Etihad Rail Stage 2 Project C0306 - PACKAGE 2C Design & Build Contract (Dubai) DCP3F - Technical Specifications - Bridges and Railway Structures

Responsible Division Responsible Discipline Document Type Document Status
C0306 Structures-Bridges Specification Issued for Construction
ETIHAD RAIL STAGE 2 PROJECT

C0306 - PACKAGE 2C
Design & Build Contract (Dubai)
DCP3F – Technical Specifications - Bridges and Railway
Structures
Dan Irish
Prepared 06-JAN-2021
Design Manager / WSP
Xu Yue
Verified 12-JAN-2021
Technical Director / CRGT
Ubaidullah Khan
Quality Process Approval 12-JAN-2021
Project QA/QC Manager / CRGT
Sun Shangxing
Approved 12-JAN-2021
Project Director / CRGT
Name Signature Date
Document Number Issued Date 12-JAN-2021
Location/
Contract No. - - Discipline - Type - Sequence Number - Revision
Subdivision
C 0 3 0 6 - S 0 2 - E C B - F S - 3 0 0 0 0 - 0 0
This document including its attachments is the property of Etihad Rail. It contains confidential proprietary information and may be legally privilege. The
reproduction, distribution, utilization or communication of this document, or any part thereof, is strictly prohibited unless expressly permitted by Etihad Rail.
UNLESS SPECIFIED OTHERWISE, THIS PRINTED COPY OF THIS DOCUMENT IS UNCONTROLLED AND FOR REFERENCE PURPOSE ONLY
C0306-S02-ECB-FS-30000-00 PAGE 1 OF 122
Version Log - Internal
Version Date Name Description of Review Changes

AA1 27-APR-2020 Dan Irish Preparer
AA2 28-APR-2020 Xu Yue Verifier
AB1 22-JUN-2020 Dan Irish Preparer
AB2 22-JUN-2020 Xu Yue Verifier
AC1 05-AUG-2020 Dan Irish Preparer
AC2 05-AUG-2020 Xu Yue Verifier
AD1 10-SEP-2020 Dan Irish Preparer
AD2 15-SEP-2020 Xu Yue Verifier
AE1 03-NOV-2020 Dan Irish Preparer
AE2 03-NOV-2020 Xu Yue Verifier
001 06-JAN-2021 Dan Irish Preparer
002 12-JAN-2021 Xu Yue Verifier
Revision Log – To Client
Revision Date Description of Changes

AA 28-APR-2020 First Release
AB 22-JUN-2020 Second Release
AC 05-AUG-2020 Third Release
AD 15-SEP-2020 Fourth Release
AE 03-NOV-2020 Fifth Release
00 12-JAN-2021 Final Release (DCP3 to DCP3F)
This document including its attachments is the property of Etihad Rail. It contains confidential proprietary information and may be legally privilege. The
reproduction, distribution, utilization or communication of this document, or any part thereof, is strictly prohibited unless expressly permitted by Etihad Rail.
C0306-S02-ECB-FS-30000-00 PAGE 2 OF 122
DCP3F – TECHNICAL SPECIFICATIONS
- BRIDGES AND RAILWAY
STRUCTURES
Table of Contents
Acronyms and Abbreviations............................................................................................................ 10
1 Introduction ........................................................................................................................ 11
1.1 Scope of this Specification ................................................................................................ 11
1.2 Design Responsibilities ..................................................................................................... 11
1.3 Construction Specifications .............................................................................................. 12
1.4 Reference Documents ...................................................................................................... 12
1.5 Approvals .......................................................................................................................... 13
1.6 Temporary Works ............................................................................................................. 13
1.7 Shoring works ................................................................................................................... 14
1.7.1 Required Submissions .......................................................................................... 14
1.7.2 Design criteria ...................................................................................................... 16
1.8 QA/QC and Records .......................................................................................................... 17
2 General................................................................................................................................ 18
2.1 Fire Resistance of Structure and Emergency Access ........................................................ 18
2.2 Earthing and Bonding........................................................................................................ 18
2.3 Vehicle Parapets for Over-Bridges (Road over Rail) ......................................................... 18
2.4 Handrails for Under-Bridges (Rail over Road) ................................................................... 19
2.4.1 Metal Handrail ..................................................................................................... 19
2.5 Provisions for Train Derailment ........................................................................................ 25
2.6 Crash Barriers.................................................................................................................... 26
2.7 Utility Diversion and Protection Structures ...................................................................... 26
2.8 Lighting.............................................................................................................................. 26
2.9 Noise Barriers.................................................................................................................... 26
2.10 Drainage ............................................................................................................................ 27
2.10.1 Drainage pipe ....................................................................................................... 27
2.11 Erosion Protection ............................................................................................................ 28
2.12 Mechanically Stabilized Embankment (MSE) Wall ........................................................... 28
2.13 Soil investigation ............................................................................................................... 28
2.14 Foundation design ............................................................................................................ 29
2.15 Excavation ......................................................................................................................... 29
2.15.1 General................................................................................................................. 29
2.15.2 Disposal of Excavated Materials .......................................................................... 29
2.15.3 Dewatering and Drainage .................................................................................... 29
2.15.4 Backfill .................................................................................................................. 31
2.16 Ground Movement and Monitoring ................................................................................. 31
2.16.1 General................................................................................................................. 31
2.17 Precondition Surveys ........................................................................................................ 33
3 Concrete Pile Foundations .................................................................................................... 34
3.1 General.............................................................................................................................. 34
3.2 Piling Design ...................................................................................................................... 34
3.3 Pile Construction Records ................................................................................................. 34
3.4 Placing Concrete under Water or Support Fluid ............................................................... 34
3.5 Finishing Pile Heads .......................................................................................................... 35
3.6 Pile Testing ........................................................................................................................ 35
3.7 Maintained Compression Load Testing of Piles ................................................................ 36
3.8 Integrity Testing of Piles ................................................................................................... 36
3.9 Rectification of Failure of MLT Pile ................................................................................... 37
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STRUCTURES
4 Structural Concrete – Rail and Civil Structures....................................................................... 38

4.1 General.............................................................................................................................. 38
4.2 Concrete............................................................................................................................ 38
4.2.1 Cementitious Materials ....................................................................................... 38
4.2.2 Cement................................................................................................................. 38
4.2.3 Silica Fume (Microsilica) ...................................................................................... 39
4.2.4 Ground Granulated Blast Furnace Slag ................................................................ 39
4.2.5 Fly Ash .................................................................................................................. 39
4.2.6 Water ................................................................................................................... 39
4.2.7 Certificate of Tests and Analyses ......................................................................... 39
4.2.8 Tests after Delivery .............................................................................................. 40
4.2.9 Rejection of Cement ............................................................................................ 40
4.3 Aggregates ........................................................................................................................ 40
4.3.1 General................................................................................................................. 40
4.3.2 Grading................................................................................................................. 40
4.3.3 Sources of Aggregates ......................................................................................... 40
4.3.4 Testing of Aggregates .......................................................................................... 42
4.3.5 Alkali-Silica Reactivity .......................................................................................... 44
4.3.6 Rejection of Aggregates ....................................................................................... 44
4.4 Admixtures ........................................................................................................................ 44
4.4.1 General................................................................................................................. 44
4.4.2 Dosing .................................................................................................................. 45
4.4.3 Submittals for Admixtures ................................................................................... 45
4.4.4 Dosing .................................................................................................................. 45
4.4.5 Submittals for Admixtures ................................................................................... 46
4.4.6 Fibres.................................................................................................................... 46
4.5 Concrete Mixtures ............................................................................................................ 46
4.5.1 General................................................................................................................. 46
4.5.2 Mixture Properties ............................................................................................... 47
4.5.3 Mixture Verifications ........................................................................................... 50
4.5.4 Submittal for Approval......................................................................................... 51
4.6 Field Testing of Works Concrete ....................................................................................... 51
4.6.1 Sampling Concrete Cylinders or Cubes ................................................................ 51
4.6.2 Frequency of Sampling Concrete Cylinders or Cubes .......................................... 51
4.6.3 Concrete Cylinders and Cubes Strength Criteria ................................................. 52
4.6.4 Workability........................................................................................................... 52
4.7 Production of Concrete ..................................................................................................... 52
4.7.1 Transport, Testing and Placement ....................................................................... 52
4.7.2 Hot weather concreting ....................................................................................... 53
4.7.3 Mixing Plant ......................................................................................................... 54
4.7.4 Concrete Curing ................................................................................................... 55
4.7.5 Additional Inspection and Testing Requirements................................................ 55
4.8 Formwork and Falsework ................................................................................................. 57
4.8.1 Design .................................................................................................................. 57
4.8.2 Construction ........................................................................................................ 57
4.8.3 Tolerance ............................................................................................................. 58
4.8.4 Preparation of Formwork before Concreting ...................................................... 59
4.8.5 Removal of Falsework and Formwork ................................................................. 59
4.8.6 Early Loading ........................................................................................................ 60
4.9 Classes of Finish ................................................................................................................ 60
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4.9.1 General................................................................................................................. 60
4.9.2 Formed Surfaces .................................................................................................. 60
4.9.3 Remedial Treatment of Formed Surfaces ............................................................ 61
4.9.4 Unformed Surfaces .............................................................................................. 61
4.9.5 Special Finishes .................................................................................................... 61
4.10 Testing of Samples Cut from the Works ........................................................................... 62
4.11 Concrete Repairs ............................................................................................................... 62
4.11.1 Assessment .......................................................................................................... 63
4.11.2 Identification of Defects ...................................................................................... 63
4.11.3 Repairs to Cracks.................................................................................................. 63
4.11.4 Preparation of Surfaces around cracks ................................................................ 64
4.11.5 Repairs to Honeycombing and Voids in Concrete ............................................... 64
4.12 Failure to Meet Specified Requirements .......................................................................... 65
4.13 Records ............................................................................................................................. 66
5 Reinforcing Steel .................................................................................................................. 67
5.1 General.............................................................................................................................. 67
5.2 Normal Reinforcement ..................................................................................................... 67
5.3 Stainless Steel Reinforcement .......................................................................................... 67
5.4 Epoxy Coated Reinforcement Bars ................................................................................... 67
5.5 Binding Wire ..................................................................................................................... 67
5.6 Dowel Bars ........................................................................................................................ 67
5.7 Manufacturer’s Test Certificate ........................................................................................ 67
5.8 Delivery ............................................................................................................................. 68
5.9 Bar Schedules and Shop Drawings .................................................................................... 68
5.10 Storage and Bending ......................................................................................................... 68
5.11 Fixing Reinforcement ........................................................................................................ 69
5.12 Welding of Reinforcement ................................................................................................ 69
5.13 Cover ................................................................................................................................. 69
5.14 Minimum Test Requirement ............................................................................................. 70
5.15 Failure to Meet Specified Requirements .......................................................................... 70
6 Precast Concrete .................................................................................................................. 71
6.1 General.............................................................................................................................. 71
6.2 Moulds .............................................................................................................................. 71
6.3 Casting............................................................................................................................... 72
6.4 Marking ............................................................................................................................. 72
6.5 Curing ................................................................................................................................ 72
6.6 Handling Stacking and Transportation.............................................................................. 72
6.7 Failure to Meet Requirements .......................................................................................... 72
7 Pre-stressed Concrete Works ............................................................................................... 73
7.1 General.............................................................................................................................. 73
7.2 Details of Design ............................................................................................................... 73
7.3 Shop Drawings .................................................................................................................. 73
7.4 Materials ........................................................................................................................... 74
7.4.1 Pre-stressing Steel and Anchorages..................................................................... 74
7.4.2 Steel Wire............................................................................................................. 74
7.4.3 Bars ...................................................................................................................... 74
7.4.4 Post-tensioning Anchorages and Coupler............................................................ 75
7.4.5 Identification and Testing .................................................................................... 75
7.4.6 Pre-tensioning Tendon Testing ............................................................................ 75
7.4.7 Post- tensioning Tendon Testing ......................................................................... 76
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7.4.8 Corrosion Protection............................................................................................ 76

7.4.9 Ducts .................................................................................................................... 76
7.4.10 Duct Area ............................................................................................................. 77
7.5 Placement of Ducts and Steel ........................................................................................... 77
7.5.1 Placement of Ducts .............................................................................................. 77
7.5.2 Vents and Drains .................................................................................................. 78
7.5.3 Placement of Pre-tensioning Steel ...................................................................... 78
7.5.4 Placement for Post-Tensioning Steel ................................................................... 78
7.5.5 Protection of Steel after Installation ................................................................... 79
7.6 Tensioning ......................................................................................................................... 79
7.6.1 General Tensioning Requirements ...................................................................... 79
7.6.2 Concrete Strength ................................................................................................ 79
7.6.3 Sequence of Stressing .......................................................................................... 79
7.6.4 Measurement of Stress........................................................................................ 80
7.6.5 Friction Test ......................................................................................................... 80
8 Grout and Mortar ................................................................................................................ 81
8.1 General.............................................................................................................................. 81
8.2 Mortar for General Purposes ............................................................................................ 81
8.3 Grouting for Pre-stress ..................................................................................................... 82
8.4 Bedding Mortar for Bearings and Base Plates .................................................................. 82
8.5 Testing............................................................................................................................... 83
9 Special Coating System for The Protection of Exposed Concrete Surfaces .............................. 84
9.1 General.............................................................................................................................. 84
9.2 Properties.......................................................................................................................... 84
9.3 Primer ............................................................................................................................... 85
9.4 Topcoat ............................................................................................................................. 85
9.5 Trial Panels ........................................................................................................................ 85
9.6 Inspection of Concrete...................................................................................................... 86
9.7 Approval Prior to Coating Application in the Works......................................................... 86
10 Structural Steelwork ............................................................................................................ 87
10.1 General.............................................................................................................................. 87
10.2 Steelwork .......................................................................................................................... 87
10.3 Shop Drawings .................................................................................................................. 87
10.4 Materials and Fabrication ................................................................................................. 87
10.4.1 General................................................................................................................. 87
10.4.2 Steelwork ............................................................................................................. 87
10.5 Fasteners ........................................................................................................................... 88
10.6 Shear Studs ....................................................................................................................... 88
10.7 Cutting, Bevelling , Fit up , Welding and Post Weld Inspection ........................................ 89
10.8 Welding ............................................................................................................................. 90
10.8.1 Welding Defects ................................................................................................... 90
10.8.2 Site Welding ......................................................................................................... 90
10.9 Holing ................................................................................................................................ 90
10.10 Submittals ......................................................................................................................... 91
10.10.1 Drawings .............................................................................................................. 91
10.10.2 Material Submittals ............................................................................................. 91
10.10.3 Fabrication and Corrosion Protection.................................................................. 92
10.10.4 Assembly and Erection......................................................................................... 92
10.10.5 Mock-ups and samples ........................................................................................ 92
10.10.6 Fabrication ........................................................................................................... 92
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10.10.7 As Built and Site Records ..................................................................................... 92

11 Protection of Steel Work from Corrosion .............................................................................. 93
11.1 General.............................................................................................................................. 93
11.2 Surface Preparation .......................................................................................................... 94
11.2.1 Pre degrease surface preparation ....................................................................... 94
11.2.2 Surface Degreasing .............................................................................................. 94
11.2.3 Abrasive Grit Blast Cleaning ................................................................................. 94
11.2.4 Equipment Requirements .................................................................................... 94
11.2.5 Metal Defects....................................................................................................... 94
11.3 Coating Systems ................................................................................................................ 95
11.3.1 General................................................................................................................. 95
11.3.2 Application Conditions ......................................................................................... 95
11.3.3 Coating Application .............................................................................................. 96
11.3.4 Stripe coats .......................................................................................................... 96
11.3.5 Handling and Storing Coated Steelwork .............................................................. 96
11.4 Coating on Joints and Fixings ............................................................................................ 96
11.4.1 High strength friction grip (HSFG) bolted joints .................................................. 96
11.4.2 Welded joints ....................................................................................................... 97
11.5 Inspection ......................................................................................................................... 97
11.6 Protection ......................................................................................................................... 98
11.7 Remedial Work ................................................................................................................. 98
11.8 Coating Application on Trial Panels .................................................................................. 98
12 Waterproofing of Concrete Structures .................................................................................. 99
12.1 General.............................................................................................................................. 99
12.2 Performance requirements .............................................................................................. 99
12.3 Water-stops ...................................................................................................................... 99
12.4 Waterproofing for Substructures ................................................................................... 100
12.4.1 Materials for waterproofing membranes .......................................................... 100
12.5 Waterproofing for Superstructures ................................................................................ 101
12.5.1 Materials for waterproofing membranes .......................................................... 101
12.5.2 Additional Bituminous Protection ..................................................................... 103
12.5.3 Integrity Testing of Waterproofing .................................................................... 103
12.6 Failure to Meet Requirements ........................................................................................ 103
12.7 Method Statement ......................................................................................................... 103
4. Shop Drawings ................................................................................................................ 104
13 Bridge Bearings .................................................................................................................. 105
13.1 General............................................................................................................................ 105
14 Finishes to Structures ......................................................................................................... 106
14.1 General............................................................................................................................ 106
14.2 Compliance ..................................................................................................................... 106
14.3 References ...................................................................................................................... 106
14.4 Materials ......................................................................................................................... 106
14.5 Submittals ....................................................................................................................... 106
14.6 Quality Assurance ........................................................................................................... 107
14.7 Delivery, Storage, and Handling ..................................................................................... 107
14.8 Sequencing ...................................................................................................................... 108
14.9 Project Conditions........................................................................................................... 108
14.10 Warranty ......................................................................................................................... 108
14.11 Manufacturers ................................................................................................................ 108
14.12 Aluminum Flush Doors, Frames and Sub-Frames ........................................................... 108
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14.13 Execution ........................................................................................................................ 109

15 Bridge Expansion Joints and Sealing of Gaps ....................................................................... 110
15.1 General............................................................................................................................ 110
15.2 Joints ............................................................................................................................... 110
15.2.1 Joint Filler and Dowel Bars................................................................................. 110
15.2.2 Joint Sealant and Waterstops ............................................................................ 110
15.3 Elastomeric Expansion Joints .......................................................................................... 111
15.3.1 General............................................................................................................... 111
15.3.2 Materials ............................................................................................................ 111
15.4 Manufacture and Fabrication ......................................................................................... 112
15.5 Installation of Bridge Deck Expansion Joints .................................................................. 112
16 Quality Control Arrangements ............................................................................................ 114
17 Preparation of As Built Drawings ........................................................................................ 115
17.1 Detail and Contents of As Built Drawings ....................................................................... 115
17.2 Planning and Preparation of the As Built Drawings List ................................................. 115
17.3 Documents to Be Issued ................................................................................................. 115
17.3.1 Red Marked Drawings........................................................................................ 115
17.3.2 As-Built Drawings ............................................................................................... 116
17.4 Submission of Red-Marked Drawings ............................................................................. 116
17.5 Submission of As-Built Drawings .................................................................................... 118
17.5.1 As-Built Submission – Subcontractor to Contractor .......................................... 118
17.5.2 As-Built Submission – Contractor to Engineer ................................................... 118
17.6 Final Certificate of As-Built Drawings ............................................................................. 118
18 Document Management .................................................................................................... 119
18.1 Numbering System.......................................................................................................... 119
18.2 Number of Copies ........................................................................................................... 119
18.3 Associated Requirements for Originator ........................................................................ 119
19 Inspection and Maintenance .............................................................................................. 121
19.1 Key Inspection Elements ................................................................................................. 121
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STRUCTURES
Tables
Table 1: Requirements for Support Fluids (Bentonite)
Table 2: Acceptable Movement of Verticality Loaded Pile
Table 3: Additional Mineral Material Properties for CEM | Cement
Table 4: Additional Mineral Material Properties for Microsilica
Table 5: Tests on Aggregates for Acceptance
Table 6: Frequency of Routine Tests on Aggregates
Table 7: Properties of Concrete Grades
Table 8: Indicative Concrete Mix Criteria
Table 9: Additional Inspection and Testing Requirements
Table 10: Formed Finishes
Table 11: Unformed Finishes
Table 12: Dimensional Tolerances on Precast Units
Table 13: Mortar Proportions by Volume
Table 14: Properties for Coating Effectiveness
Table 15: Additional Requirements for Waterproofing Membranes
Table 17: Elastomer physical properties
Table 18: Table of Actual Condition of Drawing
Table 19: Number and Format of Copies to Be Submitted
Table 20: Key Elements of the Structure Requiring Regular Maintenance
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Acronyms and Abbreviations

AASHTO American Association of State Highway Transportation Organisations
ACI American Concrete Institute
AREMA American Railway Engineering and Maintenance-of-Way Association
ASTM American Society for Testing and Materials
BS British Standard
CIRIA Construction Industry Research and Information Association
Cl Chloride
EN European Standard
ERL Etihad Rail (the Engineer/Client)
ERN Etihad Rail Network (the Project)
FHWA Federal Highway Administration
GCC Gulf Co-operation Council
K Potassium
kg kilogramme
kJ kiloJoule
kN kiloNewton
kPa kiloPascal
m metre
MPa MegaPascal
Na Sodium
PVC Poly Vinyl Chloride
Si Silicone
SO4 Sulphate
UAE United Arab Emirates
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STRUCTURES
1 Introduction
1.1 Scope of this Specification
1 This Technical Specification covers the technical requirements for design and construction of Over-
Bridges (Road over Rail) and Under-Bridges (Rail over Road) and civil structures (collectively referred to
in this Technical Specification as Rail Structures), including culverts, underpasses and utility protection
structures.
2 All contractor queries relating to this Technical Specification or the Drawings will be submitted to the
Engineer promptly in writing in the form of a Technical Query (TQ) for clarification and instructions.
3 Management Plans and Procedures that are referenced in this Specification are Contractor documents,
except for plans and procedures that are specified as Engineer documents.
4 Where anywhere in the Specifications or the Contract reference is made to the agreement, consent,
acceptance or the like of the Engineer such agreement, consent, acceptance or the like will be obtained
in writing through submittals, inspection requests or other similar communications process as agreed in
advance with the Engineer.
5 The notification by the Engineer of his agreement, consent, acceptance or the like to any submission by
the Contractor will in no way lessen the Contractor’s duties and responsibilities under the Contract to
supply the Works complete fit for purpose and in compliance with all of the Contract Documents.
6 For the avoidance of doubt, any expressed or implied approval or acceptance of any of the Contractor’s
work by the Engineer will not transfer any responsibility or liability for said work from the Contractor to
the Engineer.
7 This specification should be read in conjunction with the Package 2C Durability Report issued by the
contractor. Document Reference is C0306-S02-ECB-RP-30018
1.2 Design Responsibilities

1. The Contractor will be responsible for the design of the bridges and structures covered by this Technical
Specification.
2. Such designs will be prepared by a Consultant registered in the UAE as a Design Consultant, submitted to
the relevant Authority and the Engineer for their acceptance or No Objection as required by the relevant
Authority and the Engineer.
3. All such designs will be independently checked as Category II for Railway Structures and as required by
the relevant Authority for other structures to the United Kingdom Department of Transport Design
Manual for Roads and Bridges BD 2/05 Technical Acceptance Of Highway Structures.
4. Where any Authority or the Engineer requires independent checking as Category III this will be deemed
to be included in the Contractor’s scope.
5. The independent check notes and certificates will be submitted to the Engineer.
6. Designs will be in accordance with the Design Criteria for Bridge & Railway Structures issued by the
Contractor as a separate document C306-S02-ECB-FS-0001
7. The design of Over-Bridges (OBR) will be based on AASHTO LRFD latest edition and local authority design
requirements; and the design of Under-Bridges (UBR), Small Underpasses (SUP), Drainage Culverts and
Utility Protection structures will be in accordance with AREMA latest edition.
8. When designing member sections, AASHTO LRFD latest edition will be governing upon AREMA for items
which are not covered in AREMA or are stricter than AREMA.
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1.3 Construction Specifications

1. Contractor will prepare detailed construction specifications for each element of works based on the final
design for the execution of works.
2. The Contractor will produce and submit construction method statement for all project works for
Engineer’s approval.
3. If the requirements contained herein conflict with requirements contained in other project
Specifications, the more stringent of the requirements will be deemed to be applicable to the Works.
4. In any event the interpretation of Engineer in these cases will be binding.
5. The construction specifications for Rail Structures will be comprehensive and to the satisfaction of the
Engineer and will comply with the requirements of this Technical Specification along with the
Appendices hereto and all Referenced Documents (latest revisions) in this Technical Specification and
the Appendices hereto unless permitted otherwise by the Engineer in writing.
6. The construction specifications for Over-Bridges will additionally incorporate the requirements of the
relevant Authorities having jurisdiction including but not limited to:
– Dubai Municipality
– Road & Transport Authority, Dubai
1.4 Reference Documents

1. The Contractor will comply with the current version of all referenced American or European Standards,
and AREMA guidelines, or in their absence with relevant International Standards, and with the
requirements of Statutory Authorities having jurisdiction.
2. The contractor will follow all local specifications and design guidelines from the relevant Dubai
authorities including those for utilities and telecommunication.
3. The contractors has issued the following specifications under the contract which will also be referred:
a) Technical Specifications Earthworks C0306-S02-ECE-FS-30000
b) Technical Specifications-Civil Works- C0306-S02-EGE-FS-10000
c) Technical Specification - Bored Concrete Piles -C0306-S02-EBB-FS-20001
d) Technical Specification -MSE walls- C0306-S02-ECB-FS-30003
e) Technical Specification - Bearings- Rail Bridges- C0306-S02-ECB-FS-30001
f) Technical Specification - Bearings- Road Bridges- C0306-S02-ECB-FS-30002
g) Design Basis Report – Earthworks - C0306-S02-EBB-RP-00001
h) Design Basis Report-Structures -C0306-S02-ECB-RP-00001
i) Durability Report C0306-S02-ECB-RP-30018
4. As a minimum, the works under the Contract will comply with the Standards and Regulations specified in
the following Sections and the Appendices to this Specification or where more stringent.
– The Contract Documents; and
– AREMA Manual for Railway Engineering;
– AASHTO LRFD Bridge Construction Specification;
– The European Standards -Sections EN 1990 to EN 1998 and complemented by British National
Annexes.
– British Standards
– National Fire Protection Association
C0306-S02-ECB-FS-30000-00 PAGE 12 OF 122
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– Road & Transport Authority (Dubai); Current Design Circulars; Structural Design Criteria for Bridge and
Underpasses
– Dubai Municipality General Specifications
– Dubai Municipality Geometric Design Manual for Dubai Roads
– Jebel Ali Free Zone Authority
– American Petroleum Institute (API) 1102 Steel Pipelines Crossing Railroads and Highways
– Concrete Society CS 163: Guide to Design of Concrete Structures in Arabian Peninsula CIRIA report
147: Design and Construction of joints in concrete structures
– CIRIA Publication C660 : Early-age thermal crack control in concrete
– CIRIA Publication C577 – Guide to construction of reinforced concrete in the Arabian Peninsula
– CIRIA Report R146 – Design and Construction of joints in Concrete Structures
– UIC 774-3, UIC 777-2R, UIC 776-2 – Track/Bridge interaction
5. Other Documents of particular application are listed in the Contract. The Contractor will advise the
Engineer in writing of any deviations from the specified Standards and Regulations.
6. In regard to conflict (if any) between any of the referenced documents, the more strict requirement will
govern.
1.5 Approvals
1. The Contractor is responsible for receiving all necessary approvals for design and construction.
2. The Contractor will ensure that all codes and other requirements of all relevant agencies are met in
design and construction.
3. Any Code and/or Standards used will in each instance be the latest edition or issue, and the most recent
revision, amendment or supplement adopted.
4. Where the requirements of more than one Code or Standard are applicable, the more restrictive will
govern.
1.6 Temporary Works

