explicitly specified in the project documentation.

2

Non-maintained luminaires shall be supplied directly from the battery system. Maintained exit luminaires etc., shall be supplied from a separate supply via an independent transformer and shall only operate from batteries during mains failure.

3

The operation of the system shall be such that on loss of one or all phases of the main electricity supply, a set of central batteries or individual battery packs shall provide power for 3 hours to illuminate emergency luminaires throughout the building. On restoration of the

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12.2

1

Battery chargers:

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Central Battery Units

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12.2.2

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mains supply the batteries shall be charged by an integral charger such that the system supplies not less than 85 % of its rated voltage after a period of 12 hours.

battery chargers shall be installed in purpose-made metallic enclosures with an index of protection IP 31 in accordance with BS EN 60529 suitable for wall or floor mounting, depending on size

(b)

battery charger enclosures may house the system batteries providing the design of the enclosure ensures safe operation with the batteries specified. This arrangement should normally be restricted to smaller systems e.g. for circuit breaker tripping supplies for power supply to emergency lighting system, central battery units shall be wall or floor mounted as required, conforming to BS 4533 Section 102.22, and be of robust, high quality construction. Enclosures shall be metal, with hinged lockable doors and with suitable ventilation provided battery charger shall operate from a 415 V, three phase or 240 V, 50 Hz single phase

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(a)

supply, unless otherwise specified

(d)

battery charger shall be rated to supply trickle charge and any standing loading plus any additional recharging load that may be imposed

(e)

battery charger shall use an uncontrolled bridge as the input stage to minimise harmonic generation on the supply system. The characteristics of each charger shall match the requirements of the specific batteries selected and the duty cycle

(f)

battery charger shall be suitable for fully automatic charging of the appropriate battery and shall be provided with: (i)

Mains „ON‟ lamp

(ii)

Main ON/OFF switch

(iii)

Charge Ammeter Discharge Ammeter

(iv)

Battery voltmeter

QCS 2014

Section 21: Electrical Works Part 12: Emergency Lighting

Page 4

(v)

Test switch facilities

(vi)

Contactor/relays to BS 5266 Part 3

(vii)

fault protection

(viii)

output current limitation

(ix)

lamp indication for appropriate faults e.g. charger fail, low volts etc., with lamp colours in accordance with BS EN 60073

(x)

common fault contact for use with a central alarm system or BMS.

units shall be provided with composite output distribution boards of the sizes and types indicated on the Project Drawings

(h)

units shall be installed complete with all necessary fixings, maintenance equipment and instructions.

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Batteries: (a)

batteries shall be suitable for the discharge duty they will be required to perform. Batteries shall be of the lead acid, sealed re-combination type or Nickel Cadmium depending on the duty requirements and as indicated on the Project Drawings. The contractor shall submit calculation to justify the Ampere-Hour capacity of the batteries for approval to the Engineer

(b)

battery system shall be provided with a suitably rated switch disconnector

(c)

Batteries shall be mounted on suitable tiered galvanized steel shelving with moulded plastic trays to contain any leakage from the battery cells and, to allow safe easy access for maintenance

(d)

battery terminals shall be coated with the battery manufacturer‟s approved grease, and shrouded if not enclosed.

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(g)

Self Contained Emergency Battery Packs

1

Where a central emergency battery unit is not installed, individual emergency luminaries shall consist of individual power packs installed within or remote to the luminaries.

2

Battery pack units shall consist of converter/inverter devices, with nickel-cadmium batteries to provide 3 hours operation under mains failure, unless the main supply is restored prior to this.

3

Luminaries with self contained battery packs shall be connected to the „live side‟ of the local lighting circuit and lamps shall operate automatically under mains failure conditions.

4

Units shall have the capability of sustaining high temperature so that they can be accommodated in fittings with high internal temperatures. However, if the internal temperature of the fittings exceeds 50 °C, the battery unit shall be mounted remote to the

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12.2.3

luminaries. In the case of remote mounting, a purpose made remote mounting box shall be provided. 5

Key operated switches shall be provided, at the locations indicated on the Project Drawings, for all self contained emergency pack unit luminaries, to control the operation of the luminaries manually for testing purposes. Test key switches shall be clearly labelled “Emergency Lighting”.

QCS 2014

Section 21: Electrical Works Part 12: Emergency Lighting

Page 5

12.2.4

Luminaries and Lamps

1

Clauses of Part II relating to luminaries and lamps shall also apply to emergency luminaries and lamps.

2

Slave luminaries shall comply with BS 4533 Section 102.22 and BS

Part 3 and be as

specified. 3

Exit sign luminaries lettering shall be both in Arabic and English. The Arabic text shall be above the English text. Maximum viewing distance for minimum legend height shall be guided as follows:

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H > L/200 H = Height of Legend L = Distance of viewer from the sign

Self contained emergency luminaries shall have a red light emitting diode installed on the luminaries so that the red light is visible.

5

With the central battery unit system, emergency luminaries shall be installed with an engraved label fixed to the outer case of the luminaries, so that it is readily identified. The label shall detail the lamp wattage and rated voltage.

6

Generally, marking of emergency luminaries shall comply with BS

7

The following illumination level shall be considered for designing the number of luminaries for emergency lighting: (refer to BS 5266, Part 1)

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4

first aid and safety equipment exit doors fire alarm call points fire fighting equipment exit and safety signs changes of direction corridor intersection adjacent areas of final exit points

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5 lux for vital positions:

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Space to Height Ratio for luminaries shall be 4:1

1 lux for normal working spaces:

on the centreline of escape route toilets lift cars and moving ways plant rooms covered car parks

Part 1.

QCS 2014

8

Section 21: Electrical Works Part 12: Emergency Lighting

Page 6

Fluorescent lamps shall be provided for both slave and self contained type luminaire installations. The lamp wattage ratings shall be chosen from the following table: Slave Self contained

: 4 watts or 8 watts : 8 watts, 18 watts, 36 watts or 58 watts

Total quantity of luminaries shall be calculated based on the illumination level requirement as per item 7 above, the type of luminaries and lamp lumens. Obstruction / Beacon lights

1

This regulation is mandatory by International Civil Aviation Organization (ICAO).

2

Where a building height is 45m or more, then the contractor shall install permanent obstruction lights as required by ICAO.

3

The contractor shall obtain local navigation authorities requirements and approval for this type of installation..