1 The Contractor will be responsible for the design, supply, and installation, and maintenance, removal of
temporary works and site restoration of all Temporary Works required for the construction of the
structures covered by this Specification to the acceptance of the Engineer.
2 All temporary works designs will be designed by competent designers experienced in the design of
temporary works for structures.
3 The designs of temporary works will be reviewed by a third -party Design Consultant registering in the
UAE who will certify in writing that the designs are adequate and safe.
4 No construction of temporary works on site will be permitted prior to the submission by the Contractor
of the design records, workshop drawings and the independent check certificate for all elements of the
required temporary works. These documents will be submitted by the Contractor to the Engineer at
least 28 days, or such other time as the Engineer will decide, before the Engineer's consent is required.
5 The Contractor will be responsible for mobilization & demobilization of Plant & material required for the
temporary works.
6 Where anywhere within this Contract the instruction, direction, acceptance or the like of the Engineer is
required for the installation or maintenance of temporary works of any kind whatsoever, said
requirements will in no way amend the requirement for the Contractor to be solely responsible for the
adequacy and safety of installation and maintenance of said temporary works.
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7 The Contractor will inspect temporary works daily as specified in the Employers Requirements to ensure
that they are safe and have not been damaged due to construction, environment exposure or
vandalism.
8 The Contractor will appoint in writing a suitably qualified temporary works coordinator responsible for
temporary works management and including ensuring compliance with all laws and regulations in
respect of the temporary works of private and public bodies and of Government departments, agencies
and other organisations.
9 The qualified temporary works coordinator will appoint temporary works supervisors to ensure that the
temporary works have been constructed in accordance with the Shop drawings and specifications. All
temporary works will be tagged and inspected in line with the permit system established for the project.
10 The Contractor will maintain a register for all temporary works required on the project.
1.7 Shoring works

1 Shoring Works shall conform to the Dubai Municipality Regulations and Guidelines for Structural Design
and any applicable acts of any authority having jurisdiction.
2 Design of Shoring shall be in accordance with AREMA – Chapter 2- Part 28 -Design of Temporary
Structures for Construction and AASHTO LRFD Bridge Construction Specifications.
3 For shoring which includes piling, the ICE Specification for Piling and Embedded Retaining Walls shall be
followed if the specifications or the above mentioned code do not provide sufficient guidance to the
Temporary Works Contractor. Where the ICE Specification is not clear, or does not provide sufficient
guidance, other internationally recognised standards may be followed, with the approval of Contractor
and the Engineer.
4 Where there are differences between the specifications and drawings and the standards, codes or acts,
the most stringent shall govern.
1.7.1 Required Submissions

a) Capability Statement
The Temporary Works Contractor shall submit a detailed Capability Statemen. The Capability Statement
shall include:
• Evidence of experience of the intended type of work, in the ground conditions present in the work areas
• Summary of rigs and excavating tools available
• Summary of the rig operators experience
• CV of project manager, technical managers and site foreman responsible for the delivery of
the works
The Temporary Works Contractor Capability Statement shall be reviewed by the Engineer for approval in
accordance with project prequalification criteria
b) Method Statement
The Shoring Contractor shall prepare a detailed Method Statement for approval by the Contractor and
Engineer. No works shall commence until the Method Statement has been approved by both parties. The
Method Statement shall include:
• Shoring type proposed
• Proposed equipment
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• Detailed phasing of works and construction sequence and methodology showing

decommissioning of shoring anchoring and/or internal propping
• The anticipated time required for installation of the shoring system from the commencement
of site works to completion of concreting and testing
• A quality plan, including all materials testing (type and frequency)
• Details of the material certification testing results and manufacturer certification
• Type of support fluid, where used. If bentonite, the type of bentonite, source, chemical and
physical properties shall be provided as well as ITP (Inspection and Testing Plan)
• Calculations to show that the density of the support fluid and the specified minimum required
levels are sufficient to maintain the stability of the trench, in the ground and groundwater
conditions envisaged
• Details of any proposed sub-contractors
• Method of monitoring of adjacent structures, services and infrastructure
• Risk Assessment Plan
• Typical construction record sheets, for example for bored cast in-situ piles this would include
pile identification, dimensions, set-out position, weather conditions, groundwater levels,
date and time of pile start and completion, casting, cut-off and pile tip elevation, installation
method, final pile head position and any other pertinent information
c) Health and Safety Plan
The Shoring Contractor shall prepare a Health and Safety Plan for approval by the Contractor. No works
shall commence until the plan has been approved. This document shall include:
• A Health and Safety Policy Statement
• A method statement detailing how the work will be carried out safely. This shall take account
of any hazard information supplied by the Contractor.
• Accident reporting arrangements
d) Design Submissions
For each shoring area, the Contractor shall submit a shoring design submission to the Engineer for review
and approval. The submission document shall include:
• Drawings showing:
o a site layout plan showing temporary and permanent works and existing adjacent
structures and infrastructure
o cross section of the proposed shoring
o Where ground anchors are proposed, these shall be shown on both the plan and cross
sections
• Geotechnical and structural calculations
• Groundwater conditions and whether dewatering is required
• Loading assumptions, for each construction stage
• Details of struts and the timing of installation and removal relative to excavation
• Anticipated construction loads
• Maximum design load to be carried by each structural element
• Anticipated theoretical deflections of the shoring and surrounding ground
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1.7.2 Design criteria

1 Settlement from temporary shoring shall be limited to ensure the combined settlement from all works
(not just temporary shoring) remains within the limits.
2 Where excavation is carried out near or under an existing structure or any portion of the Work, the
Contractor shall prevent damage due to shoring with methods approved by the Engineer.
3 A schedule of critical structures, services and infrastructure shall be provided by the Contractor.
Permissible damage criteria shall be defined on a case by case basis. Additional Method Statements may
be requested by the Contractor or the Engineer for works adjacent to critical structures, services and
infrastructure.
4 Monitoring of adjacent critical structures, services and infrastructure shall be carried out by the
Contractor, where required.
5 Any excavation or filling work required for the installation of shoring shall be undertaken in accordance
with the Earthworks Specification.
6 All excavations shall be clear of water. If required, dewatering shall be undertaken in accordance with
approved Dewatering method statement.
7 The shoring works detailed in this document are temporary and shall not form part of the permanent
works. As such waterproofing and protective coatings are not required but may be used at the discretion
of the Contractor.
8 Shoring shall be properly maintained until the permanent work is sufficiently advanced to permit the
shoring to be removed. The Engineer approval is required before the removal of shoring. If the
Contractor proposes not to remove the shoring on completion of the permanent work, the Engineer’s
prior approval shall be sought.
9 The design life of shoring systems shall typically be 2 years unless additional design life is required and
specified by the Contractor.
10 The shoring system shall allow for free and safe movement of workers, equipment and materials in to,
out of, and around the excavation.
11 The size, type, and design of shoring is the Contractor’s responsibility. The Contractor shall assume full
responsibility for the design, construction, and safety of the support system.
12 If the proposed support system includes ground anchorages the Contractor shall provide the
geotechnical profile for which each anchor is intended, the maximum design and proof loads, and the
criteria proposed for deformations under proof loads.
13 This section provides high-level design criteria for shoring; however, criteria may need to be modified
when working adjacent to critical infrastructure/structures.
14 The shoring system shall be designed to support ground and groundwater loads, utility loads, traffic and
construction loads, and all other applicable surcharges to prevent damage to or minimise movement of
existing buildings, structures and services. The minimum construction surcharge shall be 20 kPa.
15 The maximum allowable lateral movement of the shoring wall ground settlement behind the shoring
shall be determined on a case by case basis depending upon the proximity to adjacent structures and
infrastructure. Instrumentation and monitoring shall be installed to monitor actual shoring deflection
against predicted movement.
16 The following are provided as typical allowable ground settlement behind shoring walls, however as
stated above, this will be confirmed on a case by case basis:
a) Shoring in ‘open areas’ (no existing services or infrastructure): 50 mm
b) Shoring adjacent to services and infrastructure: 30 mm
c) Shoring adjacent to road surfaces and other paved surfaces: 15 mm
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d) Shoring adjacent to bridge foundations: 10 mm

17 The Contractor shall ensure that the design of the shoring takes consideration of the natural
groundwater level and also any proposed dewatering
18 Shoring design shall be based on the ground model and geotechnical parameters provided in
geotechnical design and interpretation reports or supplementary geotechnical design technical notes or
calculation packages related to the shoring submission.
1.8 QA/QC and Records

1. Notwithstanding the Contractor’s responsibility to carry out the Works in accordance with the Contract,
the Contractor will notify the Engineer in advance of submission so that adequate notice of delivery of
documents for design submissions, proposed materials to be used and work activities on Site to allow
them to review these items in detail to verify the Engineer’s acceptance of the same.
2. Time schedule and content of each submittal will be agreed with Engineer at start of the project
3. The Contractor will carry out the Works in accordance with the Contract in accordance with his accepted
QA/QC procedures.
4. The Contractor will provide a unique reference code for each civil structure to facilitate identification
and future maintenance, in accordance with The Engineer’s requirements
5. All records, including internal audits by the Contractor, will be available for inspection by the Engineer at
any time during the Contract and subsequent warranty periods.
6. This obligation will be passed by the Contractor to each of his sub-contractors, designers, suppliers and
the like.
7. All design criteria, specifications, records of any kind or other requirements of each Authority, whether
the Engineer or any other party, to whom ownership of any element of the Works will be handed over,
will be identified by the Contractor at the earliest stages of and throughout the whole period of the
Contract.
8. The Contractor will comply with all such requirements including the preparation, collation and delivery
of all required documents, calculations and evidence required to prove his compliance to both the
Authority and the Engineer to the satisfaction of both the Authority and the Engineer.
9. As-Built drawings for all completed structures will be submitted by the Contractor to the Engineer.
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2 General
2.1 Fire Resistance of Structure and Emergency Access
1. The Contractor will carry out study to specify the fire resistance of the structural elements based on the
location and functional requirement of the structure.
2. All structural elements will have minimum two hours fire resistance, and protective coating to be applied
where necessary.
3. For protection structures crossing oil and gas utilities, concrete material will be used with appropriate
minimum fire resistance that is designed to withstand increased heat flux from a jet fire that results from
loss of containment from a pipeline (eg from pipeline containing LPG, jet fuel, or natural gas, etc)
4. Emergency egress points will be provided for long multi-span bridge structures in accordance with NFPA
130 requirements.
5. Contractor to also refer to the Civil Technical Specs C306-S02-EGE-FS-30001
2.2 Earthing and Bonding

1. All earthing and bonding within structures including stray current and cathodic protection will be in
accordance with the requirement of the Technical Specification - Systems Common Specification (Doc No.
X0231-S23-ERS-FS-00003).
2. The details of the earthing and bonding is covered in the JV Earthing and Bonding Control Plan for the
project. The contractor will refer to this document for all detailing to be included. C0306-S02-GHS-RP-0003
3. The overall & local resistance of the earthing system to the mass of earth shall have a maximum resistance
value of 1 ohms (Main Earth Terminal to ground).
4. Minimum welding distance between the rod shall be 110mm
5. The minimum rebar size used for earthing shall be 20mm
6. The material shall comply with AREMA /AASHTO and where applicable to the relevant BS EN standard
and/or UL (Underwriters Laboratories) -Standard for Safety- Grounding and Bonding Equipment
7. High strength copper alloy U bolt clamp with low resistance suitable to hold T20 rod shall be used to
connect additional cable with Rebar. The clamp shall be mechanical type, minimum tightening torque 10
Nm
8. U bolt rod clamp type GUV or equally approved shall be used to clamp the rebar with wire
9. Earth plat/test point should be provided on pier for future testing. The earth point should be pre welded
type with cable.
10. The minimum cable size used between test point and U clap/ T bar shall be 70mm², Cable should be PVC
insulated.
2.3 Vehicle Parapets for Over-Bridges (Road over Rail)

1. Parapets will be solid high containment concrete parapets on Over-Bridges and normal containment on
the approaches.
2. The Design will be in accordance with Design Criteria for Bridge & Railway Structures issued by the
contractor for approval. C306-S02-ECB-FS-0001
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3. For the span length of the Over-Bridge, the high containment parapet will have the safety fence from the
top of the parapet and extending a minimum height of 2.0m above the top of parapet level.
4. The safety fence will be extended on top of the normal containment parapet, with a minimum 2.0m
height from top of parapet, for a length of not less than 5m from each end of the bridge and will
terminate in a further transition reducing to 1.0m high at a distance of 10m from the end of the bridge.
5. The safety fence will compose of steel post with wire mesh.
6. Metal rails affixed to the top of concrete parapets will be in accordance with BS6779 Part 3.
7. Unless accepted otherwise by the Engineer, all such metal will be Hot-dip Galvanized steel as per ASTM
A123.
2.4 Handrails for Under-Bridges (Rail over Road)

2.4.1 Metal Handrail
1. Handrails shall be designed to restrain personnel and minor maintenance equipment from falling from
the bridge onto the road right of way below.
2. Design loads for handrails shall be in accordance with AREMA Chapter 15 Section 8.5.
3. The design shall be designed so as to minimise damage to the bridge superstructure and allow speedy
replacement in the event of impact from a train which, during a derailment event, is not contained by the
derailment control and/or protection measures implemented in the design that limit the transverse
movement of a derailed train.
2.4.1.1 METAL FABRICATIONS

2.4.1.1.1 General
a- This section covers the specifications of railings and decorative metal fabrications.
b- General Performance: Decorative Metal fixtures shall comply with performance requirements without
failure due to defective manufacture, fabrication, installation, or other defects in design or construction.
c- Comply with the applicable requirements of NFPA 101, 130 and 255 relating to this.
d- Protect and isolate all dissimilar metals and non-compatible substrates, materials or finishes from all
Work of this Section to prevent galvanic corrosion, staining and other damages
e- Comply with the standards listed in the references for the work of this Section. Should there be
overlapping requirements among different standards then the more stringent requirements shall apply.
2.4.1.1.2 Quality Assurance
1. Company specializing in high quality architectural metal fabrication and installation with minimum of five
(5) years documented experience (most recent 1 year). Aluminum extrusion manufacturers for aluminum
must possess five (5) years experience or better.
2. Fabricate and install architectural metalwork and sundries to withstand the anticipated imposed loadings
without failure including excessive deflection, structural defects, flaws in finishes and other defects in
the Work
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3. Design shop drawings under direct supervision of a professional structural engineer experienced
in design of this work and licensed in the region in which the project is located.
4. Provide materials that have a minimum service life expectancy of 25 years.
2.4.1.1.3 Materials
A. Materials – Miscellaneous
1. Stainless steel grade 316

2. Structural steel BS 4
3. Galvanized steel BS EN 10142
4. Aluminum: ASTM B 308
5. Glass: floated toughened glass
6. Brass
7. Bolts: ASTM A 307, A 325, A 345.
8. Grout: non shrink cementations grouts premixed ready for use requiring addition of water only, setting
time 15 to 30 minutes, developing not less than 25 N/mm². Compressive strength after one day and
expansion of up to 1% to overcome plastic settlement in the unset material.
9. Paint: epoxy polyurethane or powder organic coating to BS 6496.
10. Primer: Zinc epoxy, suitable for application to items embedded in concrete.
11. Gaskets, weather resistant neoprene.
B. Materials – Aluminum
1. Extruded Aluminum: ASTM B 221 (ASTM B 221M), 6063 alloy, T6 temper.
2. Sheet Aluminum: ASTM B 209 (ASTM B 209M), 5052 alloy, H32 or H22 temper. Aluminum-Alloy Drawn
Seamless Tubes: ASTM B 210 (ASTM B 210M), 6063 alloy, T6 temper.
3. Aluminum-Alloy Bars: ASTM B 211 (ASTM B 211M), 6061 alloy, T6 temper. E. Bolts, Nuts,
Rivets, Screws and Washers: Stainless steel.
4. Welding Materials: AWS D1.2/1.2M:2003; type required for materials being welded.
5. Isolation tape: Polymer alloy film with elastomeric coating, 30 mils thick, specifically designed for
corrosion and electrolytic protection of embedded metals, where risk of bimetallic contact exists.
C. Materials – Ancillary Materials
Shims
1. At connections subject to thermal movement or other movement, separate all pairs of moving surfaces
with friction reducing pads. Pads shall have minimum 3mm thickness, shall sufficiently reduce friction
to permit movement, shall be resistant to wear, shall be positively retained in position (open ended
slots are not acceptable). Pads shall not be subjected to heat damage from welding or cutting or to
excessive pressure from over-tightening of bolts.
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2. Shims which transfer shear forces (tending to slide on shim against another) shall be steel plates, set
in a staggered pattern and fillet welded to each other and to the adjacent steel surfaces. The shims
and welds shall be structurally designed to support the applied loads.
3. Plastic shims are acceptable at static connections for which the shims transfer only compressive
forces.
4. Wood shims are not acceptable.
5. Shims to be designed to support the applied loads
a) Fasteners: Comply with the following
1. Do not use metals that are corrosive or incompatible with materials joined.
2. Provide concealed fasteners for interconnecting metal work components and for attaching them to
other work, unless exposed fasteners are unavoidable or are the standard fastening methods.
3. Provide flat-head machine screws for exposed fasteners, unless otherwise indicated on drawings.
4. Anchors: Proprietary-made anchors shall all be stainless steel SS316 for cast-in type or expansion-
type as appropriate for the particular application. Anchors shall be threaded or wedge-type; fabricated
from corrosion- resistant Stainless Steel, in accordance with referenced standards. Powder coated
anchor screw caps shall be provided for exposed locations with matching colour of the handrail.
2.4.1.1.4 Welding
1. Welding of Aluminum
a) Welding of Aluminum shall be done in the factory and in conformance to BS EN 1011- 4:2000.
b) Weld shall use insert gas process using an electric arc with a protective envelope of argon gas.
Oxy-acetylene welding is not permitted as a substitute. Do not solder aluminum.
2.4.1.1.5 Grinding, Polishing and Finishing
a) All welded exposed joints shall be suitably ground flush with adjoining material and neatly finished
to harmonies therewith.
b) Wherever material has been sunken or depressed by welding operation, such depressions shall
be suitably hammered and peened flush to adjoining surface, and if necessary, again ground to
eliminate low spots.
c) All ground surfaces shall be smooth, consistent with good workmanship.
d) Care shall be exercised in all grinding operations to avoid excessive heating of metal and
metal discoloration. In all cases grain of rough grinding shall be removed by successive polishing
operations.
e) Texture of final polishing operation shall be uniform and smooth, consistent with reasonable
care and good workmanship.
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f) General finish of all equipment shall be of high grade. The Contractor shall seek approval from
the Engineer should there be doubt as to what constitutes acceptable standard of workmanship.
g) Butt joints and contact joints, wherever they occur, shall be close fitting, flush and shall not require
solder as filler.
h) Wherever brake bends occur, they shall be free of under extrudence and where such brakework
does match uniform appearance of material, all such marks shall be removed by suitable grinding,
polishing and finishing.
i) Wherever sheared edges occur, they shall be free of burrs, fins or irregular projections and shall
be finished over such sheared edges.
j) Where mitres or bull nosed corners occur, they shall be neatly finished with under edge of material
neatly ground to uniform condition and in no case are overlapping materials to be acceptable.
2.4.1.1.6 Exposed Mechanical Fastening
a) All fixings and anchoring of architectural metal work shall be concealed, unless specifically shown
on the drawings. If indicated on the drawings, exposed flush countersunk screws or bolts, are to
be located unobtrusively; consistent with design of structure, except where specifically noted
otherwise in the drawings.
b) Supply components required for anchorage of metal fabrications. Fabricate anchoring and related
components of same material and finish as metal fabrication, except where specifically noted
otherwise.
c) All architectural metals shown on the drawings as curved so be fabricated to the required radius.
Segmented panels will not be accepted.
d) Prior to crating, finished panels shall be inspected for blemished, chips and for flatness.
e) Any panel not meeting the requirements of this specification shall be rejected. Items found
damaged at any time shall not be installed
f) Items found damaged at any time shall not be installed
2.4.1.1.7 Finishes – Aluminum
1. Anodized Aluminum Surfaces: Comply with AA DAF-45 for aluminum finishes. Apply one coat of
bituminous paint to concealed aluminum surfaces in contact with cementitious or dissimilar materials.
Component and design details to be submitted to the Engineer for approval.
2.4.1.1.8 Structural Performance of Handrails and Railings:
1. Thermal Movements
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a) Provide handrails and railings that allow for thermal movements resulting from maximum change
(range) in ambient and surface temperatures by preventing buckling, opening of joints,
overstressing of components, failure of connections, and other detrimental effects.
2. Control of Corrosion
Prevent galvanic action and other forms of corrosion by insulating metals and other materials from
direct contact with incompatible materials. Use materials that do not stain exposed surfaces of
panel finishes and joint materials
2.4.1.2 Coating / Paint

2.4.1.2.1 SECTION INCLUDES
A. Shop applied coatings for metal.
2.4.1.2.2 REFERENCES
A. ASTM International (ASTM):
2.4.1.2.3 SUBMITTALS
A. Submit under provisions of Administrative Requirements.
B. Product Data:
1. Manufacturer's data sheets on each product to be used.
2. Preparation instructions and recommendations.
3. Storage and handling requirements and recommendations.
4. Typical installation methods.
C. Selection Samples: For each finish product specified, two complete sets of color chips
representing manufacturer's full range of available colors and patterns.
D. Verification Samples: For each finish product specified, two samples, minimum size 6
inches (150 mm) square representing actual product, color, and patterns.
E. Shop Drawings: Include details of materials, construction and finish. Include relationship
with adjacent construction.
2.4.1.2.4 QUALITY ASSURANCE

A. Manufacturer Qualifications: Company specializing in manufacturing products specified in
this section with a minimum five years documented experience.
B. Installer Qualifications: Company specializing in performing Work of this section with

minimum 5 years documented experience with projects of similar scope and complexity.
C. Source Limitations: Provide each type of product from a single manufacturing source to
ensure uniformity.
D. Mock-Up: Construct a mock-up with actual materials in sufficient time for Engineer’s
review and to not delay construction progress. Locate mock-up as acceptable to Engineer
and provide temporary foundations and support.
1. Intent of mock-up is to demonstrate quality of workmanship and visual

appearance.
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2. Retain mock-up during construction as a standard for comparison with completed

work.
4. Do not alter or remove mock-up until work is completed or removal is authorized.
2.4.1.2.5 DELIVERY, STORAGE, AND HANDLING
A. Store and handle in strict compliance with manufacturer's written instructions and
recommendations.
B. Protect from damage due to weather, excessive temperature, and construction

operations.
2.4.1.2.6 PROJECT CONDITIONS
A. Maintain environmental conditions (temperature, humidity, and ventilation) within limits

recommended by manufacturer for optimum results.
B. Do not install products under environmental conditions outside manufacturer's
recommended limits.
2.4.1.2.7 SEQUENCING
A. Ensure that products of this section are supplied to affected trades in time to prevent
interruption of construction progress.
2.4.1.2.8 WARRANTY
A. Manufacturer's Warranty: Provide manufacturer's standard limited warranty not less than
10 years.
2.4.1.2.9 MANUFACTURERS
A. Acceptable Manufacturer as per Engineer approval
B. Substitutions: Not permitted.
2.4.1.2.10 PAINT SYSTEMS
1. Performance and Design Requirements:
a. Film Cure, ASTM D5402: Withstands 150 MEK double rubs.
b. Film Hardness (Pencil Method), ASTM D3363: Minimum hardness of F.
c. Formability and Adhesion, ASTM D4145: No loss of adhesion at 68 degrees F
plus or minus 1.8 degrees F (20 degrees C plus or minus 1 degree C) using No.
610 Scotch cellophane tape and subjected to a 3T 180 degree bend and tape pull
test.
d. Humidity Resistance, ASTM D2247: No field blisters.
e. Film Integrity: During first 25 years of exposure, paint film shall have no evidence
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of cracking, flaking, or checking apparent on ordinary outdoor visual

observations.
f. Chalking, ASTM D4214, Method A: For the first 20 years, vertical installations
shall not chalk more than a No. 8 rating, and non-vertical installations shall not
chalk more than a No. 6 rating.
g. Color Change, ASTM D2244: For the first 25 years, vertical installations shall not
change color more than five (5) delta E color units and non-vertical installations
shall not change color more than seven (7) delta E color units.
2. Color: As indicated on Drawings.
3. Color: To be selected by Engineer from Manufacturer's full range.
2.4.1.2.11 EXAMINATION
A. Do not begin installation until substrates have been properly constructed and prepared.
B. If substrate preparation is the responsibility of another installer, notify Engineer in writing
of unsatisfactory preparation before proceeding.
2.4.1.2.12 PREPARATION
A. Clean surfaces thoroughly prior to installation.
B. Prepare surfaces using the methods recommended by the manufacturer for achieving the
best result for the substrate under the project conditions.
2.4.1.2.13 INSTALLATION
A. Install in accordance with manufacturer's instructions, approved submittals and in proper

relationship with adjacent construction.
2.4.1.2.14 CLEANING AND PROTECTION
A. Clean products in accordance with the manufacturer's recommendations.
B. Touch-up, repair or replace damaged products before Substantial Completion.
2.5 Provisions for Train Derailment

1. Etihad Railway structures will be designed in such a way that, in the event of a derailment, the resulting
damage to bridge structures is limited to a minimum.
2. Design provisions for train derailment will comply with the contractors Design Criteria for Bridge &
Railway Structures. C306-S02-ECB-FS-0001
3. Crash walls will be provided to protect Over-bridge sub-structures in case of train collision as per AREMA
Chapter 8 Clause 2.1.5 or the over-bridge piers/abutment wall will be designed for train impact loadings.
4. Adequate concrete up-stand walls will be provided on all Under-Bridges and approaches structures to
retain train vehicles on track area and to mitigate the risk of train overturning or fall from the bridge.
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2.6 Crash Barriers

Crash barriers will be provided to protect Under-Bridge and Small Underpasses sub-structure piers and
abutments as per AASHTO LRFD 3.6.5.
2.7 Utility Diversion and Protection Structures

1. The Design and Build Contractor will take into consideration the presence of existing and proposed
utilities and corridors and make provisions as per relevant stakeholder requirements.
2 The functional, design and construction requirements to divert or protect the utilities will be in
accordance with relevant utility stakeholder requirements, AREMA Chapter 1 and Chapter 8, API 1102,
Guidelines for 3rd Party Utility Under Track Crossing and General Civil Works Technical Specification.
3 All underground utility crossings of railway will be designed to carry AREMA Cooper E-80 train live
loading as per Contractors Design Criteria for Bridges and Railway Structures.
2.8 Lighting
1 Provisions for external lighting level will be made in all Bridge structures as per relevant highway agency
and/or local authority requirements and standards and General Civil Works C0306-S02-EGE-FS-0001
which covers general lighting .
2 Application and technical performance specifications will comply with Technical Specification: MEP
Services for Doc No: X0231-S23-EAM-FS-00001.
2.9 Noise Barriers

1 The Contractor will establish the need for noise mitigation on bridges which may include:
a) Consideration of track form and alignment, noise impacts, topography and receptors in the detailed
design
b) Noise insulation at receptors where appropriate
c) Acoustic barriers or other attenuation measures
2 The requirements for noise barriers may include reflective or absorbent parapets, barriers, screens,
partial or full enclosures, landscaping or planting, the size and extent of which will be determined by the
following previous Environmental Impact Assessment’s (EIA) and recent EIA Terms of Reference (TOR),
subject to the approval of the Engineer for the Abu Dhabi, Dubai and Northern emirates.
a) EIA for the Emirate of Abu Dhabi Stage 2, February 2013 (1303-S02-EWA-RP-00001)
b) EIA for the Emirate of Dubai Stage 2, September 2012 (X0103-S02-EWA-RP-00074)
c) TOR for Stage 2 Border Connections (X0231-S2B-EWA-RP-10002)
d) TOR for Stage 2 Abu Dhabi Realignment (X0231-S2C-EWA-RP-10002)
e) TOR for Stage 3A, Dubai and Northern Emirates (X0231-S2D-EWA-RP-10002)
3 The mitigation measures on the bridges during construction and operational phase of the project
need to be designed by the Contractor to suit local conditions and comply with Federal and Local
statutory requirements as detailed in the following previous Environmental Impact Assessment’s
(EIA) and recent EIA Terms of Reference (TOR), subject to the approval of the Engineer for the Abu
Dhabi, Dubai and Northern emirates.
a) EIA for the Emirate of Abu Dhabi Stage 2, February 2013 (1303-S02-EWA-RP-00001)
b) EIA for the Emirate of Dubai Stage 2, September 2012 (X0103-S02-EWA-RP-00074)
c) TOR for Stage 2 Border Connections (X0231-S2B-EWA-RP-10002)
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d) TOR for Stage 2 Abu Dhabi Realignment (X0231-S2C-EWA-RP-10002)

e) TOR for Stage 3A, Dubai and Northern Emirates (X0231-S2D-EWA-RP-10002)
4 During construction, the noise levels at appropriate distances from the source will be predicted and an
assessment of construction noise impact in accordance with BS 5228-1: 2009 Code of Practice for Noise
and Vibration Control on Construction and Open Sites (BS 5228) and British Standard 6472-1:2008:
‘Guide to evaluation of human exposure to vibration in buildings. Vibration sources other than blasting’
will be undertaken.
5 Predictions will be compared against and meet the Federal and Local authority requirements on
Acceptable Noise Levels (ANLs). Particularly, Dubai Roads and Transport Authority (RTA) have also issued
Noise and Vibration Guidelines (2014), which applies to rail projects within Dubai emirate and provides
thresholds for Construction and Operational Noise and Vibration thresholds. In addition, reference is
also made to Executive Council Resolution No. (1) of 2017 which regulates the Railways in the Emirate of
Dubai.
6 During operation, the Calculation of Railway Noise (CRN) Technical Memorandum (UK Department of
Transport, 1995) will be used to predict noise levels at representative receptors along this route section
at distances up to 300m from the track.
7 The actual geometrical and attenuation effect of the noise barrier will be determined by the modelled
noise at the environmental sensitive receptor.
8 Where noise barriers are required, the design of bridges will incorporate barrier materials with a mass
per unit of surface area in excess of 10 kg/m2 [ISO standard (9613-2)] to limit transmission through and
around the barrier.
9 There will be no gaps between any joints on the barrier.
2.10 Drainage
1 Bridge drainage will consist of all necessary furnishings, gullies, pipes, channels, grates and frames on
bridge decks to collect surface water from the structures and drain pipes which are connected to the
collection system by hoppers.
2 The gully and channel grates and frames may be of cast iron or structural steel with or without integral
cast hoppers.
3 In the absence of integral cast hoppers, fabricated uPVC or GRP hoppers will be provided.
4 For Over-Bridges and underpasses, the drainage design will follow the relevant local Municipality
requirements and any other relevant Authority as outlined in the General Civil Works Technical
Specifications -C0306-S02-EGE-FS-10000-00-Technical Specs-Civil Works.
5 Drainage culverts are to be provided at low points where flow paths meet the alignment.
6 Backfill materials behind abutments and wing walls will be granular, free-draining materials Earthwork
Technical Specifications to prevent build-up of hydrostatic pressure behind the wall. C0306-S02-ECE-FS-
30000
7 Drainage structures including box/pipe culverts will be designed in accordance with General Civil Works
Technical Specifications. C0306-S02-ECE-FS-3000
2.10.1Drainage pipe
1 The pipe and fittings inside the concrete pier and bridge shall be uPVC non-pressure pipes manufactured
and tested to BS EN 1401 – 1 : 2009 .
2 UPVC pipes shall be installed in accordance with the manufacturer’s guidelines, pipes shall be with BSI
kite marked
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3 UPVC fittings shall be injection moulded factory made and kite mark certified and shall conform to BS EN
1401-1
4 Fabricated fitting may be permitted only for non-standard fittings not shown in Pipe manufactures
Technical Catalogue
5 uPVC pipes shall be capable of withstanding ultraviolet degradation. A rodent inhibitor shall be
incorporated in the material of the pipe. Pipes shall be manufactured with integral flexible rubber ring
joints made to BSEN 681-1: 1996 EPDM type ‘D’ material and kite marked.
6 uPVC pipes for gravity pipelines shall be SN4 stiffness class and have a standard dimension ratio, D :t
(diameter to thickness), of between 35 and 45
2.11 Erosion Protection

Erosion control and slope protection structures will be designed in accordance with the contractors approved
documents as listed below and reference document numbers provided in Section 1.4
• Design Criteria Earthwork,
• General Civil Works Technical Specifications
• Earthwork Technical Specifications.
2.12 Mechanically Stabilized Embankment (MSE) Wall

1 Design and construction of MSE walls for Over-Bridges will be in accordance with current AASHTO
Standard Specifications for Highway Bridges.
2 Design and construction of MSE walls for Under-Bridges, Small Underpasses and Utility Protection
Structures will be as per AREMA Chapter 8 Part 7.
3 Structure dimension, internal and external stability of the MSE walls and embedment length will be
designed as per AASHTO LRFD Section 11.
4 The type and grading and soil material and all details will comply with Technical Specification -MSE walls-
C0306-S02-ECB-FS-30003 and C0306-S02-ECB-RP-00004- Design Brief- MSE Walls.
5 The factor of safety against pull-out of reinforcing elements will be 1.75 for rail supporting structures to
account for rail traffic induced vibrations.
6 On the transition between earthworks and structures, suitable measures will be taken to limit
differential settlement to 6.0mm between the structure and the earthwork.
7 Consideration will be given to the potential for accelerated corrosion or deterioration of structural
elements of MSE in a site-specific durability study. Durability of panels shall be studied in the Package 2C
Durability Report issued by the contractor. Document Reference is C0306-S02-ECB-RP-30018
8 Geosynthetic reinforcement will be of the type and size designated by an approved supplier’s material
and manufacturing specifications.
2.13 Soil investigation

1 The Contractor will carry out soil investigations to carry out foundation design, minimum one borehole
per foundations locations will be carried out.
2 The depth of the bore hole will be decided based on the anticipated foundation type and depth.
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2.14 Foundation design

Foundation design will be carried out based on the results of the soil investigation and for allowable settlement
for which the superstructure can be designed to considering functional and serviceability requirement of the
structure.
2.15 Excavation
2.15.1 General
1 The Contractor will perform all underground excavation, as well as that required in open cuts, in
accordance with this Specification or as required by the Contract.
2 Except where otherwise specified in this Section, all excavations will comply with the requirements of
the Earthworks Specification (C0306-S02-ECE-FS-30000).
3 Prior to commencing any excavation for temporary or permanent works, the Contractor will prepare and
submit appropriate designs, drawings and method statements relating to his proposed methods of
working.
4 Such methods will ensure that there is no damage to or deterioration of the final surfaces of the
excavations and ensure that surface settlement and distortion to adjacent structures are kept to
acceptable limits.
5 The Contractor will provide suitable excavation support (i.e. shoring) for deep excavations near existing
structures and seek Engineer’s approval before commencement of excavation in compliance with Clause
1.6 Temporary Works.
6 The Contractor will carry out excavation with the utmost care to minimise movement, subsidence and
damage to overlying and adjacent properties and to the Works.
7 All necessary precautions will be taken in order to prevent softening or deterioration of excavated
surfaces through exposure.
8 Excavation will be carried out in sections, limited to lengths, depths and widths as appropriate to the
ground conditions, to the equipment and the conditions and the excavation will be taken out to the lines
and levels specified with minimum over-break.
9 Where necessary to ensure the safety and security of the Works, excavation for underground Works will
be continuous by day and night, unless the Works are demonstrated to be safe and are inspected by the
Contractor at appropriate intervals.
10 Where the excavation is to be discontinued for any period of time the face must be supported in a such
manner that ground movement prevented.
2.15.2 Disposal of Excavated Materials

1 Excavated material, which is not acceptable or cannot be accommodated for use in the Works, will be
disposed of in spoil dumps or elsewhere as approved by the Engineer.
2 Excavated material, which can be used at a later stage in the Works, will be temporarily stockpiled in a
dumpsite as proposed by the Contractor and agreed by the Engineer.
2.15.3 Dewatering and Drainage

1 If the Contractor needs to undertake any dewatering in order to achieve the Works, the Contractor will
provide to the Engineer a comprehensive submission for dewatering system, designed and certified by a
registered Geotechnical Engineer.
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2 Dewatering plans will provide details on the proposed dewatering equipment, sequence of installation,
discharge control and removal, and means for compliance with all environmental, health and safety
plans and procedures and requirements of applicable Government Authorities with regard to treating
ground water extraction prior to discharge.
3 The plan will include estimated flow quantities and sediment control measures to comply with relevant
Emirate local government Authority applicable regulations.
4 In areas where high pressure aquifer is expected, installation of depressurization systems will be
considered.
5 Upon completion of the installation of depressurization system and prior to excavation, the Contractor
will carry out a multiple well pumping test from wells capable of functioning for the intended duration of
the dewatering works, to demonstrate the adequacy of the pumping system and cut-off wall.
6 The ground water drawdown within excavations will be not less than one metre below excavation level.
7 The drawdown system design will be consistent with the design of the excavation and the relevant
standards governing the design, including any requirement to limit ground settlement surrounding the
proposed excavation.
8 For all dewatering methods used, the design and construction of both the Temporary and Permanent
Works will include for adequate groundwater cut-offs in order to control any change in groundwater
table in the ground surrounding the dewatered area from the typical expected fluctuations, to within
acceptable limits.
9 In the absence of any specific design criteria, and where control of groundwater drawdown is required,
then the drawdown of the water outside the cut-off wall will be limited to 2m below the lowest
recorded groundwater level prior to commencement of the dewatering.
10 The Contractor will keep all underground areas substantially free from water by providing drains,
ditches, pipes, pumps, sumps, etc. to drain water away.
11 The Contractor will provide necessary dewatering system that shall have the necessary capacity and
backup. The level of backup shall be specified by the Contractor in his method statement, for Engineer
approval.
12 The Contractor will submit to the Engineer details of his proposals for dealing with water from any
source prior to commencing underground work.
13 Where removal of groundwater by pumping is required then the Contractor will provide, install, operate
and maintain all necessary pumps, piping and other equipment required, including sufficient numbers of
standby pumps and generators to serve during periods of breakdown or maintenance.
14 Where water bearing seams, fissures or broken ground is yielding undesirably large quantities of water,
the Contractor will grout such seams, fissures or broken ground to stem the same.
15 The Contractor will provide devices for measuring the quantities of water removed from underground
excavations, by pumping or by gravity as the case may be, as per environmental requirements.
16 The Contractor will treat the discharge water to comply with environmental standards and remove any
suspended particles and/or other contaminants before discharge.
17 This may include providing settlement tanks before discharge to a sewer/storm drain or a water
treatment facility.
18 The dewatering contractor shall keep the site free from flood water.
19 JV should refer to the Etihad Rail Approved EIA report- X0231-S02-EWA-RP-00004& 00005-AA
20 Prior to start of any dewatering works on the project site, the dewatering contractor shall confirm:
• The location of all underground services and structures (e.g. excavating trial pits, and arrange work to
prevent damage to any services or structures);
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• The detailed design of the dewatering system including proposed equipment, number of wells, and
Anticipated flow rates along with his proposed installation and testing procedures are suitable to
ensure proper functioning of the dewatering system in the ground conditions indicated by the results
of the geotechnical and hydrogeological investigations.
• A site specific calculation is to be conducted during construction
• The final dewatering design shall include as a minimum a detailed assessment of available ground
investigation and pumping test reports, discharge and drawdown calculations for the different
construction stages with a numerical groundwater flow model, evaluation of required number of wells
(including sufficient contingency), well layout, well design, well depths, monitoring system and type
of dewatering system and discharge points
2.15.4 Backfill
1 Backfill material general specifications will be in accordance with Earthwork Technical Specifications
C0306-S02-ECE-FS-30000.
2 The Contractor will submit for Approval his proposals for ensuring that all voids between any of his
Temporary works left in position and any structures are completely filled with Approved material.
3 These proposals will also include measures for ensuring that all voids are completely filled during the
removal of Temporary Works.
2.16 Ground Movement and Monitoring

2.16.1 General
1 As part of his design the Contractor will liaise with the owners or stakeholders of the structures that are
affected by the Works to determine the acceptable movements, settlements, distortions or vibrations,
and to agree upon suitable monitoring for the duration of the Works.
2 Such monitoring may include manual monitoring, regular acquisition of data from data loggers or real-
time data collection from remote monitoring systems as required.
3 The Contractor will propose and carry out ground and structure monitoring for all the Works which are
affected or affecting either public or private structures including, but not limited to, buildings, bridges,
railway, roads, footpaths, slopes, utilities and pipelines, as required.
4 The Contractor will be responsible for the design, supply, installation, protection, operation, repair and
replacement of the required instrumentation.
5 The Contractor will submit any such monitoring plans and plans of action for approval and obtain
approval from the relevant owners, stakeholders or Approving Authorities prior to commencement of
the Works.
6 The Contractor will prepare a Generalised Plan of Action to determine the general Response Actions to
be taken by the Contractor in the case of Response Levels being reached for each instrument type and
certain groups of instruments and key locations, for approval by the Engineer.
7 The Generalised Plan of Action will include emergency Response Actions to be taken by the Contractor in
case of an Alarm Level being reached.
8 The Contractor will prepare a Detailed Plan of Action, based on the submitted Generalised Plan of
Action, and specific to a particular location as a result of Response Levels having been reached or
imminently to be reached for a particular instrument or group of instruments.
9 Response Actions will comprise active and passive measures by the Contractor to be taken when
Response Levels are reached.
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10 Response Levels will include Alert, Action and Alarm Levels, and these will be defined by the Contractor
and are to be implemented as part of the instrumentation and monitoring Works.
11 Ground and structure monitoring will be established a minimum of 2 months prior to commencement of
any ground excavation, ground treatment or dewatering.
12 The Contractor will collect and interpret the instrumentation data, evaluate whether the response to
construction activities is reasonable, and carry out the Response Actions.
13 The frequency of the monitoring readings will be agreed with the Engineer, and monitoring records and
data will be made accessible to the Engineer as required.
14 The Contractor will inform the Engineer within 24 hours should an instrument reading reach an Alert
Level.
15 The Engineer may instruct the Contractor to submit a Detailed Plan of Action before an Action Level
status is reached.
16 The Detailed Plan of Action will include actions to be implemented for reaching the Alert Level and
Action Level.
17 The Contractor will implement the Response Actions identified in the Detailed Plan of Action for
reaching Alert Level.
18 Where in the opinion of the Engineer instrument reading trends indicate that an Action Level may also
be reached, then the Contractor will implement the Response Actions for reaching Action Level.
19 Should any instrument readings reach an Action Level then the Contractor will implement the Response
Actions for reaching the Action Level.
20 These actions will limit further excavation-induced movements and changes in groundwater and
piezometric levels, and control vibrations, to maintain the structural integrity of adjacent structures /
buildings and utilities.
21 The Contractor will take all necessary steps so that the Alarm Level is not reached. Work may then only
proceed if the Response Actions have been implemented and are in the opinion of the Engineer shown
to be effective.
22 The Contractor will make appropriate amendments to the Detailed Plan of Action where necessary.
23 Should any instrument readings reach an Alarm Level then the Contractor will implement emergency
Response Actions to diminish the deformations and ground responses including suspension of works.
24 The Contractor will submit a complete report for review of the construction methods, full history of
movements and Response Actions to be taken related to construction sequence for the Engineer
Approval.
25 Work may only resume upon the written instruction of the Engineer.
26 Data collected in the field by the Contractor will be stored in the “Instrumentation Database” developed
and maintained by the Contractor throughout the duration of the Contract.
27 The Contractor will be responsible for the daily entry of instrumentation data into the Instrumentation
Database.
28 The Contractor will make the Instrumentation Database accessible to the Engineer, the Engineer’s staff
and third parties as authorized by the Engineer.
29 During the course of the Works, the Contractor will submit instrumentation and monitoring
interpretative reports to the Engineer on a weekly or monthly basis as required.
30 Monitoring locations will be discussed with the local authorities and the JV will submit method
statements for the monitoring where required. Within the ER contract there are not specific locations
where instrumentation and monitoring are required. The impact assessment and monitoring plan would
be submitted to the authority for review and approval during the NOC application process.
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2.17 Precondition Surveys

1 The Contractor will employ a suitably qualified surveyor with sufficient engineering qualifications and
experience to identify any potentially significant site features that may affect the performance, stability,
integrity of existing and proposed structures.
2 The Contractor will, in the presence of witness by the Engineer or their representative, perform a visual
and photographic survey and record the pre-reconstruction condition of all buildings or other significant
structures, bridges, utilities, pipelines, highways, footpaths within the zone of influence of the Works.
3 The Contractor will define the condition including any pre-existing damage, if any, that may be a basis
for discussion of future claims for damage, if any, that may be caused to existing structures as a direct
result of the Works.
4 The Contractor will fill in a survey form for each structure and take detail photographs including of any
recorded deficiency.
5 Contractor will provide coordinates of the structures in the survey reports.
6 Photographs will be of sufficient resolution to clearly show details of any surveyed areas, sufficient to
serve as a definitive record of the condition of the structure and to allow comparison after completion of
the Works.
7 The survey forms, photographs, including digital image files or negatives, with additional notes and
sketches as may be appropriate, will be neatly bound into a report for submission to and approval by the
Engineer, prior to commencement of the Works.
8 The Engineer may request, that additional survey information be undertaken during the construction
phase or subsequent to the completion of construction as required.
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3 Concrete Pile Foundations

3.1 General
1 The Works under this section will be designed and constructed according to the provisions of the
Contract and of these Specifications; and as shown on the design and shop drawings prepared by the
Contractor.
2 For concrete and reinforcement Specifications see Structural Concrete and Reinforcing Steel sections of
this document. Section 4 and 5
3 Site will be reinstated to original conditions after construction operations.
4 The Contractor will verify ground conditions for all piling locations.
5 Concrete Mix Designs are covered in the 2C Durability Report issued by the contractor under document
reference C0306-S02-ECB-RP-30018
6 Piles shall not be bored so close to other piles which have recently been cast and which contain
workable or unset concrete that a flow of concrete could be induced from or damaged cause to any of
the piles.
3.2 Piling Design

1 The Contractor will engage a Design Consultant registered in the United Arab Emirates to design the
foundations for each structure and its piled foundations.
2 The Contractor will determine suitable support arrangements for the pile bore for each pile location and
will verify the effectiveness of the same prior to placing reinforcement or concrete in the bore.
3 In areas where soil conditions are poor and pile boring may cause soil collapse, the Contractor will use
temporary casing to support the excavation.
3.3 Pile Construction Records

1 The Contractor will maintain and make available with all records of borings, materials and testing for the
construction of each pile.
2 The records for each pile will be uniquely identified and cross-referenced on the piling record drawings.
3 Pile will be installed in following maximum permitted tolerances:
– Position: 75 mm in any direction at commencing level.
– Verticality: 1 in 75 deviation from the vertical
– Rake: 1 in 25 deviation from the specified rake for piles raking up to 1:5
4 No method of forcible correction will be permitted unless it can be proved that the integrity, durability
and performance of the piles will not be adversely affected.
3.4 Placing Concrete under Water or Support Fluid

1 Concrete placed under water or support fluid will be by means of a tremie in such a manner that
segregation does not occur and concrete will not be discharged freely into the water or drilling fluid.
2 Before concreting commences, any accumulation of silt or other material at the base of the pile or
boring will be removed by the Contractor.
3 The frequency of testing support fluid and method and procedure of sampling will be proposed by the
Contractor to suit his method of construction.
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4 Control tests for density will be carried out daily on the support fluid using suitable apparatus.
5 The measuring device will be calibrated to read within 0.01 g/ml.
6 For average solid conditions the results will generally be within the ranges stated in Table 1 below.
Table 1: Requirements for Support Fluids (Bentonite)
Property to be Measured Range of Results @ 20oC Test method From the American
Petroleum institute (API) Publication
RP13B
Density Less than 1.10 g/ml Mud Density Balance
Fluid Loss Less than 40ml 30-minute test
Viscosity 30-90 seconds or less than 20 cP Marsh Cone method or Fann
Viscometer
Shear Strength (10-minute gel 1.4 – 10 N/m2 or 4 – 40 N/m2 Shearometer or Fann Viscometer
strength)
Sand Content Less than 5% Screen

pH To the levels expected in the most PH indicator paper strips Or Electrical
aggressive areas of the Middle East pH meter
Note: Where the Fann Viscometer is used, the fluid sample will be screened by a 300-micron sieve before testing.
7 The tremie pipe will extend to the base of the boring and a sliding plug will be placed in the boring to
prevent direct contact between the first charge of concrete in the tremie pipe and the water or drilling
fluid.
8 At all times during concreting, the tremie pipe will penetrate the previously placed concrete and will not
be withdrawn from the concrete until completion of concreting.
9 Sufficient quantity of concrete within the pipe will be maintained at all times to ensure that the pressure
from it exceeds that from the water or drilling fluid.
3.5 Finishing Pile Heads

1 The top of the pile will be brought above the required cut-off level of the pile head by an amount
sufficient to ensure a sound pile of uncontaminated concrete at the cut-off finished level.
2 When trimming the pile to the specified cut-off level, the Contractor will take care to avoid shattering or
otherwise damaging the rest of the pile or damaging the reinforcement.
3 The reinforcement will be exposed for a sufficient distance to permit it to be adequately bonded to the
structure.
3.6 Pile Testing

1 Pile load testing will be carried out to confirm the design assumptions. A method statement for all
proposed pile load testing will be submitted by the Contractor, a minimum of four weeks prior to piling
commencement date, for the acceptance of the Engineer.
2 A minimum of one working pile at each bridge location will be tested by Maintain Compression Load Test
(MLT) to 150% of the design working load. Additional tests may be required by Local Authorities at
bridges that carry roadway traffic.
3 For structures, other than bridges, one working load test pile loaded to 150% of the design working load
will be required per site.
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4 Where a number of structures are in proximity to each other they may be considered as one site if the
geotechnical data provided by the Contractor for each structure location is proved to be equivalent to
the satisfaction of the Engineer.
5 The Contractor will construct at least one trial pile (which is not a Contractor works pile) which will be
tested by Maintained Compression Load Test (MLT) to 200% of the design working load at each bridge
site and the MLT results will be submitted for the acceptance of the Engineer prior to construction of
permanent piles.
6 The Trial pile will not be incorporated into or made part of the Permanent Works.
7 In case of soil inconsistency, additional non-working pile test will be done as directed by the Engineer.
8 Calliper logging for entire pile bore for piles diameter more than 1000mm will be carried out before
concreting according to ASTM D 6167-97.
9 Test piles (≥ 1000 mm in diameter) will be installed with displacement transducers at the pile head.
10 Dial gauges will not be used on these piles without the prior acceptance of the Engineer.
11 Three displacement transducers will be fixed, spaced at 120° part.
12 Piles will be instrumented with strain gauges and Each pile is to be instrumented with four levels of
strain gauges.
13 First level will be near the pile head and last near the pile toe to assess the load transferred to the pile
toe.
14 Each of these levels will have four strain gauges spaced at 90° apart.
15 Strain gauges will be accurate to within a tolerance of 1µ strain
16 Pile instrument is required only for non-working piles test.
3.7 Maintained Compression Load Testing of Piles

1 For any period when the load is constant during the testing, time and movement will be recorded
immediately on reaching the load and at 15 minute intervals for 1 hour, 30 minute intervals between 1
hour and 4 hours; and at 1 hour intervals between 4 hours and 48 hours after the application of the
increment of load.
2 The movement of the pile under the full test load of the pile after its subsequent removal will be within
the limits defined by detailed designer and approved by the Engineer. Except when approved by the
Engineer otherwise, the following values in Table 2 will be adhere to:
Table 2: Acceptable Movement of Verticality Loaded Pile
Movement under Working Load Movement under 150% of Working Load Movement under 200%
Working Load
10mm 15mm 20mm
3 The residual set of any working load test pile measured 24 hours after removal of the load will not
exceed the differential settlement used in design or 6mm, whichever is the lesser.
4 Testing will be in compliance with BS8004.
3.8 Integrity Testing of Piles

1 Integrity testing will be required for all piles. The testing will not be commenced until a minimum of 7
days after concreting.
2 The method of integrity testing will be Cross-hole Sonic Logging Method for all working piles and non-
working piles with a minimum of four sonic tubes for each pile.
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3 Testing will be carried out by a specialist firm competent in the interpretation of test data.
4 The Contractor will give all available details of the ground conditions, pile dimensions and construction
method to the specialist firm before the commencement of integrity testing in order to facilitate
interpretation of the tests.
5 The test results and findings will be recorded and made available within 7 days of the completion of each
phase of testing.
6 The report will contain a summary of the method of interpretation including all assumptions,
calibrations, corrections, algorithms and derivations used in the analyses.
7 If the results are presented in graphical form, the same scales will be used consistently throughout the
report.
8 The units on all scales will be clearly marked and uniquely referenced for each pile and cross- referenced
on the record drawings.
9 In the event that any anomaly is found in the results indicating a possible defect in the pile the
Contractor will demonstrate that the pile is satisfactory for its intended use or will carry out remedial
works which may include pile replacement or downgrading, (in addition to remedial work); in all cases,
the Contractor will seek acceptance from the Engineer.
3.9 Rectification of Failure of MLT Pile