12.3

INSTALLATION

12.3.1

Wiring

1

Where the emergency lighting system installation is via a central battery unit, the wiring to emergency luminaries shall be carried out in MICC, PVC sheathed cables, unless specified otherwise.

2

Where the emergency lighting scheme is self-contained emergency packs, the wiring system shall either be in MICC Cables as above or in PVC insulated single core wires in conduits.

3

Generally, cables shall be 2.5 mm cross-sectional area unless specified otherwise.

4

The Contractor shall pay careful attention to cable routings so as to keep cable runs to the shortest possible length and ensure the overall volt drop on any circuit is within the tolerances of the luminaries connected and within the limits specified in the QGEWC regulations.

12.3.2

Installation of Batteries

1

The manufacturer‟s recommendation/instructions shall always be followed.

2

Insulated tools shall be used.

3

Personnel erecting battery banks shall remove metallic objects from their person i.e. watches, rings etc.

4

Eye and hand protection shall be provided.

5

Batteries shall not be left on site for prolonged periods without being trickle charged to maintain their condition i.e. if delivery is some weeks before commissioning of the charger.

6

Due care shall be observed when handling acidic substances.

2

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12.2.5

QCS 2014

Section 21: Electrical Works Part 12: Emergency Lighting

Page 7

12.3.3

Luminaries and Lamps

1

Luminaries and lamp installation shall comply with the requirements stipulated in Part 11 for general light fittings.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 13: Telephone Installations

Page 1

13

TELEPHONE INSTALLATIONS .................................................................... 2

13.1

GENERAL ...................................................................................................... 2

13.1.1 Scope 13.1.2 Reference Standards 13.2

2 2

PRODUCTS ................................................................................................... 2

13.2.1 General 13.2.2 Telephone Outlets

2 2

INSTALLATION ............................................................................................. 3

13.3.1 13.3.2 13.3.3 13.3.4

Incoming Line/Site Services Conduits and Trunking Telephone Outlets Special Requirements

13.4

RECORD DRAWINGS .................................................................................. 4

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13.3

3 3 3 3

QCS 2014

Section 21: Electrical Works Part 13: Telephone Installations

Page 2

TELEPHONE INSTALLATIONS

13.1

GENERAL

13.1.1

Scope

1

This Part specifies the general requirements for telephone installations carried out as part of a contract for other works. It shall be read in conjunction with the other Parts of the Specifications and the Project Drawings.

2

Related Parts and Sections are as follows:

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General Provisions for Electrical Installations Cables and Small Wiring Conduits and Conduit Boxes Trunking Cable Trays Wiring Accessories and General Power Structured Cabling Systems Testing

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This Section Part 1 Part 6 Part 7 Part 8 Part 9 Part 10 Part 14 Part 23

.

13

Reference Standards

1

The following standards and documents of other organisations are referred to in this Part, and shall be complied with.

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BS 13631....................3A plugs, socket outlets, adapters and connection units

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Telecom Provider .......Regulations

PRODUCTS

13.2.1

General

1

Telephone cabling and equipment supply and installation shall be carried out by an approved Ooredoo contractor specialising in telephone installations.

2

All telephone related installations carried out by the Contractor shall conform to the Ooredoo standard specifications and regulations together with this specification and the Project Drawings.

3

3 The Contractor shall supply and install cable ways, empty conduits with draw wires and/or trunking, telephone points and outlets, PVC ducts, telephone junction boxes, and manholes as required and shown on the Project Drawings unless otherwise Specified.

13.2.2

Telephone Outlets

1

The Contractor shall supply and install telephone points and the associated mains power outlets which shall conform to BS .

2

The telephone outlets shall be jack type and from the same manufacturer, and finish as for the lighting and general power outlets, unless specified otherwise.

3

Telephone outlets shall be of the type approved by Ooredoo.

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13.2

QCS 2014

Section 21: Electrical Works Part 13: Telephone Installations

Page 3

13.3

INSTALLATION

13.3.1

Incoming Line/Site Services

1

The Contractor shall supply and install the incoming line underground through Ooredoo approved PVC-u pipe ducts with draw wires, together with the manholes/draw pits as indicated on the drawings.

2

The works shall be carried out in co-operation with Ooredoo Engineers.

3

Standard Ooredoo type manhole and manhole covers shall be utilised, appropriate to the manhole location.

4

External ducts shall be installed in a 775 mm deep trench, on 75 mm of dune sand, covered

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with 75 mm of dune sand, and completed with selected filling materials. Trenches for Q-Tel ducts through rockfill shall be lined with geotextile filter fabric material as specified in Section 6 Clause 14.9.4.

6

Contractor shall arrange with Ooredoo for inspection of the installation during execution stage and on completion, all costs are deemed to be included in his price.

13.3.2

Conduits and Trunking

1

The Contractor shall if required by the Project Specification or on the Project Drawings, allow for the supply and installation of an empty conduit system complete with draw wires and/or a trunking system between the outlet points and the telephone equipment area.

2

Conduit installations shall be concealed within the building fabric and/or concealed in suspended ceiling voids.

3

Conduit and trunking installations shall conform to the requirements of the Specifications and Ooredoo requirements.

4

Unless otherwise specified, the minimum size of the conduit installed shall be 25 mm

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The Contractor shall be responsible for liaison with the specialist telephone installer and/or Ooredoo engineers to ensure that:

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diameter and telephone underground duct 50 mm diameter as subscriber duct.

(a)

the proposed conduits and trunking are adequate to accommodate cables

(b)

the specialist installer is provided with the programme requirements and that his work is carried out in accordance with the Contractor’s main programme.

13.3.3

Telephone Outlets

1

Outlets shall be installed at locations indicated on the drawings and at the same heights as the general power socket outlets, unless otherwise specified in the Project Documentation.

13.3.4

Special Requirements

1

The Contractor shall consult the Ooredoo not less than one month before it is proposed to commence work to ascertain whether any underground installations will be affected by the proposed works, in which event the Contractor shall make all necessary arrangements with Ooredoo to safeguard the installation.

QCS 2014

Section 21: Electrical Works Part 13: Telephone Installations

Page 4

The Contractor shall give at least one week’s notice in writing to Ooredoo of the dates upon which it is intended to operate plant or equipment or carry out work for which permission has been given in writing by Ooredoo; such operations of work shall only be carried out in the presence of Ooredoo unless notice shall be obtained in writing from Ooredoo that they do not require to be present.