1 In the event of a pile failing a load test, notwithstanding any contrary proposals by the Contractor, the
Engineer may insist on the following methods of rectification (as a minimum):
a) When a trial pile fail - an additional trial pile will be bored as directed by the Engineer and tested. If
this second trial pile fails, the Engineer will order such changes in the design of the pile as he considers
necessary.
b) When part of the main piling operation fail - a further pile in the same group will be tested. If this
second test pile fails, the Engineer will order such changes in the design of the pile/pile group as he
considers necessary.
c) In the case of the first pile of the main piling operation failing a test load, but subsequent piles passing
the load test, a new pile will be driven to replace the defective pile in a position agreed by the Engineer
at the expense of the Contractor. SRS 109.
2 In the event of additional works being carried out as a result of new piles being required under this
Clause, the cost of this additional work will be at the expense of the Contractor.
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4 Structural Concrete – Rail and Civil

Structures
4.1 General
1 The Works under this section will be done according to the provisions of the Contract and of these
Specifications; and as shown on the design and shop drawings prepared by the Contractor.
2 The Contractor will propose the mix designs and concrete quality to provide the required design life for
each structure as provided in Design Criteria document C306-S02-ECB-FS-0001
3 Where no other design life is specified a value of 100 years will be deemed to be required.
4 The Contractor has produced detailed durability study for concrete specific to the environmental
conditions encountered on site to demonstrate the suitability of concrete mix, covers to reinforcement,
curing methodologies, waterproofing and/or coating and the like proposed in the detail design to
achieve the required design life. Refer to report C0306-S02-ECB-RP-30018
5 No concrete will be placed in any part of the Works prior to the acceptance by the Engineer of both the
durability study report and of all required test results proving conformance of the concrete trial mixes
with the durability report’s recommendations.
6 Concrete Mix Designs are covered in the 2C Durability Report issued by the contractor under document
reference C0306-S02-ECB-RP-30018
4.2 Concrete
4.2.1 Cementitious Materials
1 Each type of cementitious material will be obtained from a primary single source acceptable to and
approved by the Engineer in good time before ordering or confirming any order.
2 Secondary sources for cementitious materials proposed by the Contractor will be accepted as contingent
and be subject to the Engineer’s approval.
3 Acceptance of materials and sources does not relieve the Contractor of the responsibility to produce
concrete that meets all of the specified requirements.
4 The Contractor’s proposal will include test certificates along with the information requested herein.
4.2.2 Cement
1 Portland cement will comply with quality control and test requirements of BS EN 196 and BS EN 197.
2 CEM 1 will comply with the supplementary mineral material properties as described in Table 3
Table 3: Additional Mineral Material Properties for CEM | Cement
Material Property Acceptance Value Frequency of Testing
Heat of Hydration ≤ 300 KJ/kg at 7 days Once A month
Fineness (Blain) -BS EN 196: Part ≥ 280 m2/kg Once A month

6:2010 ≤ 375 m2/kg
Na2O+0.658 K2O ≤ 2.5% Each delivery
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4.2.3 Silica Fume (Microsilica)

1 Silica Fume will be assessed according to ASTM C1249-93 with modifications given in Table 4.
Table 4: Additional Mineral Material Properties for Microsilica
Material Property Limiting Value
Moisture ≤ 3.0%
Loss on Ignition ≤ 6.0%
SiO2 ≥ 85.0%
Cl ≤ 0.01%
Available as Na2O ≤ 1.5%
Particle Larger than 45 µm ≤ 10.0%
2 The method of incorporation of the silica fume into the mix will be subject to the approval of the
Engineer.
3 The Contractor will submit a method statement describing the plant and equipment proposed for
batching and mixing and the timing of addition of the silica fume to the mix.
4 The method statement will be supported by a letter from the silica fume supplier approving the
methodology.
4.2.4 Ground Granulated Blast Furnace Slag

Ground granulated blast furnace slag will comply with quality control and test requirements of BS EN 15167.
4.2.5 Fly Ash

1 Fly ash will comply with quality control and test requirements of ASTM C618.
2 The use of Fly Ash will not exceed 25% of total cementations content in structural members.
4.2.6 Water
Water used in concrete and curing will comply with quality control and testing requirements of BS EN 1008.
4.2.7 Certificate of Tests and Analyses

1 Before any type of cementitious materials is incorporated into the Works, the Contractor will submit full
details of tests and analyses including chemical variations and typical results to the Engineer for his
acceptance in writing.
2 In addition, each consignment of cement will be accompanied by a certificate in English from the
manufacturer showing that the cement offered has been tested and analysed, the date and a tabulation
of the results alongside the limiting property specified.
3 Two copies of each certificate will be sent by the manufacturer direct to the Engineer on site in advance
of the delivery to site of the consignment to which the certificate relates.
4 Each consignment will be given a distinctive mark by the manufacturer and details of this mark will be
recorded on the relevant test certificates.
5 Auto control methods of testing cement manufactured on a continuous basis may be acceptable as an
alternative if approved by the Engineer.
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6 Cementitious material which has been manufactured for longer than 6 months on the proposed date of
delivery to the site will be inspected, sampled and tested for compliance as delivered by an accepted
independent laboratory.
7 No cementitious materials to be incorporated into any works on site will contain lumps.
4.2.8 Tests after Delivery

Each consignment of cement may after delivery on Site and at the discretion of the Engineer be subjected to
the whole of the tests and analyses required by the relevant Standard and by this Specification and/or such
other tests as the Engineer may deem necessary.
4.2.9 Rejection of Cement

Any cement found to be unsatisfactory on account of test results or any other fault will be rejected and will
be removed from the Site without delay.
4.3 Aggregates
4.3.1 General
1 Aggregate will be from sources approved by the Engineer.
2 Aggregate will not be composed of or contain any inclusions of materials likely to cause staining or
otherwise to disfigure finished concrete surfaces.
3 Fine and coarse aggregates for all types of concrete will comply in all respects with the requirements of
BS EN 12620, BS 882 of 1992, ASTM C33.
4 Maximum size of aggregates will not exceed 20mm.
5 Any aggregates which do not comply in respect of cleanliness will be mechanically washed in clean, fresh
water complying with Clause 2.4 to remove clay, silt, salts and any adherent coatings and other
impurities in order to comply.
4.3.2 Grading
1 Grading of fine aggregates will generally fall within Zone M only of Table 4 of BS 882 except that other
grading may be used where tests and trials on concrete verify its suitability.
2 Coarse aggregates will be prepared as single sized aggregates and blended to produce a graded
aggregate complying with BS EN 882 for the nominal aggregate size indicated on the Drawings.
4.3.3 Sources of Aggregates

1 For a source of aggregate supply to be acceptable, the Contractor will give details of the precise location
by name and grid references, the precise location and depth of test samples taken, a description of the
representability of all samples to areas for which acceptance is being sought, and an assurance that the
source has sufficient reserves of aggregate of the required grading and of the same quality as the test
sample for the carrying out of the Works.
2 The Contractor will arrange for each grade of aggregate offered to be subject to the tests set out in
Table 5 as appropriate.
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Table 5: Tests on Aggregates for Acceptance
Serial No Test Test Method Limits
1. Description and Classification BS 812 Equivalent to Petrographic Examination
2. Visual examination of fine and BS 812 Fine aggregates to be free from all organic matter
coarse aggregates (standard colour or lighter). Equivalent to test for Organic
Impurities in fine aggregates
3. Petrographic Examination ASTM C295 Report to be obtained from supplier
4. Particle Size Distribution by sieve BS 812 Fine aggregate BS 882

analysis Coarse aggregate shall be prepared as single sized
aggregate and blended to produce normal size grading.
The combined grading shall be within the appropriate
grading limits given in BS 882.
5. Clay, fine silt and fine dust ASTM C117 3.0% max for natural sands (Uncrushed rock)
(material finer than BS 0.075 5.0% max for crushed stone sands for Fine aggregates
sieve)
1.0% max for coarse aggregates
6. Clay Lumps ASTM C142 Not more than 1% by weight
7. Flakiness Index BS 812 25% max for all coarse aggregate test fractions
8. Elongation Index BS 812 25% max for all coarse aggregate test fractions
9. Angularity Number BS 812 0 to 11 for coarse aggregates

Not required for fine aggregates
10. Specific Gravity of coarse and BS 812 Minimum SSD 2.65 for Coarse Aggregate (CA) Minimum
fine aggregates SSD of 2.55 for Fine Aggregate (FA).
11. Water Absorption of coarse and BS 812 2.0% Max for Coarse aggregate and Fine aggregate
fine aggregates
12. Bulk Density BS 812 Same as Specific Gravity (Test no 10 above)
13. Organic Impurities in fine ASTMC40 Fine aggregates to be free from all organic matter
aggregate (standard colour or lighter)
14. Aggregate Crushing Value BS 812 23% max for Standard test
15. “Ten per cent Fines” Value BS 812 Not less than 100kN
16. Aggregate Impact Value BS 812 25% max for Standard test fraction
17. Abrasion Resistance

i) for small coarse ASTM C131 25%
aggregate by the Los
Angeles Machine
ii) for large size coarse

aggregate by the Los ASTM C535 25%
Angeles Machine
18. BS EN 1744- Coarse more than 10mm: Max: 0.4%
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Serial No Test Test Method Limits

Total acid soluble Sulphate 1:1998 Between 10mm and 5mm: Max: 0.4%
Content (as SO3)
19. Total Chloride (Cl) BS 812 Part 118 0.03% max in coarse aggregates by weight 0.06% max in
fine aggregates by weight
20. Voided Shell Content BS 812 Part 106 3% max in material retained on a BS 2.36mm sieve
21. Cement– Aggregate Reactivity ASTM C277 Aggregates may initially be assessed for its reactivity in
ASTM C289 accordance with ASTM C289 and if potential reactivity is
ASTM C342 indicated, then mortar bar tests in accordance with ASTM
ASTM C586 C227 shall be carried out. Cement-Aggregate
Combination ASTM C227: Limits :6 month expansion
0.10% max.
22. Soundness (5 cycles Mg SO4) ASTM C88 Fine aggregate 12%

Coarse aggregate 12%
3 The laboratory will be a suitable independent laboratory in respect of both availability of facilities and
competence of personnel.
4 The Engineer may require witnessing the sampling and the tests.
5 Part of each sample submitted for source acceptance will be used for concrete trial mixes and part will
be retained as a reference sample for comparison with subsequent deliveries.
6 Subject to the results of the testing being satisfactory, the Engineer will require trial concrete mixes to
be made and tested, all as specified herein, prior to acceptance of a particular source of aggregate.
4.3.4 Testing of Aggregates

1 Subject to the results of the testing being satisfactory, the Engineer will require trial concrete mixes to
be made and tested, all as specified herein, prior to acceptance of a particular source of aggregate.
2 During the course of the Works, the Contractor will provide from time to time and as required by the
Engineer from each source of aggregate approved for incorporation in the Works a certificate stating
that the aggregates consistently conform to the requirements of this Specification and will forward such
certificates to the Engineer for his retention.
3 The Engineer will have the right to require the Contractor at any time to draw samples of aggregates
from stockpiles on the Site or any other locations to be indicated by the Engineer.
4 Samples of aggregate are to be drawn in accordance with BS 812 as directed and tested in a laboratory
approved by the Engineer in accordance with the appropriate clauses of the aforementioned Standards.
5 Unless otherwise instructed by the Engineer, the aggregates in use will be regularly tested in an
independent laboratory at a frequency shown in Table 6.
Table 6: Frequency of Routine Tests on Aggregates
Serial No Property Test Method Test Frequency Rate
1. Grading BS 812 Part 103 Each 2 weeks or per 100m³ whichever is more
frequent
2. Material finer than BS 812 Part 103 Each 2 weeks or per 100m³ whichever is more
0.075 mm frequent³
3. Clay lumps and ASTM C142 Each 2 weeks or per 100m³ whichever is more
Friable Particles frequent³
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Serial No Property Test Method Test Frequency Rate
4. Lightweight pieces C123 More frequent of monthly or per 200m3
5. Organic impurities BS 1377, ASTM C40 More frequent of monthly or per 200m3
6. Water absorption ASTM C128/C127 Twice weekly
7. Specific gravity ASTM C128/C127 Twice weekly
8. Shell content BS 812 Part 106 Each 2 months or per 100 m3 whichever is more
frequent.
9. Particle shape BS 812 Part 105.1 Each 2 months or per 100 m3 whichever is more
frequent.
10 Acid soluble chlorides, BS 812 Part 117 on each delivery of aggregate

Cl (1): Qualitative Appendices A/B
Each 6 concrete days if result is the limit and each
Quantitative BS 812 Part 117 month if result is less than 75% of the limit
Appendix C
11. Acid soluble sulphates BS 812 Part Each 12 concrete days if result is more than 75% of the limit
S03 118 snd each 2 months if result is less than 75% of the limit
12. Soundness, MgS04 (5 ASTM C88 Each 48 concrete days

cycles)
13. Mechanical strength [BS EN 1097-

2] Each 72 concrete days
10% Fines or impact BS 812 Parts
value Los Angeles 111, 112
abrasion
ASTM C 131/C 535
14. Drying shrinkage(2) [BS EN 1367-4] At the start of the project and whenever there is a
BS812 Part 120 change in the source of supply
15 Potential reactivity of ASTM C295, C289 At the start of the project of aggregates and wherever
aggregates(2): there is a change in the source of supply
of carbonate ASTM C586 C227, C1260

of cement/aggregate
combination
16. Moisture variation by In accordance with the Specification but not less than
moisture meters t w i c e daily
6 Where the chloride content is variable, it may be necessary to test every load using the rapid field test
(Quantab test): in the event of disagreement regarding the results of the field test, laboratory testing
(Volhard test) in accordance with BS196 or BS812 as appropriate will be used to determine chloride
content.
7 Drying shrinkage and potential reactivity of aggregates will be determined initially at the start of the
project and then whenever there has been a change of source or whenever there has been a change of
quality of the aggregates.
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4.3.5 Alkali-Silica Reactivity

1 The Contractor will satisfy the Engineer at all times that the aggregate or aggregates he proposes to use
for concrete do not possess potential alkali aggregate reactivity properties when in contact with alkali
ions from any source.
2 The required analyses and tests will be carried out in an independent laboratory that has been approved
by the Engineer.
3 Aggregates to be used in mixes will be subjected to Petrographic analyses in accordance with ASTM C295
and subsequently tested by the Chemical Method set out in ASTM C289 or by the gel pat test as
described in National Building Studies, Research Paper No. 25 (NBSR 25) published by Her Majesty’s
Stationery Office, London. Aggregates may initially be assessed for its reactivity in accordance with ASTM
C289 and if potential reactivity is indicated, then mortar bar tests in accordance with ASTM C227 shall be
carried out. Of Cement-Aggregate Combination ASTM C227: Limits :6 month expansion 0.10% max.
4 The gel pat test will be used for those aggregates for which the Chemical Method is not suitable as
determined by the Petrographic analyses.
5 If, after 28 days storage in alkali, no reactivity is apparent on the surface of the gel pats, the aggregate
will provisionally be acceptable for use in the Works until the results of mortar bar tests and
Petrographic analyses are known and final acceptance or rejection is given.
6 Alternatively, aggregate considered “innocuous” after testing in accordance with ASTM C289 will
similarly be provisionally accepted.
7 Aggregate which is provisionally acceptable after testing using the gel pat tests will, in addition, be
tested by the Mortar bar method for 6 mortar bars in accordance with ASTM C227.
8 Aggregate will be acceptable if the average expansion of the six mortar bars does not exceed 0.10% after
6 months storage in accordance with ASTM C227.
9 Use of tested aggregates may be permitted after 3 months storage of mortar bars if the independent
laboratory certifies that the expansion at 6 months is unlikely to exceed the specified 0.10% but this will
be confirmed by measurements on mortar bars after storage for 6 months.
10 The Engineer may at any time require repetition of tests to confirm that the aggregates do not possess
potential alkali reactivity properties.
4.3.6 Rejection of Aggregates

1 No aggregate will be used for concrete in the Works without complete test results compliant with the
Specification are available for the source of supply, the chemical and physical properties and the trial mix
results.
2 All non-compliant aggregates will be removed from the Site without delay.
4.4 Admixtures
4.4.1 General
1 The use of admixtures will be proposed by the Contractor as part of his design of the concrete mix and
will comply with the requirements of BSEN934 or ASTM C494.
2 The proposed admixtures will be certified by the supplier as compatible with all of the requirements of
the Specification and free from any chemicals detrimentally reactive with any constituent of the
concrete or the embedded reinforcement.
3 The addition of calcium chloride, accelerators and air-reducing agents, will not be permitted, unless
otherwise accepted by the Engineer.
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4 Concretes incorporating Silica Fume will incorporate a super plasticising admixture specially formulated
to aid dispersion of the silica fume throughout the mix.
5 The admixture will be certified as suitable for the intended purpose by the concrete mix designer and
details of the proposed admixture will be submitted to the Engineer for approval.
6 No consignment of admixture will be delivered to site, except for pre-production testing of concrete
mixes, until all test results are proved satisfactory.
4.4.2 Dosing
1 Admixtures will be introduced into the mix by means of acceptable automatic dosing equipment that
feeds a fixed quantity of admixture into the mixer at the same time as water is added to the mix or in
accordance with the manufacturer’s recommendations.
2 This equipment will be maintained daily and a measuring cylinder suitable for checking the calibration
will always be available.
3 The Contractor will ensure that his batch plant has an accessible outlet pipe to enable these calibration
tests to be carried out.
4 All chemical admixtures will be introduced to the concrete mix in liquid form and if made up into that
form by the Contractor, they will be subject to satisfactory testing by the Engineer prior to use.
5 The dispensing device will:
a) Be capable of delivering the specified amount to within + 3% of the quantity of admixture in each
batch.
b) Have provision for dispensing the admixture directly into a container so that accuracy can be checked.
The equipment will include a glass-measuring cylinder for calibration.
c) Have a sight glass to allow a visual check on the type and quantity of admixture being dispensed.
d) Have an effective anti-foaming device if admixtures used are subject to foaming.
4.4.3 Submittals for Admixtures

Both the amount of admixture to be added and the method of use require the approval of the Engineer.
4.4.4 Dosing
1 Admixtures will be introduced into the mix by means of acceptable automatic dosing equipment that
feeds a fixed quantity of admixture into the mixer at the same time as water is added to the mix or in
accordance with the manufacturer’s recommendations.
2 This equipment will be maintained daily and a measuring cylinder suitable for checking the calibration
will always be available.
3 The Contractor will ensure that his batch plant has an accessible outlet pipe to enable these calibration
tests to be carried out.
4 All chemical admixtures will be introduced to the concrete mix in liquid form and if made up into that
form by the Contractor, they will be subject to satisfactory testing by the Engineer prior to use.
5 The dispensing device will:
a) Be capable of delivering the specified amount to within + 3% of the quantity of admixture in each
batch.
b) Have provision for dispensing the admixture directly into a container so that accuracy can be checked.
The equipment will include a glass-measuring cylinder for calibration.
c) Have a sight glass to allow a visual check on the type and quantity of admixture being dispensed.
d) Have an effective anti-foaming device if admixtures used are subject to foaming.
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4.4.5 Submittals for Admixtures

1 Both the amount of admixture to be added and the method of use require the approval of the Engineer.
2 The Contractor will provide sufficient technical information to demonstrate that the usage of the
proposed admixture will result in the production of concrete that satisfies the requirements of the
Specification.
3 Consent or rejection of admixtures by the Engineer will be on the basis of the results of trial mixes
together with the technical information received.
4 No consignment will be delivered to site until the Engineer has given consent.
5 No amendment to the proposed admixtures or the proposed dosages will be made by the Contractor
subsequent to the approval by the Engineer of a mix design without the further approval of the Engineer
based upon a re-submission by the Contractor of the admixture data and certification.
6 Such further approval by the Engineer may be withheld subject to completion of trial mixes confirming
that the proposed admixtures or their proportions produce a concrete compliant with the Specifications.
7 Such trial mixes will be undertaken by the Contractor if required by the Engineer at no cost to the
Engineer and any delay associated with such trial mixes will not be grounds for any claim by the
Contractor.
4.4.6 Fibres
1 If fibres are to be added to the concrete mixture the products will be supported by a British Board of
Agreement Certificate or other accepted independent certification to confirm product characteristics
and successful project history.
2 Fibres will be composed of virgin polypropylene and will be either monofilament or fibrillated provided
that the selected fibres do not adversely affect the capillary absorption properties of the mixture (i.e.
their use does not increase the capillary index (Ic) above the value obtained from the control mixture).
3 Optimal fibre dosage in terms of effect upon workability, strength, and capillary properties will be
determined by making comparative tests of companion specimens from the proposed mixture, both
with and without fibres, to be submitted to the Engineer prior to mixture verification.
4 Strength tests on standard laboratory specimens of fibre concrete will be in full compliance with the
strength requirements of this specification.
5 Consistency (Slump) tests of fibre concrete will be at least 75mm, and the concrete will be highly mobile
when vibration is introduced.
6 The capillary Index (Ic) determined from capillary suction tests of fibre concrete carried out on three
tests specimen from three individual field cured cube specimen (either 100 or 150mm size) at 7 days of
age (normal wet curing period).
4.5 Concrete Mixtures

4.5.1 General
1 Unless noted otherwise elsewhere in the Technical Specifications or on the Drawings, cement for the
Permanent Works will be a combination of Ordinary Portland Cement (OPC) CEM I including as necessary
ground granulated blast furnace slag (GGBS) and/or silica fume (SF) to meet the requirements of the
Specifications.
2 Where GGBS forms part of the combination and the alumina content of the slag exceed 14% then the tri-
calcium aluminate (C3A) content of the Portland cement fraction will not exceed 10%.
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3 The Contractor may propose methods to mix ordinary Portland cement and ground granulated blast
furnace slag in the mixer as an alternative method to supply of a cement formed by crushing cement
clinker and GGBS together in manufacturing plant conditions.
4 This alternative method will be used only if the proposed combination is produced in controlled
conditions in accordance with BS 8500-1 and is fully compliant in all its properties with a plant prepared
combination.
5 The Contractor will be responsible for the design of the concrete mix conforming with the performance
requirements set out in the design and the durability report C0306-S02-ECB-RP-30018 and for
demonstrating that the proposed mix meets all of the performance requirements.
6 The mix designs will take account of the requirements for concrete durability: as a minimum, reinforced
concrete will be considered to be subject to severe or very severe exposure conditions.
7 Before placing any concrete in the Permanent Works the Contractor will obtain the acceptance of the
Engineer for his designed mix.
8 The target design mean strength of each concrete mix will be 1.64 times the standard deviation of test
results for that mix which will be taken as not less than 3.5MPa where insufficient test results are
available to determine a statistically relevant standard deviation for the mix.
9 The Contractor will advise the Engineer of the qualified Ready Mix Concrete Supplier that he is proposing
to use at least 45 days prior to placing concrete.
10 The Engineer will verify the acceptability of the Supplier and the mix design requirements.
11 Any acceptance of the design mix will be deemed withdrawn if there is change in the constituent
element of the mix.
12 The Contractor will design a new mix to suit the changed constituents to obtain Engineers acceptance
prior to its use in the permanent works.
13 Mix design will be submitted to the Engineer at least 30 days prior to placing concrete.
14 Concrete mix trials will be submitted to the Engineer at least 21days prior to concrete placing.
4.5.2 Mixture Properties

1 The general properties of the grades of concrete to be used in the Works are set out in Table 7 and the
Durability Report C0306-S02-ECB-RP-30018. Indicative mix design criteria are set out in Table 8. The
contractor will adhere to the mix designs within the durability report.
Table 7: Properties of Concrete Grades
Concrete Max. Binder Content (kg/m3) Max. Water/ Min. Coarse Max. Free
Grade Aggregate Cement ratio Aggregate (%) Water (%)
(Cylinder/Cube Size (mm) (l/m3)
) (N/mm2)
Min. Max.
20/25 20 - 250 - - -
(blinding,
benching, etc.)
40/50 20 360 450 0.40 45 -
45/55 20 380 450 0.40 45 -
50/60 20 380 450 0.40 50 125
C55/65 20 435 505 0.40 50 125
C60/75 20 435 505 0.40 50 125
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Concrete Max. Binder Content (kg/m3) Max. Water/ Min. Coarse Max. Free
Grade Aggregate Cement ratio Aggregate (%) Water (%)
(Cylinder/Cube Size (mm) (l/m3)
) (N/mm2)
Min. Max.
40/50 10 400 470 0.4 45 -
Table 8: Indicative Concrete Mix Criteria
Structural Mix Design Indicative Binder Proportions Range Additional Initial surface
Element Reference Strength member or Absorption Test
(Cylinder/C OPC GGB SF coating (ISAT) to BS
ube) (%) S (%) (%) 1881 Pt. 208
(N/mm2) ml/m2/sec (10
minutes)
Blinding MC1 20/25 100 - - - -
Foundation RC1 40/50 10 to 30 65 to 85 5 to 8 Casing in marine 0.20

/Piles splash zone.
Water- proofing
to Drawings.
Pile cap, RC2 40/50 10 to 30 65 to 85 5 to 8 Water- proofing 0.20

Substructure to Drawings.
Approach Coating per
Slab , Section 2.8
Retaining
Wall
Column, Pier RC3 40/50 10 to 30 65 to 85 5 to 8 Coating per 0.20

Section 2.8
Reinforced RC4 45/55 10 to 30 65 to 85 5 to 8 Coating per 0.20

concrete deck Section 2.8
slab
Cast in-situ RC5 45/55 60 to 75 20 to25 5 to 8 Water- proofing 0.20

post- to Drawings.
tensioned Coating per
concrete Section 2.8
Precast pre- RC6 45/55 60 to 75 20 to25 5 to 8 Coating per 0.20

stressed Section 2.8
concrete.

post- to Drawings.

post- to Drawings.
Foundation RC1A 40/50 10 to 30 65 to 85 5 to 8 Casing in marine 0.20

/Piles splash zone.
Water- proofing
to Drawings.
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Structural Mix Design Indicative Binder Proportions Range Additional Initial surface
Element Reference Strength member or Absorption Test
(Cylinder/C OPC GGB SF coating (ISAT) to BS
ube) (%) S (%) (%) 1881 Pt. 208
(N/mm2) ml/m2/sec (10
minutes)
Pile cap, RC2A 40/50 10 to 30 65 to 85 5 to 8 Water- proofing 0.20

Substructure to Drawings.
Approach Coating per
Slab Section 2.8
Column, Pier RC3A 40/50 10 to 30 65 to 85 5 to 8 Coating per 0.20

Section 2.8
2 Water / Cement ratio will be determined as the ratio of the combined volume in litres of water and all
liquid additives to the total weight in kilogrammes of all cementitious materials.
3 Coarse aggregate (considered as the size fraction between 20 and 5mm) will be the percentage of total
volume of the mixture.
4 Each grade of concrete will be designated by its specified 28-day compressive characteristic cylinder
strength according to ASTM C31/C39 or Compressive strength of Cubes as per BS 1881 Part 116 in Mega
Pascals followed by the nominal maximum size of aggregate in millimetres and such other unique coding
as will be determined from the durability report.
5 Workability will be such as to enable the concrete to be fully compacted without segregation around the
reinforcement, pre-stressing ducts and other inserts detailed on the Contractor’s drawings, and to
completely fill the formwork and provide the specified surface finish under prevailing climatic
conditions.
6 Concrete mixtures will be designed for a minimum slump (consistency) as shown below. Concrete Slump
- the use of high percentage of GGBS in concrete mixes may cause difficulties in handling concrete
(pumping, placing, finishing...); therefore, it is recommended to specify and accept higher slumps for
such mixes in order to avoid any addition of water to the concrete mix on the construction site.
a) 100 mm ±25 where concrete is to be placed in water-free shaft and,
b) 175mm ±25 where concrete is to be placed by tremie method under drilling fluid
c) 200+/-40mm where concrete mixes are placed by pumping method
7 The above values will not be altered unless approved otherwise by the Engineer in special conditions
such as placement of concrete on sloped surfaces.
8 Where pumped concrete is used, this slump requirement will apply at the point of discharge.
9 The Contractor will prepare and complete full trials upon concrete mix designs for each grade of
concrete to be used in the Works.
10 The Concrete strength will be defined in terms of the 28-day characteristic cylinder strength or cube
strength
11 The strengths will be those assumed for the design of the structure and will be achieved by the
Contractor in the finished Works.
12 Prior to using any concrete mix in the Works, and as directed by the Engineer, a minimum of two sample
trial panels for each mix will be cast using the formwork material to be used in the Works and containing
a representative arrangement of reinforcement, particularly for congested reinforcement arrangements,
to confirm the workability and finishes attainable.
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13 The panels will be no less than 1m2 on each formed face in trial panels.
14 Should the Engineer reject any sample panel, the Contractor will take such action as may be necessary
until a sample comprising two test panels will be acceptable.
15 All concrete will be capable of being transported and readily compacted by the accepted method into a
dense homogeneous mass without segregation, bleeding or plastic cracking: surface cracking or other
types of surface pattern cracking will be grounds for rejecting concrete as cast.
16 Bleeding will not exceed 0.5% after 1 hour from completion of mixing nor 1.5% maximum when tested in
accordance with ASTM C232 Method B.
4.5.3 Mixture Verifications

1 Mixture verifications will be performed for each mixture designation for the initial acceptance of each
mixture designation, prior to start of concreting.
2 During the course of work if source of aggregate changed, additional verification will be performed for
Severe or Very Severe Exposure Conditions – each 500m3 or every 6 months; and for all other concrete
each 500m3 or every 6 months. or as directed by the Engineer.
3 The above frequency will be increased by the Engineer where variability is considered by the Engineer to
be excessive, where significant shifts in the moving average of properties occurs or where tests of
concrete properties fail to meet the requirements of the Specifications.
4 Mixture verification will consist of the testing and submittal of all materials to be used in the concrete to
confirm compliance with this Specification.
5 Where certain materials are already in use and approved for use in the Dubai projects, the Engineer has
the option to waive this specific test regime for each mixture designation, but full scale and
independently witnessed plant trials will be carried out to confirm the mixture composition for fresh and
hardened properties of the mixture.
6 Concrete proportions will be moisture and yield adjusted prior to approval of the final mixture
proportions.
7 In the absence of prior approvals, the following tests are required and also are also detailed further in
the Durability Report C0306-S02-ECB-RP-30018:
i. Halide content of ingredients and calculated total for mixture
ii. At middle one third, measure
a. Fresh Slump (consistency)
b. Fresh Density
c. Fresh Placement Temperature
d. Slump loss over 120 minutes, measured at 30 minutes intervals
iii. Temperature rise on the surface and core of 1m3 specimen on an hourly basis over a period of 72
hours.
iv. Hardened density of laboratory and field cured specimen at 7 and 28 days.
v. Compressive strength at 7 and 28 days on both laboratory and field cured specimens.
vi. Initial surface absorption test as per BS 1881: P-208: 1996 shall be carried out on 3 laboratory cured
and 3 field cured specimens obtained from individual cubes at 7 and 28 days age.
vii. Air content tests as per BS EN 123501-7
viii. Flexural strength of prism as per BS EN 12390-5, at 7 and 28 days. Limit- Minimum is set by the
Modulus of Rupture, which is about 10-15% of compressive strength of concrete
ix. Bleeding as per ASTM C232
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x. Splitting tensile of concrete cylinder as per ASTM C496, at 7 and 28 days. Limit= 0.7*SQRT(fck).
xi. Depth of water penetration as per BS EN 12390 at 28 days
xii.Water absorption of hardened concrete as per BS 1881 P122 at 28 days
xiii.
Rapid Chloride permeability test to ASTM C1202 at 28 days
xiv.Chloride Migration Coefficient test to NTB 492, at 28 days - Range - Refer to Durability report C0306-
S02-ECB-RP-30018
8 Mixture verification will be accepted and progress with the concrete works approved by the Engineer
when the results of the above tests are in accordance with the requirements of this Specification.
4.5.4 Submittal for Approval

1 The following sequence for submittals and acceptance will be applied for each concrete grade and no
Permanent Works may be carried out until all stages have been completed to the Engineer’s satisfaction.
– Submission of final comprehensive report on the examination, sampling and testing of aggregates,
cement and water sources in accordance with the Specifications.
– Submission of methods of processing, storage, batching and mixing all materials on site with full
details of plant to be used,
– Submission of mix design (concrete mix) proposals,
– Completion of full-scale trial mixes.
– Satisfactory concrete performance and test results from the trial mixes,
– A detailed method statement showing his proposals for concreting all the sections of the Works a
minimum of thirty days before any concrete work commences
2 At any time during the works the Engineer may require the Contractor to make full resubmission of any
concrete mix for acceptance or to provide a new mix design for use if in the solo opinion of the Engineer
there is evidence of variability in the designed mix performance.
3 Such submission will include trial laboratory testing.
4 All such submissions will be at Contractors expense and no extra payment will be made by the Engineer.
4.6 Field Testing of Works Concrete

4.6.1 Sampling Concrete Cylinders or Cubes
1 Samples will be taken on site at the point of discharge of the concrete.
2 If pumping is used, then the concrete cylinders samples will be taken at the hose discharge point.
3 Test cylinders will be made, cured, stored, transported and tested in accordance with ASTM C31 and
ASTM C39 or Compressive strength of Cubes as per BS 1881 Part 116.
4 Each sample will comprise nine cylinders and the age at testing. Each Sample will Comprise (9 cubes or
Cylinder and the Age at 7,28 and 56 days to be tested
5 The Engineer may direct the Contractor to make an additional two cylinders for testing at no additional
cost.
6 The additional cylinders or cubes will be cured and stored before testing (at an age of 28 days) in the
same conditions as the elements cast with the same batch of concrete from which these cylinders or
cubes were taken.
4.6.2 Frequency of Sampling Concrete Cylinders or Cubes

1 For each mix two samples will be taken at random during each of the first five days of use of the mix.
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2 Thereafter, the greatest frequency of the following requirements will be required:

a) One sample for each mix used on any day.
b) One sample for each structural unit or part thereof cast as a single pour.
c) One sample for each 10 cubic metres of concrete for post-tensioned deck, piles, pile caps, abutments
or piers.
d) One sample for each 50 cubic metres of concrete for elements excluding piles, abutments and piers.
3 Where in the opinion of the Engineer, cylinder or cube test results show an unacceptable variability the
testing frequency will be increased until the variability has been removed.
4.6.3 Concrete Cylinders and Cubes Strength Criteria

1 The cylinders will be tested in accordance with ASTM C39 or Cubes Compressive strength as per BS 1881
Part 116 and the mean of the three results will be taken as the test result.
1 When the difference between the individual results divided by their mean exceeds 15% the test result
will be deemed invalid.
2 When both the following conditions are met, the concrete complies with the specified compressive
strength:
a) The average strength determined from any group of four consecutive test results will exceed the
specified strength by not less than 3.5N/mm2.
b) Each individual test result will be greater than the specified strength less 3N/mm2.
3 If only one test result fails to meet the second requirements (b) then that result will be considered to
represent only the particular batch or concrete from which those cylinders or cube were taken.
4 If the average strength of any group of four consecutive test results fail to meet the first requirement (a)
then all the concrete in all the batches represented by all such results will be deemed not to comply with
the strength requirements.
5 For the purposes of above Clause, the batches of concrete represented by a group of four consecutive
test results will include the batches from which samples were taken to make the first and the last sets of
cylinders in the group of four, together with all the intervening batches.
4.6.4 Workability
1 The workability of the fresh concrete will be such that the concrete is suitable for the conditions of
handling and placing so that after compaction it surrounds all reinforcement, tendons and ducts and
completely fills the formwork.
2 Workability will be measured for Each Truck or at such time as directed by the Engineer Using Slump
Test to BSEN 12350 part-2 Only.
4.7 Production of Concrete

4.7.1 Transport, Testing and Placement
1 Full details of the method of statement for concreting including the tremies use will be submitted at
least 4 weeks in advance to the Engineer's acceptance.
2 The Contractor will provide a written request for reinforcement inspection at least 48 hrs prior to
concreting to the Engineer and will wait for Engineer's acceptance prior to proceed with concreting.
3 During the placing of concrete for reinforced work a competent steel-fixer and carpenter will be in
constant attendance to adjust or correct the position of reinforcement and formwork as necessary.
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4 No concrete will be placed in a foundation until the extent of excavation and the character of bearing
material have been verified and no concrete will be placed in any structure until the placement of
reinforcing steel and the adequacy of the forms and falsework have been inspected by the Engineer.
5 Concrete will not be placed in any part of the Works until the Engineer’s acceptance has been notified.
6 If concrete has not started within 24 hours of such acceptance being given, a new inspection request will
be submitted to the Engineer.
7 Concreting will then proceed continuously over the area between construction joints.
8 Prior to placing any concrete on natural surfaces a blinding concrete will be laid to a minimum of 100mm
thickness.
9 This blinding will be suitably cured prior to subsequent concrete placement.
10 The blinding will be clean and free from any dust or impurities prior to subsequent concrete placement.
11 The timetable for a pour of concrete is to be so arranged that no face of concrete will be left more than
30 minutes before fresh concrete is deposited against it or more than 90 minutes after the mixing of the
concrete forming the face (90 minutes from the introduction of water to the mix).
12 No concrete work will be stopped or temporarily discontinued within forty-five (45) centimetres of the
top of any finished surface, unless such work is finished with a coping having a thickness less than forty-
five (45) centimetres in which case the joint will be made at the under edge of the coping.
13 Concrete will be deposited in horizontal layers to a compacted depth not exceeding 400mm where
internal vibrators are used or 300mm in all other cases.
14 Concrete will not be dropped into place from a height exceeding 2m.
15 When trunking or chutes are used, they will be kept clean and used in such a way as to avoid
segregation.
16 Where steep slopes are required for placing concrete with chutes, the chutes will be equipped with
baffle boards or being short lengths that reverse the direction of the movement.
17 Chutes and the use of chutes must be agreed with the Engineer prior to their use.
18 All chutes will be kept clean and free from coating of hardened concrete by thoroughly flushing with
water after each run.
19 The water used for flushing will be discharged clear of the concrete already in place.
20 No concrete will be placed in flowing water.
21 Underwater concrete will be placed in position by tremies, or by pipeline from the mixer.
22 Where the concrete is placed by the tremie, its size and method of operation will be in accordance with
BS 8004.
23 During and after concreting under water, pumping or dewatering operations in the immediate vicinity
will be suspended.
24 Concrete placed below ground level, excepting only piles, caissons or barrettes, will be protected on its
outside faces using polyethylene sheeting, bitumen rubber latex emulsion flexible damp and vapour-
proof liquid membrane conforming to BRE Digest No. 54, or similar.
25 Concrete will not be subjected to disturbance between 4 hours and 24 hours after compaction.
26 Re-compaction of the upper layers of deep lifts to prevent of anneal plastic settlement cracking will be
subject to the approval of the Engineer.
27 Mixture verification will be in accordance with Section 4.5.3.
4.7.2 Hot weather concreting

1 For concreting in hot weather guidelines set out in ACI 305R will be followed.
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2 Concrete will not be placed if the rate of evaporation of water exceeds 1kg/m²/hr.
3 The contractor will record the ambient temperatures three times daily.
4 Temperature of concrete will be monitored; and when concrete is deposited it will have a temperature
of not less than 15 degrees Celsius and not more than 30 degrees Celsius
5 In case that the atmosphere temperature not falling within the above prescribed range as mentioned in
4.7.2.4 , then the contractor will propose methods of insulation (heating or cooling) to ensure that the
above temperature range is achieved.
6 In all cases the Contractor will seek the Engineer acceptance prior to placing concrete. The temperature
of the concrete when placed shall not exceed 30 deg.C nor shall concrete be mixed or placed when the
shade air temperature is 40 deg.C or above, or is expected to reach such a level during concreting,
without special permission from the Engineer
7 Hot weather increases the temperature of fresh concrete causing increased concrete water demand,
accelerated concrete shrinkage loss, increased rate of setting leading to placing and finishing difficulties,
increased tendency for plastic shrinkage cracking, increased concrete temperature resulting in lower
ultimate strength and increased potential for thermal cracking.
4.7.3 Mixing Plant

1 The concrete batch plant will be suitable in type, capacity and design for its purpose and subject to
acceptance by the Engineer.
2 Mixers for designed mixes will be of the pan type: continuous mixers will not be permitted.
3 Mixers and their accessories will be an internationally recognised standard such as BS 1305, and will be
in good condition.
4 The performance of the batch plant and its disposition will be adequate for the Works programme.
5 Mixers will operate at the speeds and mix for at least the length of time recommended by the
manufacturer: mixing time will be increased if necessary to achieve a uniform distribution of materials in
the mix and a uniform colour.
6 Mixers which have been out of use for more than 30 minutes will be thoroughly cleaned before any
fresh concrete is mixed.
7 A small first batch will be used to coat the mixer and this coating batch will not be incorporated in the
Works.
8 Standby mixing capacity will be provided by the Contractor (sufficient to ensure continuity of concreting
in the event of breakdowns of mixing plant) and will be maintained ready for immediate use during the
course of all concrete pours.
9 Precautions will be taken to avoid the loss of cementitious material during windy conditions.
10 The batching plant will have separate balances for cementitious materials and aggregates.
11 The weighing and water dispensing mechanisms will be maintained in good order, and their accuracy will
be maintained to ensure batch weights within the tolerances required by the specification.
12 Facilities will be provided for calibration of all weighing equipment, gauges and meters for use in the
manufacture of concrete.
13 Calibration checks will be carried out at monthly intervals.
14 Automatic recording equipment will maintain a record of each material used, including quantity, number
of batches mixed and classification of mix, and dates and times of operation.
15 At all times when concreting is being carried out, the Contractor will have available sufficient standby
plant to cover the operations of mixing, transporting, placing and compaction of concrete in the event of
plant breakdowns.
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16 Volume batching (i.e. measuring constituents by volume) will not be permitted.

17 Independent calibration of the plant will be carried out every 6 months.
4.7.4 Concrete Curing

1 In severe exposure locations curing compounds will not be permitted, and curing will be a combination
of wet curing and using impervious sheet membranes.
2 The curing period and methodology will be highlighted in Contractor’s method statement, in line with his
construction method, and submitted for approval by the Engineer.
3 The method of curing used will minimise the loss of moisture from the concrete.
4 On concrete surfaces that are to be waterproofed or coated, curing membranes will not be used unless
agreed by the Engineer.
5 The Contractor will prove the effectiveness of each proposed curing method by trials on site in the
exposure conditions in which the curing material or process is to be used.
6 Should exposure condition change relative to the conditions during testing then the trials will be
repeated as required.
7 Curing will be continuous and fully effective to produce concrete in compliance with the exposure
conditions but in any event, will not be for less than 14 days unless agreed otherwise by the Engineer.
4.7.5 Additional Inspection and Testing Requirements

1 Testing as set out in Table 9 will be undertaken to the frequency shown during production of concrete
for the Works. These are also detailed in the Contractors Durability Report C0306-S02-ECB-RP-30018
2 Admixture testing frequency to be for every 1000m3 of concrete poured. Each separate consignment of
admixture shall be tested by the manufacturer before delivery and certified copies of such tests shall be
supplied to the Engineer before usage.
3 Each separate consignment of cement shall be tested by the manufacturer before delivery and certified
copies of such tests shall be supplied to the Engineer before any part of the consignment is used in the
works.Any consignment not used within 2 months from the date of manufacture will not be allowed to
be used in the works
4 Additives to concrete- GGBS and Silica Fume to be tested for every 500m3 of concrete poured. Each
separate consignment of the additives shall be tested by the manufacturer before delivery and certified
copies of such tests shall be supplied to the Engineer before usage.
5 The testing frequency for the Chloride Migration Coefficient Test should be in line with the other
durability tests i.e. For Severe or Very Severe Exposure Conditions each 500m3 or every 6 months and
for all other concrete each 500m3 or every 6 months or directed by the Engineer.
Table 9: Additional Inspection and Testing Requirements
Sampling Test
ITEM Test Frequency Rate
Method Method
a. Cement - as per BS EN 196 BSEN BSEN-196 Each 500m3 of concrete poured.

196-7
b. Steel
1. Deformed S. Bar as per BS BS 4449 BS 4449 Each size 100 ton

4449:
2. Strand as Per BS5896/ASTM A BS 5896 BS 5896 /ASTM 20T ASTM A 416

416: A 416 onn
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Sampling Test
Method Method
as
per:
c. Concrete
1. Air content, as per BS EN BSEN BSEN Once at the time of mix design of
123501-7:2000 12350-1 12350-7 concrete or as directed by the
Engineer.
2. Flexural strength of Prism as BSEN BSEN Once at the time of mix design of
per BS EN 12390-5 12350-1 12390-5 concrete or as directed by the
Engineer.
3. Bleeding as Per ASTM C232 BS 1881 - C 232 One at the time of mix design of
concrete or as directed by the
101 Engineer.
4. Splitting Tensile of Conc. BS 1881 - C-496 One at the time of mix design of
Cylinder as per ASTM C- 101 concrete or as directed by the
496:1996 & others Engineer.
5. Depth of Water Penetration (BS BSEN 12350-1 BSEN 12390-8 For Severe or Very
EN 12390 P-8:2000) Severe Exposure Conditions each
500m3 or every 6 months; and for
all other concrete each 500m3 or
every 6 months or as directed by
the Engineer.
6. ISAT as per BS 1881- p-208 BS 1881- BS 1881 - For Severe or Very Severe Exposure
101 Part 208 Conditions each 500m3 or every 6
months; and for all other concrete
each 500m3 or every 6 months or
as directed by the Engineer.
7. Water absorption of Hardened BS 1881- 1881-122 For Severe or Very Severe Exposure
Conc. As per BS 1881 P122 101 Conditions each 500m3 or every 6
8. Rapid chloride permeability BS 1881 - ASTM C 1202 For Severe or Very Severe Exposure
101 Conditions each 500m3 or every 6
9. Chloride Migration Coefficient NTB 492 Each 500m3 of a particular grade of

structural concrete or as directed
by the Engineer.
9. Slump test - as per BS 1881 P102 BS 1881- BS-1881- 102 From each transit mixture load
101 arrived at site
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Sampling Test
Method Method
10. Concrete Mix Design (Mixing All mixes are to be designed once
and Sampling in the lab) as per BS for verification and approval.
1881 P125 & In Site (Sampling) as
per BS 1881 P 101
11. Kerbs-as per BS 7263 BS 7263-1 BS 7263-1 Sample to be taken from each
batch of upto 1000 kerb in whole
consignment
d. Water 3148 BS 3148 One 1 - gallon sample shall be

obtained prior to use from each
source and at least once every
week for quality testing
For further durability testing that the contractor will follow please refer to the project durability report C0306-
S02-ECB-RP-30018
4.8 Formwork and Falsework

4.8.1 Design
1 Formwork and falsework will be the designed to BS 5975, BS EN 12812 of equivalent approved.
2 The formwork and falsework systems will be designed to withstand the worst combination of self-
weight, formwork and falsework weight, formwork and falsework forces, reinforcement weight, wet
concrete weight, construction and wind loads, together with all incidental effects caused by placing,
vibrating and compacting the concrete.
3 Detailed drawings for falsework and centering will be prepared by the Contractor along with relevant
calculations and all these documents will be certified in writing as checked by an independent Consulting
Engineer registered in the United Arab Emirates.
4 The Contractor will prepare detailed strength and deflection calculations and drawings of the formwork
he proposes to use and submit full details at least one month prior to start of work.
5 The Detailed shop drawings for formwork & falsework with relevant calculations with independent
checkers certificate will be submitted to the Engineer at least 30 days prior to work commencement.
6 All void formers shall be expanded polystyrene with following properties;
a. Cross breaking strength – 140 KN/m2 minimum
b. Compressive stress – 70KN/m2 at minimum 10% compression
c. Water vapour transmission at 38 C and 90% relative Humidity, microgramme metres/newton hour
(Mgm/Mh), maximum per 50 mm sample thickness – 25
d. Thermal conductivity W/m² C at 10 C mean temperature, maximum – 0.037
e. Dimensional stability at 80 C per cent maximum – 0.5
4.8.2 Construction
1 Load test on false work to be carried out without additional cost to Contract.
2 As directed by the Engineer, the Contractor will verify the settlement at site under the scaffolding by
doing plate loading test.
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3 All formwork will be of such quality and strength as will ensure rigidity throughout the placing, ramming,
vibration and setting of the concrete without visible deflection.
4 The Contractor is responsible for the integrity of the formwork.
5 All formwork will be so constructed that there will be no loss of material from the concrete.
6 After setting, the concrete will be in the position and of the shape and dimensions prescribed.
7 The finished surface of exposed concrete will be of a quality specified on the drawings.
8 All curved surfaces will be formed with plywood or steel of a quality and construction to provide the
required finish within tolerance.
9 The plywood to be marine ply or three layers of poly-urethane varnish to be applied to commercial
plywood.
10 Where internal metal ties are permitted, they or their removable parts will be extracted without damage
to the concrete and the remaining holes filled with mortar.
11 No permanently embedded metal part will have less than specified cover to the reinforcement unless its
durability is assured so as not to adversely affect the durability and design life of the element in which
the part is embedded.
12 After completion of construction of any formwork and falsework, or part thereof, and prior to loading
falsework, the Contractor and the independent consulting engineer who checked the falsework design,
will certify in writing that the executed falsework has been checked and no deviation from the certified
detailed drawings has been found.
13 No formwork and falsework will be used for construction of the Works without this certification.
14 The Contractor will in all cases request the acceptance of the formwork by the Engineer in sufficient time
to allow an inspection to be made and will not commence concreting until such acceptance is obtained.
15 The period between the Contractor’s request for acceptance and his intention to commence concreting
will be not less than one clear normal working day and the Engineer’s may require a longer period if, in
his opinion, the formwork is of such complexity as to require it.
16 Acceptance of the formwork by the Engineer will not absolve the Contractor of his responsibilities under
the Contract.
17 The Contractor will construct the formwork and falsework in accordance with the submitted Shop
Drawings.
18 Variations from the formwork and falsework Shop Drawings will not be permitted unless the Engineer is
provided with revised Shop Drawings that have been stamped, signed and dated by an independent
Consulting Engineer registered in United Arab Emirates.
19 Tie Rods (i.e. tension/anchorage bars, RHS, SHS, CHS or Angle sections) to be used for thin structural
elements, thin walls/columns, retaining walls, and wing walls, etc. as per construction requirements and
developed by Contractor’s design.
20 The Contractor will be responsible to remove and re-construct any damaged structural member due to
formwork or false work failure at his own cost.
4.8.3 Tolerance
1 The formwork will be set to such lines and levels as to ensure that the following tolerances are not
exceeded in structures as cast.
2 For all buried concrete:
a) Generally, deviation from line by + 25mm or -12mm
b) Additionally, for concrete surfaces that are to be waterproofed, abrupt irregularities in the surface
finish will not exceed 3mm
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3 For visible soffits, edge beams, sides of parapets and the like: +/- 3mm but not more than 3mm in 3.5m.
4 For all other concrete: +/- 6mm but not more than 3mm in 3.5m.
4.8.4 Preparation of Formwork before Concreting

1 The inside surfaces of forms, except for permanent formwork, will be coated with a suitable release
agent.
2 Release agents will be applied strictly in accordance with the manufacturer’s instructions and will not
come into contact with the reinforcement.
3 Different release agents will not be used in formwork to concrete which will be visible in the finished
works.
4 A panel will be constructed utilizing the proposed release agent to verify that the agent is suitable for
use with each concrete mix and that it does not adversely affect the finish or exhibit discolouration of or
any significant retard of the surface mortar strength.
5 Immediately before concreting all forms will be thoroughly cleaned out.
6 The Engineer should inspect and accept the formwork and the falsework prior placing of concrete;
however, such acceptance will not relieve the Contractor of his responsibilities for the safety, integrity,
accuracy, & efficiency of the work.
7 The Contractor will submit a written request to the Engineer for formwork/falsework inspection at least
48 hrs prior placing of concrete.
4.8.5 Removal of Falsework and Formwork

1 The proposed time at which the formwork is struck is subject to Engineer acceptance.
2 At the time of striking any falsework and/or formwork, the concrete will be of sufficient age and strength
for it to withstand the effects of striking, including the effect of thermal shock or the loss of surface
durability upon premature exposure, and to be able to withstand the resulting stresses without adverse
effects.
3 Falsework and formwork will be constructed so that the side forms of members can be removed without
disturbing the soffit forms and, if props are to be left in place when the soffits forms are removed, these
props will not be disturbed during the striking.
4 Formwork will be removed without damage to the concrete.
5 The Contractor will determine in advance for each designed mix, location of concrete casting and
arrangement of falsework and formwork the appropriate minimum time from completion of casting to
striking of formwork that will ensure that the striking of falsework and/or formwork will have no adverse
effect on the concrete.
6 The time at which the formwork is struck will be the Contractor’s responsibility and will be subject to
acceptance in advance by the Engineer.
7 In the absence of any justification submitted by the Contractor, the minimum periods between
completion of placing concrete in a section of the works and the removal of forms will be as follows:
a) Sides of beams, walls and columns: 2 days
b) Soffits of beams and slabs (props left in): 7 days
c) Soffits of beams and slabs (props removed): 14 days
d) Soffits of precast beams: 7 days
8 Where it is intended to re-use formwork it will be thoroughly cleaned and made good to the satisfaction
of the Engineer.
9 Site will be reinstated by the Contractor after removal of formwork and false work.
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4.8.6 Early Loading