3

Ooredoo may require work to be executed on their installations during the period of the Contract; the Contractor shall afford all facilities to Ooredoo’s contractors or workmen until their diversion work is complete. The Contractor shall co-ordinate the work of Ooredoo and his own activities and when necessary shall amend his programme of work to suit all requirements of Ooredoo in connection with their diversion work and keep the Engineer informed in writing of all arrangements made.

13.4

RECORD DRAWINGS

1

The Contractor shall keep accurate record drawings of the arrangement, positions and details of all works constructed by him. These drawings will be of forms and to scales approved by the Engineer and his designated representative.

2

As soon as each drawing has been completed, two prints shall be submitted to the Engineer and his designated representative for approval.

3

If the Drawings or documents are not approved, one copy shall be returned to the Contractor with marked indications of the alterations required. Upon final approval one copy of the drawing or document shall be stamped "Approved" by the Engineer or his designated representative and returned to the Contractor forthwith.

4

After such approval is given, the Contractor shall supply to the Engineer two prints of the finalised drawings, and the digital files in CAD format on CD, for the use of the Engineer.

5

All record drawings shall be completed within 30 days of the commencement of the Maintenance Period.

6

Record drawings will show accurately the exact locations of all road crossings, ducts, joint boxes, etc., fully dimensioned and triangulated.

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END OF PART

QCS 2014

Section 21: Electrical Works Part 14: Structured Cabling Systems

Page 1

14

STRUCTURED CABLING SYSTEMS ........................................................... 2

14.1

GENERAL ...................................................................................................... 2

14.1.1 Scope 14.1.2 Reference Standards

2 2

PRODUCTS ................................................................................................... 2

14.2.1 14.2.2 14.2.3 14.2.4 14.2.5 14.2.6

General Copper Cables Optical Fibre Cables Patch Panels Patch Cords/Line Cords Outlets

14.3

INSTALLATION ............................................................................................. 5

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14.3.1 Containment Systems 14.3.2 Testing and Commissioning

2 2 3 4 4 5 5 5

QCS 2014

Section 21: Electrical Works Part 14: Structured Cabling Systems

Page 2

STRUCTURED CABLING SYSTEMS

14.1

GENERAL

14.1.1

Scope

1

This Part specifies the general requirements for structural cabling system used in data transmission applications for buildings or sub-systems thereof.

2

Related Parts and Sections are as follows:

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General Provisions for Electrical Installations Cables and Small Wiring Conduits and Conduit Boxes Trunking Cable Trays Uninterruptible Power Supply Systems Testing

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This Section Part 1 Part 6 Part 7 Part 8 Part 9 Part 18 Part 23

.

14

Reference Standards

1

The following standards and documents of other organisations are referred to in this Part, and shall be complied with:

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BS EN 60950.............. Safety of information technology equipment, including electrical business equipment

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EN 50173 ...................Information Technologies: Generic Cabling Systems

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ISO/IEC 11801 ...........Generic Cabling for Customer Premise Cabling EIA/TIA SP-2840

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ANSI/EIA/TIA 455-30,46,51,53,61 ANSI/EIA/TIA 568A

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ANSI/ICEA S-83-569 (Ref. B.1.40) Bellcore TR-TSY-000020

PRODUCTS

14.2.1

General

1

The Contractor shall provide structured cabling installations for telephone and computer networks, including distribution frames, patch panels, racking systems (cabinets), patch cords, outlets, adaptors, conduits, PVC ducts and junction boxes, in accordance with the Project Specification and Drawings.

2

Wiring for cabling systems shall be carried out by a Specialist Contractor approved by the Engineer and Ooredoo, who has 5 years experience in Qatar.

14.2.2

Copper Cables

1

Copper cables shall be 24 AWG, 4 pair 0.170 mm diameter, polymer alloy jacket, category 5, unshielded twisted pair (UTP), suitable for extended multi-media transmission distance over frequency range up to 100 MHz, with extremely low noise characteristics.

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14.2

QCS 2014

Section 21: Electrical Works Part 14: Structured Cabling Systems

Page 3

2

Cables shall conform to ANSI/EIA/TIA 568A, Category 5 and EIA/TIA SP-2840 horizontal UTP.

3

Cables shall conform to the following performance data:

14.2.3

NEXT (dB) worst pair at 100 MHz

:

38 dB

Attenuation (dB/100 m)

:

22.0 dB/100 m

Impedance ±7 % (Typical)

:

100 ohms ±7 %

Optical Fibre Cables There are two types of optical fibre cables, one is multi-mode, graded index optical fibre and another is Single Mode optical fibre.

.

Multi-mode, graded index optical fibre.The multimode graded index optical fibre cables with nominal 62.5/125 µm core/cladding diameter, which are optimized for use in both wave lengths 850 nm and 1310 nm.

(b)

Fibres shall comply with ANSI/EIA/TIA 592-AAAA (Ref. B1.18) and also with ANSI/EIA/TIA 568A Paragraph 12.5.1 on mechanical terminations.

(c)

Outdoor optical fibres shall be used to connect buildings to the main distribution frame.

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(a)

Outdoor optical fibres shall comply with the same specifications, however cables shall also be, jelly filled, rodent proof specifically made for outdoor applications and shall be used for installation in ducts and shall be flexible and resistant to pulling and torsion forces, with 12 strands ,unless otherwise specified in the project specification. Optical fibres shall meet the graded-index multi-mode performance specified in Table 14.1. Table 14.1 Graded-Index 62.5/125 µm Multi-mode Cable Characteristics 850 nm 1300 nm

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Multi-mode, Graded Index Optical Fibre.

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1

3.75

0.4

Bandwidth - MHz. km

160

500

Attenuation shall be measured in accordance with EIA fibre optic test procedure ANSI/EIA/TIA 455-46, 61, or 53 (Ref. B1.39). Information transmission capacity shall be measured in accordance with the ANSI/EIA/TIA 455-51, or 30 (Ref. B1.39).

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Attenuation - dB/km

(c)

3

Mechanical and environment specifications for indoor fibre optical cables shall be in accordance with ANSI/ICEA S-83-569 (Ref. B1.40). Outdoor fibre optic cables shall be in accordance with Bellcore TR-TSY-000020 (Ref. B1.36).

Single Mode Optical Fibre. (a)

The Single mode optical fibre cables which are optimized for use in both wave lengths 1310 nm and 1550 nm.