1 Concrete will at no time be subject to loading, including its own weight, which will induce a compressive
stress in it exceeding 25% of its compressive strength at the time of loading or of the specified 28 day
strength, whichever is lower.
2 Where early loading is proposed to be imposed upon concrete the Contractor will provide calculations to
verify that the early loading does not adversely affect the long-term performance and durability of the
concrete and will seek Engineers acceptance in advance of imposing such early loading.
3 No superstructure load will be placed upon finished concrete supporting elements until, as a minimum,
curing has been completed.
4 The Contractor will not place any temporary loads on slabs, or allow access to traffic or construction
equipment unless the Contractor’s calculations show that the early loading does not adversely affect the
long-term performance and durability of the concrete.
4.9 Classes of Finish

4.9.1 General
Final Finishes for any concrete surface is subjected to acceptance by the Engineer.
4.9.2 Formed Surfaces

1 The class of finish of formed surfaces will be shown on the detail design drawings. The description of
each class of finish for formed surfaces is stated in Table 10.
Table 10: Formed Finishes
Class Description Element
Class F1 As struck. Used only for concealed work and will be the as-cast surface Inside box girder sections
produced using closely jointed sawn timber boards, planked formwork,
plywood, sheet metal or other suitable proven form material. The surface
will be free from voids and honeycombed areas.
Class F2 The irregularities in the finish will be no greater than those obtained from
the use of wrought thickness square edged boards arranged in a uniform
pattern. The finish is intended to be left as struck but imperfections such as
fins and surface discolouration will be made good by methods approved by
the Engineer.
Class F3 The formwork will be lined with a material agreed with the Engineer to Exposed faces of piers,
provide a smooth finish of uniform texture and appearance. This material abutments, bridge decks,
will leave no stain on the concrete and will be so joined and fixed to its parapets and curbs and such
backing that it imparts no blemishes. It will be of the same style and other surfaces where smooth,
obtained from only one source throughout. The Contractor will make good uniform surfaces are required.
any imperfections in the finish as required by the Engineer. Internal ties and
embedded metal parts will not be allowed.
Class F4 The requirements for Class F4 are as for Class F3 except that internal ties
and embedded metal parts will be permitted. The ties will be positions to a
regular pattern.
2 Permanently exposed concrete surfaces to Classes F4, F3 and F2 finish will be protected from rust and
stains of all kinds.
3 Unless otherwise described in the Contract, all formwork joints for exposed surfaces of concrete to Class
F2, F3 and F4 finish will form a regular pattern with horizontal and vertical lines continuous throughout
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each structure and all construction and movement joints will coincide with these horizontal or vertical
lines.
4.9.3 Remedial Treatment of Formed Surfaces

1 An inspection of the concrete surface will be carried out immediately after removing the formwork, and
any remedial treatment to surfaces proposed by the Contractor will be submitted to the Engineer for
agreement and will be carried out without delay once agreement is reached.
2 Portions of the structure which cannot be finished or properly repaired to the satisfaction of the
Engineer will be removed.
3 Any concrete, the surface of which has been treated without reference to the Engineer will be rejected.
4 Surfaces of slabs intended to receive bonded applied cementitious applications such as setting beds,
grout, etc. shall be roughened with stiff brushes or rakes before final set. For other applications the slabs
shall be floated to uniform sandy texture or trowelled to smooth finish as required.
4.9.4 Unformed Surfaces

5 The class of finish of unformed surfaces will be shown on the detail design drawings. The description of
each class of finish for unformed surfaces is stated in Table 11.
Table 11: Unformed Finishes
Class Description Element
Class U1 The concrete will be uniformly levelled with a screed board to produce a plain,
textured or ridged surface to the profile shown on the Construction Drawings. Plain
texture surface will be obtained by screeding or light brushing, and will not have
abrupt irregularities exceeding 3 mm. No further work will be applied to the surface
unless it is used as a first stage for a Class U3 finish.
Class U2 After the concrete, has hardened sufficiently to prevent laitance from being worked Exposed faces of
to the surface, a Class U1 finish will be floated by hand or machine sufficiently to slab tracks (if any).
produce a uniform surface free from screed marks.
Class U3 When the moisture has disappeared, and the concrete has hardened sufficiently to
prevent laitance from being worked to the surface, a Class U1 finish will be steel-
trowelled under firm pressure to produce a dense, smooth uniform surface free from
trowel marks.
Class U4 This finish is for concrete areas that are to receive waterproofing systems as agreed Bridge decks,
with the Engineer. The concrete will be uniformly levelled to a U3 finish. The pile cap,
accuracy of the finished surface will be such that it does not deviate from the
required profile by more than +/- 5mm over a 3m gauge length or have any abrupt abutment/piers top
irregularities more than 3mm. Prior to the installation of the deck waterproofing surface
system the surface will be lightly sand blasted to remove laitance. Any plastic cracks
must then be sealed using low viscosity epoxy before application of the
waterproofing membrane.
6 Surfaces finish will conform to trial panels approved by the Engineer.
4.9.5 Special Finishes

Where special finishes are specified in the Drawings the Contractor will make trial panels for the formed
finishes specified for inspection and acceptance by the Engineer.
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4.10 Testing of Samples Cut from the Works

1 Where the finished concrete is suspected by the Engineer of being defective and/or where the cylinder
strength or cement content criteria has not been met, cylindrical core specimens of 150- or 100-mm
nominal diameter will be cut from the hardened concrete for the purpose of examination and testing.
Defective concrete is classed as cracking, crazing, blistering, delamination, dusting, curling,
efflorescence, scaling and spalling. Testing will be required to confirm the mitigation required based on
the extent of the defective area. Method statement will be issued providing details on defects and
corresponding repair methodology.
2 The proposed repair material should have minimum strength equal to or more than the parent material
and the application should follow the manufacturers recommendation as described in the approved
Method statement.
3 The grout used for repair should be non-shrink cementitious or epoxy grout as per the defect identified
and should meet the requirements of the Durability report.
4 The cutting equipment and the method of doing the work will be prepared and submitted by the
Contractor and be subject to the approval of the Engineer.
5 The specimens will be examined and records of the inspection, including photographs, prepared prior to
testing and all subsequent sample preparation and testing will be in accordance with BS 1881.
6 If the cylinder strength from the samples is less than the required cylinder strength, or if in the opinion
of the Engineer the concrete fails to meet the specified requirements in other respects, the concrete in
that element of the Works of which it is a sample will be considered not to comply with the
Specification.
7 For these criteria “element” means the volume between construction joints or other joints of a discrete
part of a structure or of a ground slab or of protective concrete or as directed by the Engineer.
8 The cost of the testing described herein will be borne by the Contractor irrespective of whether the test
results comply with the Specifications.
4.11 Concrete Repairs

For detailed requirements for treatment for concrete repairs please see summary below
1 A procedure to be followed for assessing cracks and resin injection of anywhere this requirement is
identified: including rechecking each crack length after 28days from its first observation, for increase in
width or length, noting whether the resin has accommodated this movement or not, and reinjection in
the event of failure.
2 Crack Repair to be in accordance to AREMA Chapter 8 – Part 14 for Rail Structures and in accordance to
AASHTO Construction Specifications for Road Structures.
3 Discreet voids/honeycombing/chips near the surface, up to 25mm deep are to be filled with mortar and
surface imperfections up to 10mm
4 Voids/honeycombing/chips greater 25mm deep are to be treated in line with; concrete patch repairs
process including removal of defective concrete and reinstatement
5 A requirement for review and preventive action to be proposed if any one defect type
(cracks/voids/honeycombing/chips, as defined in this specification) occurs:
I. In 3 or more elements, out of any 10 constructed consecutively of any given type;
II. Or in 5 or more instances in any one element
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III. Or if the summation of crack widths over a 2m portion of an element should not exceed 1mm
(recognising that the minimum practical width for measurement is around 0.15mm), and cracking
greater than this should also be injected
4.11.1Assessment
Key stages in the assessment process are:
• assessment of the condition of the structure;
• identification of causes of deterioration;
• deciding the options for protection and repair;
• selection of the appropriate principle(s) of protection and repair;
• selection of methods;
• definition of properties of products and systems;
• specification of maintenance requirements following protection and repair
The condition assessment and identification of causes of deterioration should always be completed to
determine if repairs are required to ensure the design life is met.
4.11.2 Identification of Defects

The contractor shall determine the extent of the defect by appropriate means such as visual inspection,
measurements, non-destructive testing, breakouts, coring etc. Appropriate records of the locations and
dimensions shall be collected and submitted to the Engineer for review.
After assessment of the significance of the defect the contractor shall select appropriate methods and
materials for the repair and submit these to the Engineer for approval. The proposed methodology shall
specify the personnel who shall carry out the works and their required competencies, including whether it
involves a specialist sub-contractor.
Crack width meter shall be made available during Engineer’s post concrete inspection
If the defect is considered by the Engineer to be sufficiently major, an NCR for further investigations to be
undertaken will be issued.
The cracks are classified as follows:
• Type 1 – Crack width is less than 0.2mm
• Type 2- Crack width is greater than 0.2mm but less than 0.3mm and depth is within steel cover.
• Type 3- Crack width is greater than 0.3mm and depth is within steel cover.
• Type 4- Crack width is greater than 0.3mm and depth is exceeding steel cover.
4.11.3Repairs to Cracks
It is expected that some cracking to concrete will occur during construction. Where cracking occurs, the crack
The cause of the cracking should be determined, as:
• it may be possible to alter construction techniques to reduce or eliminate the further
cracks; and
• it is required to select an appropriate repair type and material.
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The Contractor shall prepare a detailed method statement covering the methods and materials (including
suppliers) to be employed for each item of work and shall be submitted to the Engineer for approval.
i. Type 1 – General assessment to be carried out and crack To be repaired during surface preparation
using filler of the coating materials.
ii. Type 2- General assessment to be carried out and crack to be repaired using solvent free, high strength
epoxy adhesive suitable for repairing and bonding, in accordance to the Manufacturer’s
recommendations and instructions. If depth exceeds the reinforcement cover then injection to be
used
iii. Type 3- Crack mapping required. To be repaired using a two component, low viscosity, moisture
insensitive, solvent free epoxy resin, in accordance to the Manufacturer’s recommendations and
instructions.
iv. Type 4- Crack mapping to be done. To be repaired by resin Injection process, in accordance to the
Manufacturer’s recommendations and instructions.
4.11.4Preparation of Surfaces around cracks

The concrete surface at least 50mm either side of the crack shall be dry blast cleaned to a sound surface free
from dirt, moss, salt staining and loose concrete. The full extent of the crack shall be found and the cleaned
area shall extend 50mm beyond the end of the crack or until the crack becomes too narrow to warrant resin
injection, based on the widths stated in 4.11.2
4.11.5Repairs to Honeycombing and Voids in Concrete

It is expected that some honeycombing or voids may be present in the concrete. The cause of the
honeycombing or voids should be determined, as it may be possible to alter construction techniques to reduce
or eliminate re-occurrence.
The extent of the honeycombing or voids and the need for concrete repairs to be carried out shall be
confirmed by the Contractor by inspection of the elements as per 4.11.1 during which the repair areas shall
be identified.
Where honeycombing or voids are limited to the near surface (top 25mm) and a coating will be applied as part
of the works, then a cementitious fairing coat shall be used to repair the defect.
Where honeycombing or voids are not limited to the near surface (top 25mm) then defective concrete (i.e.
honeycombed) shall be removed until sound concrete is reached. Care shall be taken to avoid damage to the
reinforcement and adjacent sound concrete.
The surface of each area of breakout to receive repair material shall be such that the repair material will flow
freely or can be hand placed, into all voids and be in contact with the existing concrete.
The perimeter of each area of concrete to be removed shall be saw cut at a minimum angle of 90° to the face
of the concrete to avoid undercutting and a maximum angle of 135° to reduce the possibility of debonding,
except for soffit repairs that do not extend behind the reinforcement, where undercutting of the edges, at an
angle of between 10 & 20 degrees to the normal, shall be used to minimise the risk of the repair material de-
bonding from the concrete substrate. All saw cuts shall be to a depth of not less than 15mm or to within 10mm
of the reinforcement, whichever is the lesser. Prior to carrying out any cutting the Contractor shall ascertain
the depth of the reinforcement along the line of the cut by means of a cover meter. Care shall be taken to
prevent over break beyond the line of the cut.
Concrete shall be removed using the following methods, as directed by the Contractor:
i. High pressure water jetting;
ii. Electric demolition hammer or lightweight pneumatic picks.
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Where concrete is to be removed by high pressure water jetting, the water shall be clean, fresh and obtained
from a Public Utility Undertaking. The Contractor shall not add chemicals to the water. Safety measures shall
comply with the Code of Practice for the Use of High Pressure Water Jetting Equipment, produced by the
Safety Committee of the Water Jetting Association. The Contractor shall employ a suitably qualified and
experienced personal with adequate training and certification e.g. as a member of the Water Jetting
Association or similar. A lightweight electric demolition hammer may be used for final trimming of the area
broken out.
Water arising from high pressure water jetting operations shall be contained near the working area, and not
be allowed to drain away into any hidden areas of existing structures. Water arising shall be deemed to be
contaminated.
Discharge of contaminated water into surface water sewers (including highways drains), watercourses, the
sea and the ground shall be prohibited. Discharge to a foul sewer shall only be permitted if written consent
from the local sewerage provider has been obtained in advance of disposal. Contaminated water may be
treated on site to remove contamination (e.g. particulates and high pH) and subsequently discharged,
however the Contractor shall obtain from the relevant environmental regulator or water authority, prior
consent to the water cleaning process and method. Otherwise contaminated water from high pressure water
jetting shall be collected and transported off-site for legal and registered disposal. Only registered waste
carriers will be permitted for this. The Contractor shall provide a certificate stating that this has been done,
listing the licensed carrier and waste disposal point used.
Prior to commencement of high pressure water jetting, the Contractor shall submit a detailed method
statement of the proposed cutting operations indicating the direction and location of cutting, the type and
performance of pump equipment, nozzle type and diameter and the proposed nozzle pressures, pump output
power and details of any protective screens.
The surface of the base concrete remaining after high pressure water jetting shall be dense with no significant
localised peaks and no loose particles of aggregate or surface cracking. Near vertical faces shall not contain
surface overhangs that might trap air during concreting.
Care is to be taken to minimise mechanical damage to exposed reinforcement. Exposed reinforcement shall
be kept clear for visual inspection and shall be photographed.
Note that during concrete breakout, the concrete around all partially exposed reinforcement should be cut
back to 20-30mm behind the reinforcement (to ensure good bond between the repair mortar and the
reinforcement) and the reinforcement should be cleaned to a standard of SA2 ½ to BS EN ISO 8501 before
applying the repair mortar. Note that treatment of reinforcement and surface preperation, casting and curing
of the repair products are key to the performance of the repair.
4.12 Failure to Meet Specified Requirements

1 Any poured concrete, which does not meet the criteria for compliance, will be rejected and will be
removed from the Site and the work, will be reconstructed to comply fully with the Specification.
2 The manner and methods of removal and reconstruction will be fully documented by the Contractor in
advance, will have the prior written approval of the Engineer and will be carried out strictly in
accordance with the terms of the written approval.
3 No additional payment will be certified in respect of demolition or other action ordered as a result of
non-compliance with the requirements of this Specification, whether or not the test cores indicate that
the strength of the concrete in place is satisfactory.
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4.13 Records
1 Records will be kept by the Contractor of the positions in the Works of all batches of concrete, of their
grade, and of all test cylinders, cores or other specimens taken from them.
1 Copies of these records will be supplied to the Engineer as soon as results are available, and on a regular
basis.
2 In particular, results of seven-day strength tests will be made available to the Engineer within two days
of testing.
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5 Reinforcing Steel
5.1 General
1 Non-metallic reinforcement may be proposed for use subject to its acceptance for use by the Engineer.
2 Non-metallic reinforcement will be in accordance with the appropriate international standards.
3 Cracks or any deformities in rebar shall not be allowed for site use
5.2 Normal Reinforcement

1 High yield deformed bars to BS 4449:2005 +A2:2009, Grade 500B with minimum yield strength,
fy=500Mpa will be used.
2 Seams or other surface defects will not be allowed, and the presence of defects will be grounds for
rejection of reinforcement steel.
3 Couplers for rebars greater than 36mm dia to be in accordance with AREMA Chapter 8 -Section 2.22
5.3 Stainless Steel Reinforcement

Stainless steel reinforcement will be ribbed bar Steel Alloy 316 austenitic stainless-steel Designation 1.4436
and strength grade 500 complying with the requirements of BS6744:2001.
5.4 Epoxy Coated Reinforcement Bars

1 Epoxy coated reinforcement bars will be used for structures in marine environment as required by site-
specific durability study.
2 Materials and coating specifications will be as per AASHTO M 284M Standard Specification for Epoxy-
Coated Reinforcing Bars.
3 The grade of steel will be the same as Normal Reinforcement.
5.5 Binding Wire

1 Binding wire for concrete structures will be 16 or 18 gauge (1.6mm or 1.2mm diameter) equivalent -steel
wire to BS 1554 or ASTM A580/A580M.
2 Ends of binding wire will be turned back into the mass of the concrete so as to have the same cover
required for reinforcement in accordance with the durability report and mix design.
3 Binding wire for use with epoxy coated steel reinforcement will be nylon coated.
5.6 Dowel Bars

Dowels in concrete structures will comply with BS EN 13877-3.
5.7 Manufacturer’s Test Certificate

1 The reinforcing steel manufacturer is to be certified by an agreed system of certification like CARES.
2 The Contractor will obtain and make available test certificates from the manufacturers for all steel
reinforcement, steel fabric and binding wire.
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3 The test certificates will state that these materials have been tested and found to comply in all respects
with the requirements of the relevant Standards.
5.8 Delivery
1 Construction
a) Load test on false work to be carried out without additional cost to Contract.
b) As directed by the Engineer, the Contractor will verify the settlement at site under the scaffolding by
doing plate loading test.
2 Each tag will show the manufacturer’s test number and batch number, mill certificates with heat number
or other designation that will identify the bars with the certificate issued for that batch steel.
3 Steel fabric reinforcement will be delivered in flat sheets which are to be clearly marked with the British
Standard or manufacturer’s reference number and the nominal weight per square metre.
5.9 Bar Schedules and Shop Drawings

1 The Contractor will produce bar schedules for all components of the work.
2 The bar schedules will show the weight of each bar, the total weight of each bar size and bending
diagrams in accordance with BS 8666 or other international standard.
3 The Contractor will submit to his designer for acceptance the bar bending schedules along with the shop
drawings.
4 These documents will be reviewed by the designer and will be certified by the designer as conforming to
the design and being in sufficient detail to allow the accurate placing of reinforcement within the
formwork.
5 The bar bending schedule is to be submitted to the Engineer after acceptance by the Contractor's
designer.
6 The Contractor will submit to the Engineer for approval along with bar schedules the shop drawings in
enough details for the production of the bar bending schedules and accurate placing of reinforcement
within the formwork.
7 Before ordering reinforcing steel, the Contractor will obtain the approval of the Engineer for the shop
drawings and bar schedules.
8 Any changes or adjustments to the drawings or the bar schedules will be submitted and approved by the
Engineer prior to the ordering of the reinforcing steel.
9 Approval from the Engineer will not relieve the Contractor of his responsibility for the correct fit of the
reinforcement and the achievement of the correct cover.
10 The Contractor will be responsible for verification that the numbers, lengths and bending details of
reinforcing bars are correct and in accordance with BS 8666:2000.
11 Any discrepancy between Drawings and the schedules will be referred to the Engineer for a decision.
12 All concrete mix design and durability testing shall comply with the recommendations of the approved
Durability Assessment Report- C0306-S02-ECB-RP-30018
5.10 Storage and Bending

1 All bars for reinforcement and steel fabric reinforcement will be stored clear of the ground on timber or
concrete racks within a covered enclosure having a concrete floor.
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2 Steel reinforcement required to be bent will be bent cold in such a manner that the material is not
damaged in any way and in accordance with BS 8666 unless otherwise noted on the bar bending
schedules.
3 Bending will be carried out within a covered enclosure having a concrete floor.
5.11 Fixing Reinforcement

1 The number, size, form and position of all the reinforcement will, unless otherwise directed or
authorised by the Engineer, be strictly in accordance with the drawings.
2 All reinforcement will be fixed in place firmly ensuring that the specified location and cover will be
maintained during fixing and concreting.
3 All reinforcing steel and fabric will be free from salts, rust, loose scale, oil, grease, mortar or other
deleterious material immediately before concrete is placed.
4 The Contractor will provide all distance pieces and spacer bars necessary to maintain the reinforcement
in the correct position and where necessary, steel stools of approved diameter and spacing between
layers of reinforcement.
5 Mechanical splices will not be permitted unless approved by the Engineer.
6 Where bars are required or permitted to be lapped, they will be securely bound together over the full
length of lap.
7 The steel reinforcement will be so connected as to form a rigid cage.
8 To prevent displacement before or during concreting, the bars will be secured one to the other with wire
binding, which will be tied in such a manner that the wire ends point inward.
9 Spacer blocks will be of appropriate dimensions made from the same concrete grade of the parent
concrete, or as directed by the Engineer, so as to be durable, not lead to corrosion of reinforcement,
have the parent concrete strength and not cause spalling of the concrete cover.
10 Spacer blocks will be wired to the reinforcement by means of binding wire complying with the
Specification cast into the concrete of the blocks.
11 Where steel fabric reinforcement is specified, adjacent sheets will be overlapped by at least two mesh
widths and will be securely bound together.
12 Splicing/Lap length shall not be more than 50% on one location and to within the range of AASTHO
5.12 Welding of Reinforcement

1 Welding of reinforcement bars will not be permitted unless approved by the Engineer.
2 Welding will conform to AWS D1.4 and it will be demonstrated that no significant loss of material
strength or ductility is incurred through the welding process.
5.13 Cover
1 The concrete cover will be stated on the design and shop drawings and will be measured from the
surface of structural, non-structural, spacer or any other steel items closest to the formwork.
2 Tolerance to cover will be as specified in the durability report and in the design.
3 No concrete will be poured if the required covers are not achieved throughout each area to be
concreted and the Contractor will rectify non-compliant cover prior to concreting.
4 All concrete surfaces are to be surveyed by the Contractor as soon as is practicable upon the removal of
formwork and actual cover readings recorded.
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5 The cover surveys are to be carried out using a calibrated electronic cover meter and the results will be
submitted in a format as agreed with the Engineer.
6 Remedial action plans will be prepared by the Contractor if this survey identifies deficiencies in the as-
built covers.
7 When the permanent works resume, and immediately prior to casting the new permanent concrete, the
protective system shall be cleaned of any salts (chlorides and sulphates) and any debris, oils or other
substances which may affect the bond with the new concrete. This treatment and surface preparation
shall be as per any relevant instructions in the manufacturer’s information sheets, to receive the
permanent concrete with adequate bond to the coating system. The treatment shall include roughening
of the surface of the coating system.
5.14 Minimum Test Requirement

1 For every 100 tons of reinforcement supplied samples will be taken and tested for following items and
test results to be submitted to the Engineer:
a) Tensile Strength
b) Yield Point
c) Elongation after fracture
d) Behaviour in the bend test
e) Behaviour in the re-bend test
f) Deviation from cross section
g) Chemical composition
h) Thickness of coating of coated rebars
i) Continuity of coating Adhesion of coating of coated rebars
5.15 Failure to Meet Specified Requirements

1 Where any of the test results are not compliant or deviate from the manufacturer’s certified values the
Engineer will be informed immediately and the batch from which the test samples were taken will be
clearly marked as not approved, will not be incorporated into the Works and will be removed from Site
immediately.
2 The Contractor will immediately and as directed by the Engineer takes samples from other batches of
reinforcement from the same supplier for testing.
3 If any of these further samples are found to be non-compliant the Engineer’s approval of the supplier
will be deemed to be withdrawn and all reinforcement from that supplier will be removed from Site
forthwith and no further deliveries from said supplier will be accepted by the Contractor.
4 Any delay arising from the Contractor sourcing reinforcement from other approved suppliers as a result
of non-compliance will not be grounds for a claim.
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6 Precast Concrete
6.1 General
1 The Contractor will submit the Shop drawings of the precast girders for the approval of the Engineer
before the start of work.
2 Any fabrication by the Contractor without written permission from the Engineer will be at the
Contractor's risk.
3 Any members not fabricated in accordance with accepted shop drawings will be rejected by the
Engineer.
6.2 Moulds
1 The sides and soffits of the moulds for precast concrete will be strongly constructed, closely jointed and
perfectly smooth, and will be so designed by the Contractor that they can be taken apart and
reassembled readily.
2 They will be accurately dimensioned and will retain their shape both in line and dimensions during pre-
casting.
3 Moulds will be capable of developing required pre-camber along the length of the precast elements.
4 The bottom surface of girders at the bearing areas will be in a true level plane, which does not vary by
more than 2 mm from a true straight edge placed in any direction across the bearing area.
5 Joints are to be caulked where necessary to prevent leakage of “fines” from the mix.
6 The moulds are to be strongly stayed on the outside to prevent bulging or distortion during the
compaction of the concrete.
7 For reinforced concrete members, a length tolerance of + 3mm will be permitted in 6 meters with an
overall tolerance of not more than +10mm in the total length of any unit.
8 For all prestressed members the length, cross-section dimensions and straightness of precast concrete
will be measured at 28 +/- 2 days after casting or as otherwise agreed with the Engineer.
9 Unless otherwise stated, allowable dimensional variations will not exceed the values in Table 12.
Table 12: Dimensional Tolerances on Precast Units
Length Variation
Up to 3m + 6mm
3 to 4.5m + 9mm
4.5 to 6m + 12mm
6m to 24m + 18mm
Above 24m +25mm
Cross Section (each direction) Variation
Up to 500mm + 6mm
500 to 750mm + 9mm
Greater than 750mm Not greater than 12mm
Bow (Deviation from intended line) Variation
Up to 3m + 6mm
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Length Variation
3 to 6m + 9mm
6 to 12m + 12mm
12 to 18m + 18mm
Above 18m +25mm
6.3 Casting
1 Precast units will be cast in one complete operation.
6.4 Marking
1 All precast units will have impressed upon them in a convenient and conspicuous position, the date of
manufacture and such distinguishing letters or numbers.
2 Marking will not be done on exposed faces.
3 As-built records will clearly identify the location of each uniquely identified precast unit. The marking
should be cross referenced with the required cylinder tests for traceability as part of QC requirement.
6.5 Curing
1 All precast units will be cured in accordance with the requirements for severe exposure concrete.
2 Steam curing may be used in factory conditions subject to the results of trials to confirm no detrimental
effect to the concrete.
3 The curing methods and duration will be determined from durability study.
6.6 Handling Stacking and Transportation

Precast units will be lifted, loaded, transported off-loaded and stacked right way up and handled and placed
without impact and ensuring that no cracking, distortion or other adverse effect occurs due to inadequate
strength, incorrect curing, incorrect handling and stacking or otherwise. Detailed method statement to be
produced providing stacking and unit handling methods and allowable deflection limits, for Engineers
approval.
6.7 Failure to Meet Requirements

Precast units which are not compliant with the design and Specification will not be incorporated into the
Works, will be marked in an unambiguous manner to identify from any angle of view that they are defective,
and will be removed from the Site or destroyed without delay.
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7 Pre-stressed Concrete Works

7.1 General
1 This work will consist of design and construction of pre-stressing precast or cast-in-place concrete
elements.
2 It includes pre-stressing by either the pre-tensioning or post-tensioning methods or by a combination of
these methods.
3 The Contractor will submit to the Engineer for acceptance, the name and address of the organization
proposed for the performance of the Post-tensioned Concrete Bridge before the post- tensioned
subcontract is awarded.
4 The named proposed organization will submit evidence that it has experience, for a period of at least the
last five years in the region, in performing work comparable to the precast, post-tensioned Works under
these Specifications.
5 The proposed organization will verify this experience by citing at least two projects comparable to this
project which have been successfully accomplished.
6 For post-tensioned concrete the guidance of UK Concrete Society Technical Report No. 47 (Second
Edition) ‘Durable post-tensioned concrete bridges’ will be followed in addition to the requirements of
these Specifications.
7 Tests for components of Post tensioning system, to be specified in the Prestress Suppliers Test
Acceptance plan and submitted to Engineer for review and approval.
7.2 Details of Design

1 Contractor will determine the details or type of pre-stressing system for use and select materials and as
needed to satisfy the pre-stressing requirements.
2 The system selected will provide the magnitude and distribution of pre-stressing force and ultimate
strength required by the detailed design drawings without exceeding allowable temporary stresses.
3 The jacking force will be shown on the detailed design drawings as the force applied to the tendon prior
to anchorage and the occurrence of any losses, including the anchor set loss.
4 The Contractor will allow provisions for future prestressing in accordance with AREMA Manual for design
specification, Volume-2, Chapter 8, Clause 26.11.3. Provision for future prestressing of unbonded
external tendons to be considered for not less than 5% of post tension force in all under- bridges.
7.3 Shop Drawings

1 The shop drawings of the pre-stressing system will show complete details and substantiating calculations
of the method, materials and equipment the Contractor proposes to use in the pre- stressing operations.
2 Such details will outline the method and sequence of stressing and will include complete specifications
and details of the pre-stressing steel and anchoring devices, working stresses, anchoring stresses, tendon
elongations, type of ducts, and all other data pertaining to the pre- stressing operation, including the
proposed arrangement of the pre-stressing steel in the members.
3 The shop drawings will have the complete fabrication, profile, and placement details for all tendons,
including types, locations, anchorages, couplings and methods of supports and, in addition,
computations for the post-tensioning of each post-tensioned tendon and for all post- tensioning strands.
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4 The shop drawings will also show, in addition to the tendons and strands, the placement, sizes, and
details of the reinforcement steel as called for in the post-tensioned concrete work.
5 Shop drawings will be prepared showing formwork and method and types of bracing.
6 Shop drawings will be submitted at least 4 weeks in advance of the start of the affected work.
7 All shop drawings, computations and related data will be accompanied by design data indicating that the
forces indicated on the design drawings are obtainable and that all post-tensioning hardware is
adequate to transmit these forces.
8 Any fabrication by the Contractor without written permission from the Engineer will be at the
Contractor's risk.
9 Any members not fabricated in accordance with accepted shop drawings will be rejected by the
Engineer.
7.4 Materials
7.4.1 Pre-stressing Steel and Anchorages
1 Strands will be uncoated seven wire strands complying with the requirements of AASHTO M203 (ASTM
A416) Supplement S1 (low relaxation) or Stress relived seven wire low relaxation super stabilised strands
complying with BS 5896 or to meet the local authority requirements or as shown on the detailed design
drawings.
2 Pre-stressing strand, however manufactured, will be in coils of sufficiently large diameter to ensure that
the strand pays off straight.
3 Prior to shipment of the strands from the manufacturer's plant, the Contractor will submit for
acceptance by the Engineer, typical stress-strain curves obtained from the mill (or accepted independent
laboratory) test performance on the strands proposed for use.
7.4.2 Steel Wire

1 Steel wire will be uncoated stress-relieved steel wire complying with the requirements of AASHTO M204
(ASTM A421) or BS 5896.
2 Low relaxation and normal relaxation wire will be in coils of sufficiently large diameter to ensure that the
wire pays off straight.
3 All cables shall comprise of uncoated cold drawn seven wire low relaxation steel super grade 270 strands
to ASTM A416 with the following properties.
Nominal Diameter 15.2mm
Nominal Cross sectional area of strand 140mm2
Ultimate Tensile strength 1860MPa
Minimum Breaking Load 260.7KN
Elastic Modulus of a Single Strand 197000MPa
Coefficient of Friction 0.20
Wobble Coefficient 0.002/m
7.4.3 Bars
1 Bars will be uncoated high strength bars complying with the requirements of AASHTO M275 (ASTM
A722).
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2 Bars with greater minimum ultimate strength, but otherwise produced and tested in accordance with
AASHTO M275 (ASTM A722) may be used provided they have no properties making them less
satisfactory than the specified material.
3 Pre-stressing bars as delivered will be straight.
7.4.4 Post-tensioning Anchorages and Coupler

1 Anchorages will be cast units and assemblies that are standard with the pre-stressing manufacturer’s
system.
2 All anchorages and couplers will develop at least 95 percent of the minimum specified ultimate strength
of the pre-stressing steel, when tested in an un-bonded state, without exceeding anticipated set.
3 Anchorages will be tested in accordance with AAREMA, AASHTO LRFD Design and Construction
Specification-Section 10 or BS 4447.
4 Proprietary anchorages will be handled and used strictly in accordance with the manufacturer’s
instructions and recommendations.
5 Anchor cones, blocks and plates will be hot dip galvanized.
6 Contractor to provide a calibration graph for each jack, calibrated not more than 6 months prior to
stressing operation.
7 The confining reinforcing steel in the local zone shall be same as that specified by the anchorage device
supplier for the particular system. Reference AASHTO LRFD Bridge Constuction specification - Section
10.3.2.3.
7.4.5 Identification and Testing

1 All wire, strand or bars to be shipped to the site will be assigned a lot number and tagged for
identification purposes.
2 Anchorage assemblies to be shipped will be likewise identified.
3 Each cable will be tagged with its number from which the coil numbers of the steel used can be
identified.
4 Each lot of wire or bars and each reel of strand reinforcement will be accompanied by a manufacturer’s
certificate of compliance, a mill certificate, and a test report.
5 The mill certificate and test report will include the chemical composition (not required for strand), cross-
sectional area, yield and ultimate strengths, elongation at rupture, modulus of elasticity, and the stress
strain curve for the actual pre-stressing steel intended for use.
6 All values certified will be based on test values and nominal sectional area of the material being certified.
7 The actual strength of the pre-stressing steel will not be less than specified by the applicable British or
ASTM Standard, and will be determined by tests of representative samples of the tendon material in
conformance with the appropriate Standards.
7.4.6 Pre-tensioning Tendon Testing

For pretensioned strands, one sample at least 2.1 metres long will be tested in accordance with the
requirements of paragraph 9.1 of AASHTO M203 (ASTM A 416M-Section 10).
The strands relaxation testing - ASTM 416 - Section 6 & 7
Static efficiency test reports are provided in the MAR of the PT supplier
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7.4.7 Post- tensioning Tendon Testing

The following lengths will be tested for each 10 ton as per ASTM A 416M, or portion thereof, lot of material
used in the work.
For wires requiring heading: 1.5 metres.
For wires not requiring heading: sufficient length to make up one parallel-lay cable 1.5 metres long consisting
of the same number of wires as the cable to be furnished.
For strand to be furnished with fittings: 1.5 metres between near ends of fittings.
For bars to be furnished with threaded ends and nuts: 1.5 metres between threads at ends.
The strands relaxation testing shall be carried out as per ASTM 416 - Section 6 & 7
Static efficiency test reports shall be provided in the Material Submittals of the Post Tension works Supplier.
7.4.8 Corrosion Protection

1 Corrosion Protection will consist of a vapour phase inhibitor (VP) powder conforming to the provisions of
U.S. Federal Specification MIL-P-3420.
2 When accepted, water-soluble oil may be used on tendons as a corrosion protection.
7.4.9 Ducts
1 Duct will be of ferrous metal sheaths, mortar-tight cast into the girders and will be hot dip galvanized.
2 The system of ducts, duct connectors, grouting connections, vents, vent connectors, drains, transition to
anchorages and caps for anchors will form a complete encapsulation for the tendon which is resistant to
ingress of air and water.
3 Ducts will be of proven corrosion resistant durable material.
4 Ducts will be tested to BS EN 523-Table 2, Section 8.3 and BS EN 524 of minimum thickness 0.4mm.
5 The system will be fully compatible with the pre-stressing anchorages, couplers and other details.
6 Where ducts are non-conductive, metal parts of the anchorages will be electrically bonded to the
adjacent reinforcement at each end of the tendon and electrical continuity of the structure over the
length of the tendon will be confirmed by testing.
7 Polyethylene duct will not be used when the radius of curvature of the tendon is less than 9 metres.
8 Rigid polyethylene ducts for use where the tendon is not embedded in concrete will be rigid pipe
manufactured in accordance with ASTM D2447, ASTM F714, ASTM D2239, or ASTM D30. For external
applications, such duct will have an external diameter to wall thickness ratio of 21 or less.
9 For applications where polyethylene duct is exposed to sunlight or ultraviolet light, carbon black will be
incorporated into the polyethylene pipe resin in such amount to provide resistance to ultraviolet
degradation in accordance with ASTM D1248.
10 Where sheaths are used the number of joints will be kept to a practicable minimum and each joint
adequately sealed against the ingress of any material.
11 Joints in adjacent sheaths will be staggered by at least 300mm.
12 Sheaths will be kept free of any matter detrimental to the bond between the sheath and the grout and,
except for material sealing a sheath joint, between the sheath and the concrete.
13 The nominal thickness of duct strip shall be 0.45mm. PT ducts shall be in accordance BS EN 523 and BS
EN 524. Primary production tests are dimensions, to-and-fro bending and leak tightness test.
14 Ducts shall be tested to Determination of lateral load resistance (BS EN 524), Determination of Tensile
load resistance (BS EN -524), Determination of flexural behaviour of steel strips sheets (BS EN 524)
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7.4.10 Duct Area

1 The inside diameter of ducts will be at least 6mm larger than the nominal diameter of single wire, bar or
strand tendons, or in the case of multiple wire, bar or strand tendons the inside cross- sectional area of
the sheathing will be at least two times the net area of the pre-stressing steel.
2 When tendons are to be placed by the pull through method, the duct area will be at least 2.5 times the
net area of the pre-stressing steel.
7.5 Placement of Ducts and Steel

7.5.1 Placement of Ducts
1 Ducts will be rigidly supported at the proper locations in the forms by ties to reinforcing steel which are
adequate to maintain proper alignment of the duct and to prevent displacement during concrete
placement.
2 Supplementary support bars shall be used where needed to maintain proper alignment of the duct. Hold
down ties to the forms shall be used when the buoyancy of the ducts in the fluid concrete would lift the
reinforcing steel.
3 Polyethylene duct and metal duct fro longitudinal or transverse post-tensioning in the flanges shall be
supported at intervals not to exceed 600mm.
4 Polythylene duct in webs for longitudinal post tensioning shall be tied to stirrups at intervals not to
exceed 600mm and metal duct for longitdunal post-tensioning in webs shall be tied to stirrups at
intervals not to exceed 1200mm.
5 Joints between sections of duct will be coupled with positive connections that do not result in angle
changes at the joints and will prevent the intrusion of cement paste.
6 Tolerance of duct installation to follow AASHTO LRFD Bridge Construction Specification – Table 10.4.1.1-
1 , tabulated below and to be provided in the Method statement for casting of Prestressed structures,
for Engineers approval.
Table 13: Duct Position Tolerances
Tolerances Vertical position Lateral position

(mm) (mm)
Horizontal tendons in slabs or in slab regions of larger ±6 ±12
members
Longitudinal draped superstructure tendons in webs ±6 ±6
Tendons over supports or in middle third of span
Tendons in middle half of web depth ±12 ±6
Longitudinal , generally horizontal, superstructure tendons ±6 ±6
usually in top or bottom of member
Horizontal tendons in substructures and foundations ±12 ±12
Longitudinal Transverse
position position
(mm) (mm)
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Vertical tendons in webs ±6 ±6

Vertical tendons in pier shafts ±6 ±6
Additionally, the following shall apply;
a. In all other cases, locate tendons within ±6mm in any direction

b. Entrance and exit angles of tendon paths at anchorages and/or at faces of concrete shall be
within ±3 degrees of desired angle measured in any direction and any deviations in the
alignment are accomplished with smooth transitions without any kinks.
c. Angle changes at duct joints shall not be greater than ±3degrees in any direction and must be
accomplished with smooth transitions without any kinks.
d. Locate anchorages within ±6mm of desired position laterlly and ±25mm along the tendon
except that minimum cover requirements shall be maintained.
e. Position anchorage confinement reinforcement in the form of spirals, multiple U-shaped bars of
links to be proporely centered around the duct to start within 12mm of the back of the main
anchor plate.
f. If conflict exist between the reinforcement and the post tensioning duct, position the post
tensioning duct and adjust the reinforcement locally with the Engineer’s approval.
g. All ducts for continuous structures shall be supplied with outlets at the high and low points of
the duct profile, except where the profile changes are small, as in continuous slabs, and at
additional locations as specified in the drawings. Low point outlets shall remain open until
grouting is started.
7.5.2 Vents and Drains

1 All ducts for continuous structures will be vented at the high points of the duct profile, except where the
curvature is small, as in continuous slabs, and at additional locations as shown on the plans.
2 Drains will also be installed at low point in ducts where needed to prevent the accumulation of water
and will remain open until grouting is started.
3 The ends of vents and drains will be removed 25mm below the surface of the concrete after grouting has
been completed, and the void filled with flowable non-shrink mortar to a level flush with the adjacent
concrete surface.
4 Waterproofing membrane over the grouted void will be double thickness for 150mm in all directions
from the edge of the mortar patch.
7.5.3 Placement of Pre-tensioning Steel

Pre-stressing steel will be accurately installed in the forms and held in place by the stressing jack or temporary
anchors and when tendons are to be draped, by hold-down devices.
7.5.4 Placement for Post-Tensioning Steel

1 When the pre-stressing steel is installed after the concrete has been placed, the Contractor will verify
that the ducts are free of water and debris immediately prior to installation of the steel.
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2 The total number of strands in an individual tendon may be pulled into the duct as a unit, or the
individual strand may be pulled or pushed through the duct.
3 Anchorage devices or block-out templates for anchorages shall be set and held so that their axis
coincides with the axis of the tendon and anchorplates are normal in all directions to the tendon.
7.5.5 Protection of Steel after Installation

1 Pre-stressing steel installation in members prior to placing and curing of the concrete or installed in the
duct but not grouted within the one day, will be continuously protected against rust or other corrosion
by means of a corrosion protection placed in the ducts or directly applied to the steel.
2 The pre-stressing steel will be so protected until grouted or encased in concrete.
3 The permissible interval between tendon installation and grouting without use of a corrosion protection
for various exposure conditions will be one (1) day.
7.6 Tensioning
7.6.1 General Tensioning Requirements
1 Pre-stressing steel will be tensioned by hydraulic jacks so as to produce the forces shown on the detailed
design drawings with appropriate allowances for all losses.
2 For post-tensioned work the losses will also include the anchor set loss appropriate for the anchorage
system employed.
3 The Contractor will submit to the Engineer for review complete details of the method, materials and
equipment he proposes to use in the post-tensioning operations, including any additions or
rearrangement of reinforcement steel from that indicated on the Drawings.
4 Such details will outline the method and sequence of stressing and will include complete specifications
and details of the post-tensioning steel and anchoring devices, working stresses, anchoring stresses, type
of ducts, and all other data pertaining to the post-tensioning operation.
5 Tendons/strands are to be stressed to a jacking load as per AASHTO LRFD requirements of the tendon
ultimate tensile strength, f’s (AASHTO LRFD table 5.9.3-1).
6 The Contractor will provide the jacking stresses values before and after seating as noted in AASHTO
LFRD, Article 5.9.3., as an easy reference for the future construction team at site.
7 The calibration of all the jacking and pressure gauges equipment will be within 6 months, prior to
stressing work commencement.
8 All strands in each tendon, except for those in flat ducts with not more than four strands, shall be
stressed simultaneously with a multi-strand jack.
9 Post-tensioning grout shall meet the grout physical properties stated in Section 10.9 - AASHTO LRFD
Bridge Construction specifications
7.6.2 Concrete Strength

Unless otherwise agreed by the Engineer, pre-stressing forces will not be applied or transferred to the concrete
until the concrete has attained the 28 days strength.
7.6.3 Sequence of Stressing

The sequence of stressing individual tendons will be as specified on the detailed design drawings and as
approved by the Engineer.
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7.6.4 Measurement of Stress

1 A record of gauge pressures and tendon elongations for each tendon will be made by the Contractor.
2 Elongations will be measured to an accuracy of 1mm.
3 Stressing force on the tendons will be applied till the calculated elongations are achieved or stipulated
jack pressure is reached with the following conditions:
a) If the stipulated elongation is reached before the stipulated pressures, continue tensions until the
stipulated pressure is achieved provided the actual elongation does not exceed 1.05 x stipulated
elongation. In case 1.05 x stipulated elongation is reached before the stipulated pressure, tensioning
will be stopped and the matter reported to the Engineer immediately.
b) If the stipulated elongations are not reached at the stipulated pressures, continue tensioning in
reasonable steps as approved by the Engineer until stipulated elongation or a pressure equal to 1.05
x stipulated pressure is reaches, (whichever is earlier). If the elongation is less than 95% of stipulated
extension at 1.05 x stipulated pressures, tensioning will be stopped and the matter reported to the
Engineer immediately.
4 Stressing tails of post-tensioned tendons will not be cut off until the stressing records have been
accepted.
5 A facility to measure any movement of the tendon in the gripping devices will also be provided.
6 Anchorage protection system shall be in accordance to AASHTO Construction specifications Section
10.11.10
7.6.5 Friction Test

1 The design will be based upon friction losses determined from friction tests carried out on one tendon
for each tendon configuration and the associated duct system.
2 Values of friction and wobble coefficients obtained in Friction Test will be used for the calculation of
theoretical elongations.
3 The friction test will be done by the Contractor at his cost.
4 Friction coefficient and wobble factor shall be confirmed by test prior to Final prestressing and subject to
the Engineer’s approval.
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8 Grout and Mortar

8.1 General
1 Mix designs for the mortar will be prepared by the Contractor.
2 Cement grout will be an intimate non-bleeding combination of Portland cement and water with a
maximum water/cement ratio of 0.42.
3 The grout will be mixed in an approved colloidal type mixer.
4 The chloride ion content of the mortar determined in accordance with BS 812 will not exceed 0.1% of
the mass of cement for mortar made with Ordinary Portland Cement and 0.2% for mortar made with
Sulphate-Resisting Portland Cement (SRC) unless otherwise determined from the durability report.
5 Calcium chloride or admixtures containing calcium chloride will not be used.
6 Plasticizers will not contain calcium chloride, and will comply with BS EN 934-4.
7 A method statement will be submitted to the Engineer that includes the product details, how the grout
will be placed and the methods that will be used to verify complete penetration of the material so that
air pockets and other defects are not present.
8 This method statement will be confirmed by casting a mock-up of the proposed grouting condition.
9 The grout shall not contain more than 0.10% (by weight of cement) chloride content, 4.5% (by weight of
cement) of sulphate content and 0.01% (by weight of cement) of sulphide ions in accordance with BS EN
447.
8.2 Mortar for General Purposes

1 Cementitious mortar will be mixed in the proportion given in Table 14 according to the mortar class
described on the Drawings.
2 For work in which cement mortars of Class 2 or 3 are required, the Contractor will select the appropriate
mortar form one of the mixes for the class given in Table 14.
3 The inclusion of lime in Class I mortar is optional. The proportions of lime given in Table 13 are for lime
putty complying with BS 890. If the lime is measured as the dry hydrate, the amount may be increased
up to 1.5 volumes for each volume of lime putty.
4 Where a range of sand contents is given in the Table 14, the higher will be used for sand that is well
graded and the lower for coarse or uniformly fine sand.
Table 14: Mortar Proportions by Volume
Class Cement: lime: sand Masonry cement: sand Cement: sand with plasticizer
1 1:0 to 0.25:3 Not applicable Not applicable
2 1:0 to 0.25:3 1:2.5 to 3.5 1:3 to 4
3 1:0.5:4 to 4.5 1:1:5 to 6 1:4.5 1:5 to 6
5 Mortar will be mixed thoroughly by mechanical means until its colour and consistency are uniform.
6 The constituent materials will be accurately gauged, allowance being made for bulking of sand.
7 Mortar will be made in small quantities only as and when required.
8 Mortar which has begun to set or which has been mixed for a period of more than ½ hour in the case of
a Class I mortar or more than 1 hour in the case of other classes will be discarded.
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8.3 Grouting for Pre-stress

1 Grouting procedures will be in accordance with the UK Concrete Society Technical Report 72 (Second
edition).
2 The Contractor will undertake grout trials in accordance with UK Concrete Society Technical Report 72
(Second edition) Grout Materials.
3 Grouting operation will start as soon as practical but not earlier than 12 hrs and no later than 3 days
after pre-stress lock-up.
4 Grouting mix will be carried as detailed in EN 446 and test methods as per EN 445.
5 All materials for grouting will be qualified by appropriate laboratory testing or certification prior to use in
the project.
6 Acceptance of grout properties will be based upon results of laboratory tests. These tests will include:
a) Grout Setting time in accordance with ASTM C 953
b) Grout Strength in accordance with ASTM C942 and as per bond and shear design strength
requirements
c) Volume Change in accordance with ASTM C1090 “Standard Test Method for Measuring Volume
changes in height of Cylindrical specimen from Hydraulic cement Grout. A value of 0.1% at 24 hours
and no more than 0.2% at 28 days in acceptable and/or BS EN 447 to ensure that tested values are
less than 0.1% at 24 hours and no more than 3% at 28 days.
d) Flow time / Fluidity test to ensure that grout completely fills the tendon ducts in accordance with
ASTM C939.
e) Bleed / Segregation test to ensure grout will be less than 2% to limit free water inside the tendon duct
and any bleed water to be reabsorbed by the grout within the specified time. Wick Induced Bleed test
in accordance with ASTM C940 (or Inclined Tube test) will be carried out.
f) Grout and ambient temperature shall be as per BSEN 446
7 Grout durability requirements shall be included in line with Durability Assessment Report and AASTHO
requirements (Table 10.9.3.2)
8.4 Bedding Mortar for Bearings and Base Plates

1 Non-shrink grout shall be used for the bedding of bearing and base plate.
2 Unless otherwise described on the drawings, bedding mortar will have a compressive strength not less
than 50 N/mm2 when tested in accordance with the requirement of this clause.
3 The stress in the mortar will not exceed that defined on the detailed design drawings.
4 Where the mortar is required to resist stress before attaining its 28 days strength the compressive
strength will be confirmed by tests on mortar cubes stored under conditions that simulate the field
conditions.
5 The assessment of the strength of the bedding mortar and stress produced by the loads will be certified
as acceptable by the Contractor’s design consultant.
6 Mixing, placing and curing proprietary bedding mortar will be carried out in accordance with the
manufacturer’s written instructions.
7 For cementitious bedding mortars, the substrate will be flushed clean with water two hours before
placing and maintained wet until placing commences.
8 Any free water on the surface of the substrate will be removed before placing the mortar.
9 Immediately after casting, the mortar will be protected to prevent evaporation for at least three days.
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10 For resinous bedding mortars the substrate will be dry, free from loose dirt and dust and will meet the
conditions specified by the manufacturer.
11 The underside of the base plate will be clean and free from loose rust and loose mill scale at the time of
bedding.
12 No internal metal shims will be allowed to remain in the hardened bedding mortar except where
permitted by the Engineer.
13 The Contractor will submit his proposals for shims for approval by the Engineer.
14 The Contractor will submit a Method Statement detailing the grouting procedures to the Engineer for
review and approval prior to commencement of the works.
8.5 Testing
1 Mortar will not be used in the Works until it has been approved by the Engineer.
2 Every batch of mortar to be used in the Works will be tested by the Contractor.
3 Testing will include flow, compression, expansion, and water absorption and elasticity tests and will be
subject to the approval of the Engineer.
4 No mortar will be incorporated into the Works without written approval by the Engineer.
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9 Special Coating System for The Protection

of Exposed Concrete Surfaces
9.1 General
1 The Special Coating System for exposed concrete surfaces will be proposed by the Contractor and will
fulfil the requirements specified herein and as directed by the Engineer.
2 Protection coating for train fumes will be applied to exposed concrete surface of existing structures in
accordance with local authority/stakeholder requirement and in agreement with the Engineer.
3 All materials will be from an approved manufacturer whose products have proven to be highly
satisfactory in similar works in environmental conditions similar to those experienced in the UAE and
Gulf Countries.
4 In this respect the Contractor, when submitting for approval the coating system proposed to be used,
will enclose also a list of works executed in environmental conditions similar to those experienced in
UAE and Gulf Countries in which the same system was successfully used.
5 The Contractor's application will be accompanied by the manufacturer's detailed product specifications
together with application instructions, and guarantee that the product is suitable for use at the
operating temperatures in UAE and Gulf Countries.
6 Trial panels will be tested for Initial Surface Absorption Test before and after priming as a check on the
effectiveness of the primer.
7 The Contractor will provide evidence, for the Engineer's approval, that the coating system will render the
concrete surface satisfying the following protection criteria:
a) Anti-carbonation: Carbon dioxide diffusion coefficient less than 8 x 10-8 cm2/s
b) Chloride Ingress: Chloride ion diffusion coefficient less than 5 x 10-9 cm2/s
c) Crack bridging ability more than 1mm to modified ASTM C836 884 at 20ºC
d) Breath ability: Water vapour diffusion coefficient greater than 3.5 x 10-5 cm2/s
8 The protection characteristics will be determined by test methods approved by the Engineer. N_SRS1
The coating system shall be an elastomeric system of single component products, a weather resistant
topcoat used in conjunction with a penetrating primer. The coating shall have the ability to provide in-depth
protection for reinforced concrete structures against corrosion associated with the ingress of chloride and
sulphate ions, carbon dioxide and other air-borne acid gases, and shall have the ability to allow water vapour
to escape from the structure.
9.2 Properties
The system will, during trials, display the properties in Table 15 when applied in accordance with the
manufacturer’s specification to samples obtained from concrete made without additives.
Table 15: Properties for Coating Effectiveness
Property Modification Acceptance Criterion
Reduction in Chloride Ion Penetration measured in accordance 90% minimum at 28 days

with ASTM C 1202-97
Water Vapour Transmission
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Property Modification Acceptance Criterion
(Method of testing and interpretation of results will be subject to >13g/m2/day

acceptance of Engineer)
Carbon Dioxide Diffusion Resistance Method of testing will be Equivalent to 500mm of 30 N/mm2 concrete
subject to acceptance of Engineer
Reduction in Water Absorption (measured against a control 82% minimum at 28 days when tested at a water cement
concrete sample in accordance with ASTM C642) ratio < 0.50
Dry film thickness Minimum 250 to 300 microns
Adhesion Minimum 1.0 MPa
Adhesion after exposure to salinated fog (NFT 30 062) Minimum 1.0 MPa
Resistance to humidity and heat (NFT 30 802) No loss of adhesion, no cracking, no bubbling, no change
in colour, no dust.
Resistant to impact (NFT 30 015) No cracking, no un-sticking
Resistance to abrasion (NFT 30 015) Max. loss of weight 25mg/100 abrasions
Resistance to salinated fog (NFT 41 002) No dusting, no cracking no un-sticking, no bubbling
Solar infra red rays Re radiates 95%
Ultra violet rays Re radiates 85%
9.3 Primer
The primer shall be a low viscosity reactive silane-siloxane/acrylic blend dissolved in a penetrating organic
carrier. The primer shall have the capability to penetrate and produce a chemically bound hydrophobic barrier
to prevent the passage of chloride and sulphate ions. The primer should also be film forming to condition and
stabilize the substrate prior to the application of the topcoat. The primer should be applied in full accordance
with the manufacturer’s instructions.
9.4 Topcoat
The topcoat shall be a pure aliphatic acrylic resin, decorative, high performance water based, pigmented
coating. It shall have resistance to water, carbon dioxide and other air-born acids and have the ability to allow
the passage of water vapour from within the structure.
The topcoat shall have elastomeric and flexural capabilities and should be applied in strict accordance with
the manufacturer’s instruction.
The system will, during trials, display the following properties when applied in accordance with the
manufacturer's specification to samples obtained from concrete made without additives.
9.5 Trial Panels