(b)

The optical fibre cables shall meet the requirements stated in ITU-T Rec. by international telecommunication Union, BS EN 50173-3 standard.

(c)

The fibre utilized in these cables have maximum attenuation at 1310 nm of 0.4 dB/km, at 1550 nm of 0.3 dB/km or less. If used for outdoor, then the fibre cable must be loose-tube non-dielectric type.

QCS 2014

(d)

Section 21: Electrical Works Part 14: Structured Cabling Systems

Page 4

Outdoor optical fibres shall comply with the same specifications, however cables shall also be jelly filled, rodent proof specifically made for outdoor applications and shall be used for installation in ducts and shall be flexible and resistant to pulling and torsion forces, with 12 strands ,unless otherwise specified in the project specification.

The single mode fibre shall be used for fibre optic network more than 300 m distance data transmission, unless otherwise justified by the manufacturer.

5

The above specified cables shall be new, unused and of current design and manufacture. Suitable optical fibre cables shall be selected based on the distance travel, bandwidth, indoor and outdoor application and shall be approved by the Engineer .The material of the fibre shall be silica glass fibre.

14.2.4

Patch Panels

1

Patch panels shall be type RJ45, 16 port, 1U type in rows of three with extension possible of up to six patch panels.

2

Patch panels shall be housed inside racking system (19” preferred) cabinets with hinged doors on either side and lockable front doors.

3

Ventilation slots shall be provided in both sides.

4

Rack size shall suit patch panels.

14.2.5

Patch Cords/Line Cords

1

Patch cords, shall be 2 metres long with adapters at both ends suitable for connection to RJ45 16 port IU patch panels.

2

Patch cords shall be Category 5 and be flexible enough to bend without loosing any performance.

3

Patch cords shall be the flexible stranded type.

4

Line cords shall have the same specifications as patch cords, however these shall be the solid type, used at wall outlets to connect computers or terminals to distribution cabling systems.

5

Cables shall comply with the performance data specified in Table 14.2.

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Table 14.2 Specifications for Category 5 solid/stranded line cords or patch cords Frequency Attenuation Next (MHz)

(Max. dB/305 m)

(Min Loss dB/305 m)

1.00

6.80

62.0

4.00

14.0

53.0

10.0

22.4

47.0

16.0

28.3

44.0

20.0

31.7

42.0

25.0

35.9

41.0

31.25

40.9

40.0

62.5

59.3

35.0

100.0

76.1

32.0

QCS 2014

Section 21: Electrical Works Part 14: Structured Cabling Systems

Page 5

14.2.6

Outlets

1

These shall be twin outlet type RJ45 to EN 60950 IBS 7008 having white moulded plastic plates with black shutters for computer outlets and white shutters for telephone outlets.

2

Outlets shall conform to the following specifications: (a)

Attenuation (dB)

:

1000 V) ..................... 2

34.1

GENERAL ...................................................................................................... 2

34.1.1 Scope 34.2

2

SYSTEM DESCRIPTION............................................................................... 2

34.2.1 Description 34.3

2

STANDARDS ................................................................................................. 3

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34.4.1 Ratings 34.4.2 Design Characteristics 34.4.3 Control System 34.4.4 Controller Keypad 34.4.5 Communications Interface 34.4.6 Fault Detection 34.4.7 Protection Features 34.4.8 Emergency Stop Control 34.4.9 Drive Enclosures 34.4.10 Factory Witness Inspections

4 5 6 8 8 8 9 11 11 12

INSTALLATION ........................................................................................... 12

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34.5.1 Documentation 34.5.2 Commissioning 34.5.3 Training

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34.5

3 4 4

PRODUCTS ................................................................................................... 4

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34.4

.

34.3.1 Codes and Standards 34.3.2 Quality Assurance 34.3.3 Warranty

12 13 13

QCS 2014

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

Page 2

HIGH VOLTAGE VARIABLE FREQUENCY DRIVE (>1000 V)

34.1

GENERAL

34.1.1

Scope

1

This Specification defines the requirements for High Voltage Variable Frequency Drive Systems (VFDs) for the operation of pump motors. The system shall consist of the following main components: Isolation breaker, Drive Isolation Transformers, High voltage Variable Speed Drives (VFDs), Output Sine Filter, and any necessary power factor correction or harmonic filter components if required to meet this Specification.

2

The Manufacturer shall prepare a complete compliance with the Specification. Any exception shall be included in the compliance statement with an explanation, clearly indicating the paragraph of the Specification to which the exception applies, and concisely stating the reasons.

3

Unless clearly identified as an exception, the Specification shall have precedence where there is conflict between Manufacturer descriptive information and the Specification.

4

The drive manufacturer shall have a proven operation for the proposed drive and active harmonic filter/if provided in the sewage treatment plants or sewage pumping stations (or similar applications –subject to Engineer‟s approval) for more than 10 years.

34.2

SYSTEM DESCRIPTION

34.2.1

Description

1

The VFD System (VFDS) shall consist of the following main components: Isolation breaker, Drive Isolation Transformers, High voltage Variable Speed Drives (VFDs), Output Sine Filter, and any necessary power factor correction or harmonic filter components if required to meet this Specification.

2

The VFD manufacturer shall provide a dedicated fused contactor or circuit breaker (Hereto called Input Isolation Switchgear); rated to protect the VFD from specified short-circuit levels. The Input Isolation Switchgear shall be controlled by the VFD. The VFD doors shall be interlocked to prevent opening when main power is available.

3

The VFD shall be supplied with 11 kV, 3 phase, 50 Hz power and shall be able operate with +/-6% voltage variation.

4

Auxiliary power 415V, 3 phase, 50 Hz and safe-line power 240V, single phase, 50 Hz will be provided on site from a separated UPS. Alarm of missing Auxiliary power supply shall be provided in the VFD and an indication lamp shall be provided on the VFD door.

5

The variable frequency drive shall control a 3-phase squirrel cage induction motor

6

The drive will be suitable for the motor(s) rated 3300V, 3 phases, 50 Hz and above.

7

The power capacity of the converter shall meet the speed-load curve of the application, even at minimum mains supply voltage. An additional service factor or over-dimensioning of the VFD is not required.

8

The VFD shall be suitable for use with a new or an existing standard squirrel cage motor with 1.0 service factor and standard High voltage insulation and have dv/dt 10 to 50µsec.

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QCS 2014

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

Page 3

9

The VFD shall control the speed by employing advanced torque control techniques and auto tuning that measure and set all constant and critical parameters of the motor automatically.

10

It will be necessary to conduct field tests to measure the harmonics with all VFDs regardless of whether filters, reactors, chokes etc. are installed or not, running at 100 percent and 50 percent loads for the duration of at least 3 hours under each load condition. If drives don‟t meet the specified performance, the Contractor shall provide an acceptable solution at no extra cost.

11

The VFD shall be selected based on the following as the main advantages:User friendly allowing the operator to configure the VFD at site with ease.

(b)

Uniform motor running at all speeds.

(c)

Power factor close to unity regardless of the speed of the motor.

(d)

High overall system efficiency

(e)

No increase of noise in the motor.

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(a)

The VFD shall be arranged to prevent nuisance tripping due to failure of supply for a short duration (transient disturbances).

13

The following indication LED lamps with labels as per the relevant QSC Section 21, shall be provided on the VFD door.

(b)

VFD General fault.

(c)

Run/Stop.

(d)

Local/Remote.

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Ventilation fan failure.

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(a)

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12

STANDARDS

34.3.1

Codes and Standards

1

The specified Variable Frequency Drive System shall be designed and materials shall be furnished in accordance with the latest revisions of applicable sections of the following Codes and Standards.

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IEEE 519 ....................Guide for Harmonic Control and Reactive Compensation of Static Power Converters. IEEE 995 ....................Recommended Practice for Efficiency Determination of AC Adjustable Speed Drives. IEEE C57.12.00-2000 General Requirements for Liquid-Immersed Distribution Power and Regulating Transformers. IEEE C57.12.01-1989 General Requirements Transformers.

for

Dry-Type

Distribution

and

Power

ANSI C57.12.10-1988 Transformers – 230 kV and Below 833/948 through 8333/10417 kVA, Single-Phase, and 750/862 Through 60000/80000 kVA with load TAP Changing – Safety Requirements. ANSI C57.12.51-1981 Requirements for Ventilated Dry-Type Power Transformers, 501 kVA and Larger, Three-Phase with High-Voltage 601 to 34500 volts, LowVoltage 208Y/120 to 4160 Volts. ANSI C57.12.70-1978 Terminal Markings and Connections for Distribution and Power Transformers.

QCS 2014

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

Page 4

IEEE C57.12.90-1999 Test Code for Liquid-Immersed Distribution, Power and Regulating Transformers. IEEE C57.12.91-1995 Test Code for Dry-Type Distribution and Power Transformers. IEEE C57.18.10-1998 Practices and Requirements for Semiconductor Power Rectifier Transformers. IEEE C57.124-1991 ...Detection of Partial Discharge and the Measurement of Apparent Charge in Dry-Type Transformers. ENV 50141 .................Radio frequency common mode. EN55011 ....................Suppression of Radio disturbances caused by electrical appliances and systems. EN 50081-2 ................Electromagnetic compatibility (EMC) IEC 146-1-1 ................Semiconductor Converters

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IEC 529 ......................Degrees of protection provided by enclosures (IP Code)

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NFPA-70.....................National Fire Protection Agency (NFPA) –70 National Electric Code (NEC), latest adopted edition.

ta

ICS7.1 ........................NEMA Safety standard for construction and guide to selection, installation and operation of Adjustable Frequency Drive Systems.

qa

OSHA .........................Standard No. 29 CFR 1910.147 – The standard for control of hazardous energy (Lockout/Tagout). IEC1000-4-2 ...............Electrostatic immunity test

as

IEC1000-4-4 ...............Fast transient immunity test

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IEC1000-4-5 ...............Surge immunity test

IEC61800 ...................Adjustable speed electrical power drive systems

er

UL 347 ........................High Voltage Industrial Control Equipment. UL 508C .....................Power Conversion Equipment

ov

UL 467 ........................Safety Standard for Grounding Equipment

o

NEMA .........................National Electrical Manufacturer‟s Association Standard MG1 (1987) Quality Assurance

1

The VFD manufacturer shall have ISO 9001 certification.

2

The VFD manufacturer shall be able to provide start-up service, 24 hour/day emergency call service, repair work, maintenance and troubleshooting training of customer personnel.

3

VFD converter shall be UL listed/EC certified.

34.3.3

Warranty

1

The drive shall be warranted by the manufacturer for a minimum of three years from the date of commissioning in PWA name.

34.4

PRODUCTS

34.4.1

Ratings

1

The VFD shall convert 11k V - 3 Phase - 50 Hz, power to an adjustable voltage and frequency for controlling the speed of the pump. The output voltage shall vary proportionally with the output frequency to maintain a constant volts/hertz value up to a nominal frequency. Above nominal frequency, the output voltage shall remain constant.

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34.3.2

QCS 2014

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

Page 5

The drive shall be designed to operate in ambient temperature between 0°C and 50 °C with a relative humidity of up to 95 % (non-condensing).

3

The drive shall be capable of being stored at a temperature between -0 °C and 70 °C.

4

The drive shall be capable of operating at altitudes up to 200 meters above sea level.

5

The drive shall be capable of operating at a minimum efficiency of 95% at full load and full speed

6

The incoming line power factor shall range between 1.0 and 0.95, lagging, over the entire operating speed range.

34.4.2

Design Characteristics

1

VFD

Converter shall be offered with minimum 18 Pulse or higher to mitigate Harmonics generated at the line side and shall confirm to IEEE 519-1992 standards

(b)

The VSD shall have a fixed and alternatively variable V/f curve characteristic suitable for the required application.

(c)

The VSD shall be capable of varying the motor speed from a maximum speed at full load and at any intermediate speed down to 10% full load speed.

(d)

The drive shall be designed to be selectable for variable or constant torque. When selected for constant torque, the drive shall supply 150% of rated current for up to one minute. When selected for variable torque the drive shall supply 110% of rated current for one minute every 10 minutes.

(e)

The rectifier shall make use of three phase Rectifier Bridge consisting of diodes for power conversion from AC to DC. The inverter section shall use latest IGCT or nontransistor based modules for minimal loss, high speed switching and very low harmonics.

(f)

The VFD shall be trouble free operation.

(g)

The VFD shall have a fuse less design, which detects failures and acts within 25 microseconds. The device should be non-rupture type.

(h)

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2

The manufacturer shall not use any control or power components that require replacement before 50,000 hours of operation minimum.

m

(i)

VFDs, using electrolytic high voltage capacitors or fuses, are not acceptable.

(j)

The Mean Time Between Failure (MTBF) of the VFD shall be greater than 50,000 hours minimum. All components of the VFD shall be considered for MTBF calculations.

(k)

The calculated Availability of the VFD shall be greater than 99.95%. The Availability shall be calculated based on the expected downtime due to corrective and preventive maintenance.

(l)

The VFD shall be capable of continuous operation (“ride-through”) in the event of a power loss of up to 1 second or more. The time limit shall be defined by the load inertia and not by the VFD‟s capability.

(m)

The VFD shall be able to safely operate, without tripping, at down to 30% under voltage of the mains supply.

(n)

The FVD drive shall be a high voltage VFD system. All power semiconductors and passive power components in both the rectifier and inverter part shall be high voltage rated components. Low voltage components are not acceptable in the power part sections

QCS 2014

Page 6

(o)

The drive must be capable of switching on to a motor already rotating in either direction.

(p)

The starting arrangement must include a ramp speed control, to achieve starting currents not exceeding normal full load current.

Drive Isolation Transformer (a)

A drive isolation transformer shall be furnished to provide power conversion from the 11 KV line voltage to the required VFD voltage and to isolate the line from harmonics and common mode voltages. The transformer shall conform to ANSI/IEEE C57.

(b)

The transformer shall be designed to withstand a short circuit. It shall maintain electromagnetic symmetry when only one secondary winding is in short circuit in order to minimize the resulting short circuit forces. The transformer shall be capable of thermally withstanding a short circuit for 2 seconds.

(c)

Transformers shall be of a high efficiency type with full load losses of less than 2%.

(d)

Transformer winding material shall be copper.

(e)

Suitable vibration dampers shall be provided with the transformer and its enclosure in order to attenuate mechanical resonance and to reduce the operational sound level.

(f)

The cable distance between the VFD and Drive Isolation transformer shall be designed for up to 50 m minimum.

(g)

The transformer shall include electrostatic shielding between the windings to carry high frequency capacitive currents to ground.

(h)

Transformer designs shall be indoor / outdoor, mounted dry type /ONAN type.

(i)

Only Rectifier grade K-factor transformers shall be utilized, with K-Factor of 6 for diode rectifiers. VFD manufacturers providing SCR type rectifiers shall include K Factor of 12 transformers for variable torque applications and K Factor of 20 for constant torque applications.

(j)

Dry type transformers shall be protected with an over-temperature protection, and any other protections as per the relevant standards, device with alarm and trip contacts and subject of Engineer‟s approval

(k)

Liquid cooled transformer / ONAN shall be equipped with an oil level indicator, an overpressure device (Buchholz or overpressure relay) and a top oil thermometer with alarm and trip contacts and subject of Engineer‟s approval. Each primary winding shall be provided with taps, adjustable in a range of +/-2.5% and +/-5% above and below nominal voltage. All taps shall be full capacity, no load type lockable type.

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2

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

(m)

If a dry type transformer is provided, the transformer shall be of Temperature Class 180C and average winding temperature rise of 115C.

(n)

If a liquid cooled transformer / ONAN is provided, the transformer shall have an average temperature rise of 60C for the oil and 65°C for the windings.

34.4.3

Control System

1

The VFD shall have a sensorless vector torque control or Direct torque control algorithm with static speed error of less than 0.2% and open loop torque step rise time under 10 milliseconds

2

Unless specified, the VFD shall not require the use of a tachometer.

3

The VFD shall be able to catch and take control of a spinning load if started while rotating equipment is already spinning. Appropriate safeguards shall be included in this operation to prevent damaging torque excitations, voltages or currents from impacting any of the equipment. The user shall have the option of employing this feature or disabling it.

QCS 2014

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

Page 7

The VFD to provide an automatic current limit feature to control motor currents during startup and provide a “soft start” torque profile for the motor-load combination. Current and torque limit adjustments shall be provided to limit the maximum VFD output current and the maximum torque produced by the motor.

5

The VFD shall accept a start/stop command and speed reference from a local VFD panel, or from a remote panel.

6

The VFD shall have the capability to avoid up to five critical operating ranges. The critical operating ranges (skip frequencies) shall have selectable bandwidth, configurable via the operator interface

7

Upon restoration of power following a power loss, if the VFD status is healthy, the VFD shall be capable of re-starting upon receiving a start signal from the main processor.

8

The VFD shall be capable of passing through a momentary power outage of 3 cycles without causing the drive to trip.

9

The modulating control scheme shall closely approximate actual sine wave current throughout the speed range of the drive. The frequency resolution of the VFD shall be 0.01Hz.

10

Each VFD shall be equipped with a front mounted operator control panel consisting of a back lighted alphanumeric display and a keypad with the functions:

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4

Run/Stop command including indication lamps on the door.

(b)

Local/Remote command including indication lamps on the door.

(c)

Increase/Decrease command

(d)

Forward/Reverse command

(e)

Menu navigation and parameter selection

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(a)

All parameter names, fault messages, warnings and other information shall be displayed in plain text to allow the user to understand what is being displayed without the use of a manual or cross-reference table. A display contrast adjustment shall be provided to optimize viewing at any angle.

12

During normal operation, the speed reference, and run/stop forward/reverse and local/remote status shall be displayed. At least 3 additional user selectable analogue values shall be available for display including the following values as a minimum:

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(a)

Motor speed, current and power.

(b)

Output frequency, voltage and torque

(c)

DC bus voltage.

(d)

Cooling air or water temperature.

(e)

Status of discrete inputs and outputs.

(f)

Values of analog input and output signals.

13

Password protection shall be provided for prevention of unauthorized parameter access.

14

If specified, hardware inputs and outputs shall be provided to interface with external operator and supervisory control and monitoring equipment. The following galvanically isolated I/O points shall be included: (a)

Analogue inputs shall be 4 - 20 mA. Analogue input signals processing functions shall include scaling adjustments, adjustable filtering and signal inversion. Analogue signal functions shall include speed reference signals.

QCS 2014

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

Page 8

(b)

Discrete (binary) inputs shall be designed for 24 VDC. Discrete input functions shall include „run/stop‟ and „remote reset‟.

(c)

Analogue outputs shall be 4 to 20 mA signals. Analog outputs shall be programmable to provide signals proportional to at least output motor speed and current.

(d)

Relay contact outputs shall be rated to switch in minimum 6 A at 24 VDC or 250 VAC. Function selections shall include „VFD ready‟, „running‟, „alarm‟ and „trip‟ indications.

The VFD output frequency shall be controllable between 0 – 66 Hz.

16

The VFD memory shall retain and record, run and fault status with a minimum of 8 last fault conditions.

17

The VFD cubicle shall be provided with additional control and accessories if any are deemed necessary to meet the operating logic as described in the particular requirement.

18

The VFD shall include any additional protective features not detailed in the specification but recommended by the manufacturer in order to avoid damage to the VFD or Motor.

34.4.4

Controller Keypad

1

The VFD shall be provided with a unit mounted but detachable LCD display unit, provided with a three meter length of cable, suitable for mounting on the cubicle door. The VFD shall allow the program stored in one drive to be copied to another drive by using the display unit and supplied software. Interconnecting cables and associated accessories together with a user manual must accompany the VFD.

2

The VFD shall include any additional protective features not detailed in the specification but recommended by the manufacturer in order to avoid damage to the VFD or Motor

3

All parameters shall be password protected to prevent tampering and unauthorised changes.

34.4.5

Communications Interface

1

The drive shall incorporate an RS 485 serial communications interface to allow full drive control, programming, monitoring and diagnostics, including access to history record.

2

The VFD shall be provided with communication interface and facility to integrate the operation of the system. The facility employing communication protocols e.g. profibus, modbus etc. shall be compatible with other system equipments such as the PLC, RTU etc.

3

The Contractor shall provide a suitably sized programming device (laptop) complete with all necessary connection cables, software and licenses for configuration and maintenance of the VFD‟s.

34.4.6

Fault Detection

1

The drive shall keep a record of the last ten trips, plus a 100 sample history record of up to ten pre-defined parameters to enable fast diagnosis and minimum down time. Automatic printout of history record to a serial printer shall be an available feature.

2

The VFD shall have a programmable fold back function that will sense a controller/motor overload condition and fold back the frequency to avoid a fault condition.

3

A dedicated microprocessor based electronic motor protection system to be provided for the protection of the motor.

4

The VFD shall be protected against short circuit between output phases and ground, analogue outputs and logic circuit.

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QCS 2014

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

Page 9

For each programmed warning and fault protection function, the VFD shall display a message in complete English words or Standard English abbreviations. At least 40 time tagged fault messages shall be stored in the drive‟s fault history

6

In order to guarantee correct fault indications and trip sequence in the event that auxiliary power source feeding the drive is lost, the drive system processor shall be connected to an uninterrupted Power supply source (either within the drive or provided externally) to supply control power for display and signals.

34.4.7

Protection Features

1

For personal safety reasons all power capacitors have to be hard grounded (mechanical interlock), before accessing any MV section of the VFD. The grounding has to be mechanically and electrically interlocked with the cabinet doors. It shall be only possible to open the doors when the capacitors are grounded.

2

For each programmed warning and fault protection function, the VFD shall display a message in complete English words or Standard English abbreviations. At least 40 time tagged fault messages shall be stored in the drive‟s fault history.

3

An Emergency-stop push button (E-Stop) shall be provided on the VFD door and one additional remote located near the motor shall be provided.

4

The VFD shall provide input phase loss protection.

5

The system offered shall incorporate adequate protection and alarms properly coordinated by the Vendor for the drive control and for motor but not limited to the following :

6

The drive shall be protected against supply-phase loss and mains discontinuity.

7

The drive shall have a selectable auto-restart after trip.

8

The drive shall be designed to shut down with no component failure in the event of any of the above fault conditions arising. Main Drive Motor & Supply Cables The Motor Phase Loss

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5

Short Circuit in the Rectifier Bridge

(iii)

Supply Phase Loss

(iv)

Overload of the Inverter.

(v)

Short Circuit of the Inverter

(vi)

Battery Test if applicable

(vii)

Communication Fault

(viii)

External Motor Protection Trip

(ix)

External Transformer Protection Trip

(x)

Process Stop

(xi)

External Emergency Off

(xii)

Overcurrent (through current control limiter)

(xiii)

Overvoltage

m

(ii)

(xiv) Phase unbalance/Single phasing (xv)

Earth fault

QCS 2014

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

Page 10

(xvi) Locked Rotor (xvii) Overspeed – 105% / Under speed – 95% (xviii) Over temperature in stator through Motor model (xix) Line breaker tripped (xx)

Cooling medium temperature high

(xxi) Loss of one cooling system in case of redundant cooling system

(iii)

Raise/lower

(iv)

Forward/Reverse

(v)

Auto/Manual mode

(vi)

Local/Remote.

(vii)

Emergency stop

.

Speed control

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Start/stop

Drive on

(ii)

Drive off

(iii)

Motor over speed

(iv)

System ready to start

(v)

Remote breaker trip

(vi)

Ventilation fan failure.

(vii)

VFD General fault.

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The system shall monitor the status of the following and provide indications.

Fault Annunciation Display of forty maximum previous faults shall be provided with a minimum of the these features (i)

Inverter overload

(ii)

Inverter high temperature

(iii)

No cooling of panel/motor

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(i)

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(c)

Following minimum control are envisaged on front of the panel unless otherwise specified.

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(b)

(e)

Following control / metering shall be provided on local control panel.

(i)

ON/OFF push button

(ii)

Speed Raise/Lower push button

(iii)

Emergency stop push button

(iv)

Local/remote selection indication

(v)

Speed indicator

(vi)

Ammeter

(vii)

ON/OFF indication

(viii)

Drive ready to start indication

QCS 2014

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

Page 11

34.4.8

Emergency Stop Control

1

An Emergency-stop (E-Stop) shall be provided on the VFD door in addition to inputs for customer supplied E-Stop command to ensure effective direct stopping of the drive if dangerous situations arise. The means provided should include direct connection to an Breaker, arranged such that its opening on-load: (a)

does not inhibit any in-built deceleration provided by the variable speed controller

(b)

does not produce additional safety hazards

(c)

does not cause damage to the controller.

Drive Enclosures

1

The converter and inverter section shall be suitably housed in sheet steel panels and shall be fabricated with 2 mm thick cold rolled sheet steel and structural steel. The panel shall be suitable for indoor installation if not otherwise specified. The panel shall be free standing, dust and vermin proof and degree of protection IP- 4X for air cooled or for water cooled if not otherwise specified. The cabinet shall be riveted/welded type construction to provide effective protection against Electromagnetic emissions.

2

The followings minimum thickness shall apply:.

(b)

Frames

(c)

Covers and Doors

- 2.00 mm

(d)

Gland Plate

- 3.00 mm

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Plinth/bed frame

- 3.00 mm

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- 2.00 mm

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34.4.9

The VFD Converter shall require front access only.

4

The VFD Converter enclosure doors shall include an electromechanical interlocking system with a safety grounding switch. The enclosure doors can be opened only if the safety ground switch connects all DC buses to ground, to ensure all stored VFD and motor energy is discharged before opening any high voltage compartment door.

5

The Output Sine Filter, Input Harmonic Filter and Power Factor Correction filter, if required, shall be factory mounted and wired into the Converter enclosure.

6

All painted surfaces shall be (ZINTEC) and must have a minimum of priming coat, undercoat and finishing coat. The undercoat and finishing coat shall be stove enamelled. The exterior shall be green to BS 4800, shade 14E53. Interior surfaces shall be white painted or shall be bright (unpainted) galvanized steel.

7

All bus bars shall be copper and corrosion protected.

8

The enclosure must be designed to avoid harmonic and inductive heating and eliminate radio frequency interference.

9

VFD noise level shall be less than 85 dB(A) for air cooled and less than 70 dB(A) for water cooled drives at 3 feet distance.

10

Anti-condensation heaters shall be provided with a thermostat and humidistat and have OFF/AUTO control on the cubicle front door. The heater shall not be in operation when the inverter is functioning.

11

The VFD shall be of Fuse less design.

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Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

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All panels shall be same height so as to form a bank, which shall give good aesthetic appearance.

13

All the control wiring shall be enclosed in plastic channel. Each wire shall be identified at both ends by wire marker tapes or PVC ferrules.

14

Power and control wiring inside the panel shall be done with PVC insulated copper conductor.

15

All Power modules and components shall be accessible from front of panel only.

16

PCB construction shall be rigid and robust. Components shall be wave soldered to the PCBs. Each component on the board must be clearly identified.

17

Suitable lifting hooks shall be provided for lifting the panel.

18

All FVD components shall be individually provided with identification engraved label.

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34.4.10 Factory Witness Inspections

Where specified in the tender documents, the stand-alone Drive (VFDs) shall be witness tested at the manufacturing facilities in the presence of Engineer and/or his representative. The detailed and complete Factory Acceptance testing procedure including the testing sheets shall be subject of Engineer‟s approval, and shall be approved by the Engineer 30 days before FAT dates are proposed. Internal test reports shall be provided to Engineer before the FAT test is performed.

2

The VFD shall be tested at 25%, 50% and 100 % load, minimum 3 hours recording the temperature rise.

3

The VFD System shall undergo standard manufacturing testing and as approved by the Engineer.

4

Each VFD shall be factory 100% load tested with a similar induction motor size on a dynamometer test stand at manufacturing facilities.

5

The FAT inspection procedure shall be submitted to Engineer for approval, and approved 30 days before performing the FAT witness test at manufacturing facilities.

6

Internal Factory test report shall be provided before preparation of the FAT witness date.

7

It will be necessary to conduct field tests to measure the harmonics with all VFDs regardless of whether filters, reactors, chokes etc. are installed or not, running at 100 percent and 50 percent loads for the duration of at least 3 hours under each load condition. If drives do not meet the specified performance, the Contractor shall provide an acceptable solution at no extra cost.

34.5

INSTALLATION

34.5.1

Documentation

1

The following documentation shall be provided:

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(a)

load de-rating (with tender)

(b)

harmonic distortion (with tender)

(c)

circuit diagrams

(d)

maintenance instructions

QCS 2014

Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

(e)

fault diagnosis

(f)

parts list with part numbers

(g)

commissioning instructions

(h)

general arrangements drawings

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A recommended spares list for two years continuous operation shall be submitted at the time of tender. Where multiple, identical units are being supplied a rationalised list, i.e. not a summation of individual drives, requirements, should be produced.

34.5.2

Commissioning

1

The manufacturer of the drive system shall have a factory trained service representative residing in the Qatar for commissioning, programming and to provide training and after sales service.

2

The representative shall be trained in the installation, maintenance and trouble-shooting of the equipment specified and shall assist the Contractor to set-up and commission the variable speed motor drives and controls.

3

System validation tests shall be performed on all VSD‟s.

4

The integrated site test on the VFD, motor and all other associated devices shall be conducted to verify the input and output current, voltage, frequency, power factor, acceleration and deceleration rate etc. in accordance with the operating characteristics as approved by the Engineer.

5

Test VFD at different operating conditions by adjusting parameters (25, 50, 75 and 100%). Record the performance and verify.

6

The power system shall be tested for harmonics, line notching and for RFI/EMI in cable circuits and in the air.

7

Tests shall be performed during normal plant operation and during operation with the emergency generator.

8

The test results so obtained shall be used to calculate the Total Harmonic Distortion (%THD) and compare the same with IEEE 519

9

The manufacturer's engineer or their trained and qualified engineer working full time with the local supplier shall conduct all tests on site.

10

Upon completion of site tests a duly signed report listing all tests and checks, together with all supporting documents and drawings where applicable, shall be submitted to the Engineer for review. The Owner‟s representative shall be invited to witness the tests.

11

Submit all test reports, drawings and supporting documents to the Engineer and obtain written approval from both prior to the system being accepted by the Owner.

34.5.3

Training

1

Site Training. The AC drive manufacturer shall provide an on-site training program for the operating personnel of minimum 7 working days. This program shall provide operating and instruction manuals, training in equipment operation, and troubleshooting of the AC drive. The training program shall include, but not be limited to:

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(a)

Instruction on the basic theory of pulse width modulation control

QCS 2014

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(b)

Instruction on the layout of the variable frequency controller indicating the location and purpose of each component

(c)

instruction on troubleshooting problems related to controller

(d)

installation and removal of printed circuit boards

(e)

actions to take under failure of controller

(f)

necessary cleaning of component parts.

Factory training. Duration of training program shall be minimum 10 days for two client persons at the manufacturing facilities.

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END OF PART

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Section 21: Electrical Works Part 34: High Voltage Variable Frequency Drives

QCS 2014

Section 21: Electrical Works Part 04: Motor Starters

Page 1

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LOW VOLTAGE MOTOR STARTERS (
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