1 Prior to applying the system in the works, trial applications will be carried out on trial panels.
2 The trials will demonstrate the method proposed for applying the system, coverage, coating thickness,
colour and final appearance of the coating.
3 Representatives of the coating manufacturers will be present at the trials and the surface
preparation and application of the coating will be carried out under their direction.
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4 The Contractor will at his own expense surface coat as many panels as required by the Engineer until a
trial panel has been accepted by the Engineer as satisfactory.
5 The coated panel, when accepted will form the standard against which the corresponding coating in the
works will be judged.
6 No application of the coating in the works will be undertaken until trials have been completed to the
Engineer’s satisfaction.
9.6 Inspection of Concrete

The Contractor will not proceed with the surface finish or making good of concrete surfaces until he has
received the Engineer’s Representative’s permission to do so and he will not apply cement slurry or mortar or
any other coating to the concrete surfaces from which the shuttering has been struck until the concrete has
been inspected and approved, by the Engineer.
After de moulding or de shuttering, post pour inspection to be carried out and any defects/ cracks in concrete
to be recorded. The defects in the concrete are to be repaired as per the approved method statement and
inspection to be done post repair. If the inspection is completed, then the contractor can proceed for the
surface preparation works.
9.7 Approval Prior to Coating Application in the Works

1 The Engineer’s approval will be obtained prior to applying the coating system and to satisfy the
following:
a) All construction work in the immediate vicinity of the structure to be coated has been completed.
b) The surface preparation of the structure has been completed.
c) The whole of the structure can be coated in a continuous operation.
d) Adequate measures have been taken to protect the property of third parties, including vehicles, from
coating splatters.
e) The weather conditions accord with the coating manufacturer’s directions for coating application.
2 The Contractor will seek the Engineer’s approval for the proposed coating system.
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10 Structural Steelwork
10.1 General
1 The Works under this section will be done according to the provisions of the Contract, these
Specifications and Design Criteria; and as shown on the design and shop drawings prepared by the
Contractor.
2 This section is to cover the fabrication of steel members.
3 Before beginning to erect any steel structure, the Contractor will submit to the Engineer for review and
approval for the erection Plan and procedure describing the methods the Contractor intends to use.
10.2 Steelwork
1. Structural steelwork will comply with the requirements specified in the design prepared by the Contractor.
2. The steelwork Contractor is responsible for checking the design of the steel structure, including
connections, for temporary forces which may arise during the erection process and prior to completion of
the permanent structure.
10.3 Shop Drawings

1 Shop drawings will be prepared by a specialist steelwork fabricator.
2 Shop drawings will be prepared insofar as is practicable in accordance with "Detailing for Steel
Construction", American Institute of Steel Construction.
3 The shop drawings will be in sufficient detail that all dimensions of each component including any holes
or fixings are clearly shown to scale.
4 The shop drawings will be reviewed and certified as correct by the Contractor’s design consultant.
5 The contractor shall submit detail Erection method statement and Erection drawing to Engineer three
weeks prior to Proceeding erection works. Allowable Fabrication and Erection tolerances. Drawings Shall
be fully coordinate with Architectural and Utilities
10.4 Materials and Fabrication

10.4.1 General
1 The Contractor will adhere to requirement of AREMA CH15, ASTM A709, ASTM A588, ASTM A572, ASTM
A36, and AWS D1.5.
2 The structural steel members will be in accordance to AREMA CH 15, Sec 1.14 "Fracture Critical
Members".
10.4.2 Steelwork
1 Weathering Steel Grade 50W (ASTM A709) has been specified for primary steel members.
2 For other elements, Grade 50 for corrosion-resisting structural steel shapes, plates, and bars as per
ASTM A588/ A588M, if required, may be used.
3 Mill/Manufacturer’s Test Certificate of the following materials shall be produced as specified in Section
10.10.2;
a) Plates and rolled sections
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b) Welding consumables
c) Bolts, nut, and washer with mechanical and chemical properties
d) Shear stud connectors
e) Corrosion protection coating materials
10.5 Fasteners
1 All bolts for field splices shall be high-strength friction grip bolts with Associated nuts and washers in
according to ASTM A325/A325M Type 3 or ASTM A490/A490M Type 3 (weathering steel).
2 Nuts (for ASTM A325 and A490 bolts) shall confirm to the requirements of ASTM A563M.
3 Washer shall conform to the standard specification for hardened steel washer AASHTO M293M.
4 HSFG bolts, nuts and Washers will be supplied as per AREMA Chapter 15.
5 The splices shall be checked as slip-critical per AASHTO LRFD 6.13.2.1.1. The contact Surfaces (faying
surface) of the bolted parts are assumed to be CLASS B according to AASHTO 6.13.2.8 and Section 1.4;
Table 15.1.11a of AREMA Chapter 15.
6 Corrosion protection for the slip critical CLASS B according to AASHTO 6.13.2.8 and Section 1.4; Table
15.1.11a of AREMA Chapter 15 shall be proposed by contractor and will be used after approval from
Engineer.
7 Field splices are as per contractor’s requirements.
8 Bolt threads are excluded from the shear plane.
The orientation of bolted splices is to be perpendicular to the top flange except where specific splice geometry
has been shown on the drawings.
10.6 Shear Studs

1 Headed stud-type shear connectors shall conform to ASTM A108, minimum yield strength 345 MPA.
2 Length and spacing of studs shall be as specified on the Structural Drawings.
3 Shear stud shall not be welded on wet surface or installed on wet decks or structural steels. Studs to be
placed on clean surface without rust, oil, water, or other material that interfere welding. Source of
welding power for shear connector stud shall consists of single generator with an output of 2000 ampere
and more. Shear connector studs shall not be installed without ferrules, after welding the ferules shall be
removed.
4 A ring test/Bend test shall be done for testing the welding of stud. Studs which are failed shall not be
reused. During the welding operations shear connector studs shall be continuously tested. A minimum of
two studs on each structural member shall be tested, with tests being made at 1/3 points of the span. If
a failure occurs, then every shear connector stud on the structural steel member upon which failure
occurred shall be tested.
5 Corrosion protection to shear stud: There shall be no corrosion protection to shear studs as the studs
will be embedded in Deck Reinforcement Concrete.
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10.7 Cutting, Bevelling , Fit up , Welding and Post Weld

Inspection
Item No Inspection and Testing ITP Clause. Tolerance/ Acceptance Criteria /Reference Code Remarks
Activities
1 Plates and Rolled 3.1 ASTM A 709 Gr50WF Type A/B/C, Z3, - Mechanical
Sections and Chemical properties.
ASTM A6 – Dimension Tolerance
ASTM A 578 Level B – Ultrasonic Testing
2 Cutting 3.2 Cutting Tolerance 2mm to 5mm Based on thickness,

Cutting equipment
etc.
3 Bevelling 3.2 As per AWS D 1.5, Clause 4 and approved drawings
4 Fit Up Inspection I- 3.3 1. Length: +1mm/m with respect to drawing for

Beam longitudinal Welding
2. Section Depth:
+3mm.
5 Fit Up Inspection for 3.3 As per AWS D 1.5, Clause 5.5

Assembly
6 During Welding 1.3, 3.4 Welding Parameters as per Approved Welding

Inspection Procedure Specification (WPS)
7 Post weld Inspections
7.1 Weld Visual Inspection 3.4, Visual Weld Defects as per AWS D1.5 Clause 5.6 and
Clause 8 .26.1
Fillet Weld Size AWS D 1.5 Table 4.1 and Table 9.2
7.2 Ultrasonic Testing 3.5 AWS D1.5 Clause 8.26.3
7.3 Magnetic Particle Test 3.6, 3.7 AWS D1.5 Clause 8.26.2
7.4 Radiography Test 3.8 AWS D1.5 Clause 8.26.2
7.5 Dimensions 3.9 AWS D1.5 Clause 5.5

a) Straightness : 1mm/m, max 10mm up to 15m
Length
b) Length : +/- 1mm per m
c) Section Depth: +/- 3mm
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10.8 Welding
1 Welding of steelwork will be in compliance with AWS D1.5.
2 All welding will be 100% visual inspected.
3 All butt welds will be Radiographic Test (RT) inspected 100% after stress relieving, subject to Engineers
approval.
4 All fillet welds will be Magnetic Particle Index (MPI) inspected 100%.
5 All bearing stiffener will be Ultra sonic Testing (UT) tested 100%.
6 Weld Electrode specification should conform to AASHTO/ AWS D1.5.
7 All welds shall be on Clean steel. Ensure to remove all coatings, galvanizing, grease, scale, rust, and other
foreign matters in location of weld. Detailing of connections, welding sequences , preheat and inter-pass
temperature method shall be such as to minimize restraint and accumulation and concentration of
through thickness strain due to weld shrinkage.
8 All welded joints visible to be Grind Flush with edge of plates. If the Welding found to be defective,
remedial measures shall be agreed with contractor, engineer, and testing agency before proceeding.
Ensure not to deform the weld while dressing.
10.8.1 Welding Defects

1 Welding defects disclosed by inspection or other investigation will be cut out and remade.
2 Joints cut out will be examined and passed before rewelding.
3 All welding repairs are the responsibility of the Contractor.
10.8.2 Site Welding

1 For site welding , facilities will be provided to obtain the same standard of workmanship here as in the
shop.
2 Welding in the air will be reduced to a minimum by assembly and erection procedure.
3 All welding in the air will be from properly positioned platforms and wherever possible will be designed
to avoid overhead welding.
4 Tacking bolts or cleats, other than those detailed, will be provided as needed but only after discussion
with the designer who will assess any implications on fatigue resistance.
10.9 Holing
1 Holes for bolts will be drilled or punched and not gas cut.
2 Bolt locations will be as shown on the design drawings or amended as accepted by the designer in
writing.
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10.10 Submittals
10.10.1 Drawings
1 Shop-drawings
i. Shop drawings shall be prepared under supervision of qualified professional Engineer and should
include complete details and schedules of fabrication, connection design and assembly of
structural steel members, Joint Geometry, procedures, and diagrams.
ii. Shop Drawings shall show fabrication of structural steel components and shall include the
following:
Detailed construction drawings, along with calculations of connections and temporary works only for
review and approval.
Details of cuts, connections, splices, camber, holes, and other pertinent data.
Include embedment drawings if any.
Indicate welds by standard symbols, distinguishing between shop and field welds, and show size,
length, and type of each weld.
Indicate type, size, and length of bolts, distinguishing between shop and field bolts. Identify
pretensioned and slip-critical high-strength bolted connections.
iii. For structural-steel connections indicated to comply with design loads, include structural
analysis data prepared, signed, and sealed by the qualified professional engineer responsible for
their preparation
iv. Drawings are to be fully coordinated against architectural and MEP drawings to show all
interfaces with the structural steel.
2 Erection Scheme drawings Including Temporary Structure Drawings if any.
3 Red Line Mark-up Drawings
4 As built Drawings
5 Weld Test Plan Drawings
10.10.2 Material Submittals

1 Steel
i. Copies of Mill test certificates will be in accordance with ASTM A6, showing Chemical Analysis
and Physical tests of the structural steel prior to commencement of fabrication.
ii. Structural steel without Mill certificates will be rejected.
iii. Two copies of Charpy V-notch certified test report will be submitted in accordance with AREMA
CH 15 table 15-1-1 prior to start of fabrication.
2 Paint
i. Copies of Manufacturer’s Test Certificate & Reports will be in accordance with EN ISO 12944 or
AREMA Chapter 15 from Approved Manufacturer
ii. Intumescent Coating Test Reports
3 Welding Consumables
i. Copies of Manufacturer’s test certificates will be in accordance with AWS D1.5, showing
Chemical Analysis and Physical tests prior to commencement of fabrication.
ii. List of consumables along with Manufacturer Credentials.
4 Fasteners
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i. Copies of Manufacturer’s test certificates will be in accordance with ASTM A325 Type 3, showing
Chemical Analysis and Physical tests prior to commencement of fabrication.
ii. List of Fasteners along with Manufacturer Credentials.
iii. ITP for Fasteners
10.10.3 Fabrication and Corrosion Protection

i. Fabrication Method statement and Risk Assessment.
ii. ITP for fabrication and Inspection Formats
iii. Surface Preparation & Painting Method statement and Durability Assessment.
iv. ITP for Surface preparation & painting and inspection Formats.
v. Preliminary Welding Procedure specification (PWPS), Welding procedure Specification (WPS) ,
Procedure Qualification Records (PQR), Welder Qualification Record and Certificates(WQR&C)
will be stamped by an inspector of ASNT Level 3 in accordance with American welding Bureau or
Equivalent international welding institute.
10.10.4 Assembly and Erection

i. Method statement and Risk Assessment.
ii. ITP for Erection and Inspection Formats.
10.10.5 Mock-ups and samples

i. Mock-up of Typical Connection Joint
ii. Mock-up for painting
iii. Samples of all materials before using.
10.10.6 Fabrication
1. Inform the Engineer when fabrication is due to start. Do not fabricate steelwork for which the drawings
have not been commented by the Engineer.
2. Before fabricating, ensure that surface condition of steel which is to be coated complies with the
requirements for cleaning given in this Specification.
3. Ensure that fabrication processes do not cause changes in properties of materials resulting in noncompliance
with specified requirements.
10.10.7 As Built and Site Records

1. The Contractor shall maintain all records necessary under this Specification, including quality records as
appropriate. Electronic records shall be maintained and backed up daily to prevent loss of data in the
event of failure of electronic data storage. Copies of all site records shall be available to the Engineer.
2. The Contractor shall supply the Engineer with all information necessary for the Health and Safety File
including as-built drawings and records, maintenance schedules, operation, and maintenance manuals,
within the time specified in the contract, after substantial completion of the Works. Information shall be
provided in the agreed format. The Health and Safety File shall be prepared by the party identified in the
Contract.
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11 Protection of Steel Work from Corrosion

11.1 General
1 Weathering steel (ASTM A709 Grade 50W) and for Other steel (Such as Secondary Members), shall be
protected with coating relevant to Corrosion category C5 according to BS EN ISO 12944, complying with
AREMA Chapter 15-8 for application and repair. HSFG Fasteners used for Main Members and secondary
members respectively, after torqueing and tightening, shall be painted with the same coating system to
match the surface.
2 The Contractor will procure a specialist advisor to determine the required system to provide a steelwork
protection coating with a minimum period between maintenance of 15 years for the exposure
conditions on the Site.
3 Surface preparation for protective coatings, such as abrasive blasting or wire brushing, will be carried
out after fabrication of major elements has taken place, and the appropriate coating will be applied as
soon as possible after preparation in accordance with the manufacturer’s specification, but in any case
within 4 hours.
4 Surface preparation and cleaning will remove loose rust and mill scale and spatter, slag, or flux deposits
and will be as per the following specifications and standards:
a) SSPC-SP 6 ‘Commercial Blast Cleaning’ or SSPC-SP 10 “Commercial Blast Cleaning as per
manufacturer’s recommendations.
b) SSPC-SP 3, ‘Power Tool Cleaning’ for steel surfaces before touch-up and repair work.
c) Priming: Immediately after surface preparation, apply primer according to manufacturer's written
instructions and at rate recommended by SSPC. Stripe paint corners, crevices, bolts, welds, and sharp
edges.
5 Coating will be applied in the shop in accordance with relevant Specifications
6 On site painting will be kept to a minimum adjacent to necessary site joints.
7 These areas will be made good and painted in accordance with the manufacturer's recommendations.
8 Type of paint coating as Epoxy based Zinc rich Primer coat, Epoxy Rich MiO intermediate coat and
Polyurethane Top Coat will be in accordance with relevant specifications as recommended by the paint
manufacturer complying durability, safety and environmental requirements of the project.
9 The protective coating system chosen will be subject to Engineer’s approval.
10 An independent protective coating inspector will be appointed by the Steel Work Subcontractor to
inspect and test the protective coating systems.
11 These independent inspections will be carried out in the shop and on site after transport and after
erection.
12 The independent inspectors’ reports will be uniquely identified and cross-referenced on the as- built
record drawings.
13 The Contractor will provide warranties that the protection system as constructed will provide 15 years of
maintenance-free performance.
14 Steelwork be rated to two hour’s fire protection by either sprayed intumescent coating free of asbestos
or fibre / concrete or similar cladding.
15 The system of fire protection will be adequate to remain effective and undamaged under the action of
vibrations arising from rail traffic.
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16 The Fireproof Coating shall be in accordance with Association for Specialist Fire Protection, ASFP _
Technical Guidance Document – TGD-11.
11.2 Surface Preparation

11.2.1 Pre degrease surface preparation
1 Surface preparation of all welds, corners, etc. shall be undertaken to ensure a compatible surface
finish is achieved for coating prior to surface degreasing and grit blasting.
2 Surface cleaning and removal of all debris associated with welding and construction or other such
contaminants shall be undertaken prior to surface degreasing and grit blasting.
3 Full visual inspection by the third-party inspector and acceptance to proceed will be required for the
above actions prior to surface degreasing.
11.2.2 Surface Degreasing

1 All steel surfaces shall be degreased using suitable solvent free emulsifying detergent and clean
potable water.
2 Degreasing shall commence at the highest part of the structures and proceed to the lowest part of
the structures to prevent contamination of the degreased areas.
3 The surface shall be allowed to dry.
4 Full visual inspection by the third-party inspector and approval to proceed will be required for the
above actions prior to dehumidification.
11.2.3 Abrasive Grit Blast Cleaning

1 Abrasive blasting cleaning will be undertaken using hard sharp angular grit/shots or garnets with
suitable methods to achieve desired surface cleanliness and profile before applying primer coat.
2 The final surface of the steel immediately prior to application of the first coat in any coating system
shall comply with SSPC-SP 6 or SSPC-SP 10 as per recommendation of the paint manufacturer
3 If vacu-blasting is used, then metallic abrasives may be used, and only metallic abrasives shall be re-
cycled.
4 The Contractor shall provide any necessary methods of containment to ensure abrasive used for
blast cleaning and debris is contained local to the area being prepared. In particular spent abrasive
should not be allowed to fall into any water courses or affect any other part of the working areas.
5 If necessary, the containment shall also offer the area of external works adequate protection from
rain and wind.
6 The containment shall control the local environment throughout the coating operations and include
the initial drying and curing of the applied coatings. This requirement is only applied when
considered viable and as agreed with the Project Manager.
11.2.4Equipment Requirements
Suitable oil, water and air filtration equipment shall be installed between the air compressor and the blasting
equipment to ensure no contamination occurs.
11.2.5Metal Defects
Any weld spatter, rough weld caps, sharp edges or other metal defects exposed after surface preparation on
all surfaces shall be removed.
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11.3 Coating Systems

11.3.1 General
1. The Contractor shall submit and obtain acceptance from the Engineer the proposed colours prior to the
works. Where two or more coats are to be used, a different colour shade shall be used for each coat.
2. The manufacturer’s recommendations regarding minimum and maximum over-coating intervals shall be
strictly followed.
3. The Contractor may propose alternative coating systems to those specified, provided the proposal
complies with the requirements of this Specification and is accepted by the Engineer.
4. The Coating system supplied shall conform to the requirements of this Specification and shall have
certification from third party coating inspector appropriate to the service environment and required
durability as given in Durability Assessment Report.
5. Paints shall be delivered in sealed containers bearing the manufacturer’s name and labelled to show the
color, the specification with which the paint complies, whether for interior or exterior use, and whether
for a priming coat, an undercoat or a finishing coat. No materials of any description shall be added to the
contents of the containers except in strict accordance with the manufacturer’s instructions and permission
and paints of different types or of different manufacturers shall not be mixed.
6. Each batch shall be dated on delivery and shall be used strictly in order of delivery. Wherever possible,
coating materials to be from one manufacturing batch.
7. Paint not used within the ‘shelf life’ period specified on the containers as per Manufacturer’s
recommendation shall be replaced.
8. Paint shall be stored in sealed containers in a store where it will not be exposed to extremes of
temperature. The temperature of the store shall be kept between 4 ºC and 27 ºC unless the storage
conditions recommended by the manufacturer allow temperatures outside this range. Any special storage
conditions recommended by the manufacturer shall be observed.
9. The Contractor shall obtain all components of the paint system from one manufacturer.
11.3.2Application Conditions
Coatings shall not be applied under the following conditions for external works.
• When the ambient temperature falls below 5°C, when steel temperature falls below 5°C or the relative
humidity rises above 85%.
• When the ambient temperature is less than 3°C above the dew point.
• When the steel or ambient temperatures are above the temperature recommended by paint
manufacturer.
• When rain, snow, fog, or mist could affect the work area
• In a dust laden atmosphere
• When the amount of moisture likely to be deposited on the surface by condensation or rain immediately
before and after coating, may have a harmful effect on the coating.
• When wind-borne dust may have a harmful effect on the coating.
Every effort shall be made to maintain the conditions above throughout the coating system application.
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Blasting operations and painting processes shall be segregated.
11.3.3Coating Application
1 All components of the coating materials shall be prepared in strict accordance with the coating
manufacturer’s printed requirements.
2 Mixing equipment shall be clean and dry and not contaminate the coating material in any way. No
mixed coating material shall be used beyond its specified pot life or when it is clearly thickening.
3 Prior to use, the base component of 2-pack materials shall be thoroughly mixed using a slow rotating
power mixer before the hardener is added. The hardener shall be added with constant slow rotating
mixer recommended by the coating supplier and the composite mixed until homogeneous.
4 Application can be by brush, roller or spray, as recommended by paint manufacturer.
5 All coats shall be applied without thinning unless recommended by the paint manufacturer and
approved by the Engineer.
6 Coatings shall only be applied to clean, dry surfaces that have been prepared to and meet the
requirements of this Specification unless otherwise agreed by the Engineer. A new coat shall not be
applied over another coat that has any contamination present. Particular notice shall be taken to
ensure no coat is applied over another that is affected by amine bloom.
7 Wet film thickness gauges shall be used regularly to check adequate wet material is applied to
achieve the DFT.
8 Each coat, at whatever thickness applied, shall be free from surface defects, particularly cratering,
pin-holing, blistering, revelling, sagging, bittiness, and cissing.
9 The finished system shall be of an even and uniform appearance.
10 The minimum and maximum over-coating times recommended by the coating manufacturer shall be
complied with and will be temperature dependent.
11 As per AREMA Chapter 15, Page 15-8-37, DFT Shal be measured as per SSPC PA2
12 All gauges shall be calibrated before use, the Engineer shall be provided with calibration records.
Any newly applied coating that is damaged shall be fully re-instated in accordance with this
Specification.
11.3.4Stripe coats
The Contractor shall brush apply an additional stripe coat of at least one high build coat to all angles, welds,
edges, Fasteners and all areas that are difficult to coat
11.3.5Handling and Storing Coated Steelwork

1 Use methods and equipment which will minimise chafing, chipping, and other damage to coated
components.
2 Ensure an adequate drying/curing period for each coat before handling.
3 Use suitable packing, lashings, lifting harnesses, nylon slings, rubber protected chains and chocks,
etc.
11.4 Coating on Joints and Fixings

11.4.1High strength friction grip (HSFG) bolted joints
1 The Contact surface of the HSFG Bolted parts i.e. faying surfaces between splice plates shall blast-
cleaned and coated to achieve Class B Coating through a Class B coating system as per
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manufacturer’s recommendation in accordance with SSPC Paint and ISO 12944 meeting the
requirements of Research Council on Structural Connections (RCSC) Class B, Appendix A (Slip
coefficient and resistance to tension creep) or unsealed pure zinc or 85/15zinc/aluminium thermal-
sprayed coatings with a thickness less than or equal to 16 mils as per AASHTO LRFD CL 6.13.2.8, to
achieve Slip Coefficient 0.5 as per Section 1.4; Table 15.1.11a of AREMA Chapter 15.
2 The splices shall be checked as slip-critical per AASHTO LRFD 6.13.2.1.1. The contact Surfaces (faying
surface) of the bolted parts are assumed to be CLASS B according to AASHTO 6.13.2.8.
3 Contractor shall propose the Painting system to achieve Class B slip Factor to Engineer for review
and approval before use.
4 The Faying surface under the bolt head, Nut and Washer in contact with steel plate shall be same as
per Clause 3.4.1.1
5 HSFG Bolts, Nuts and Washers shall be supplied in Black condition without any coating.
6 Surface Preparation for Faying surface: unpainted blast-cleaned surfaces to SSPC-SP 6 or better
11.4.2Welded joints
1 The Contractor shall ensure that areas within 200mm of known site welds shall not be painted until
all welding and testing is completed. Where this is not practicable the Contractor shall ensure that
the paint coat is removed by grinding and each coat is stepped back to enable preparation of fusion
faces for welding.
2 Welds and surfaces which have been affected by welding shall receive the preparation and
protective systems which are applied to the parent surfaces.
3 The joints having been made and passed inspection, the parent and joint materials, exposed parts of
bolts, nuts and washers, weld and weld affected areas shall be prepared and painted.
4 All bolted joints shall be sealed against the ingress of moisture. Before painting commences gaps at
joints shall be plugged with approved filler. The perimeter of all joints shall be sealed with
subsequent coats of paint.
11.5 Inspection
1 The Contractor shall be responsible for carrying out all inspection and quality control testing in
accordance with this Specification and Approved Inspection and Test Plan. Personnel undertaking
inspection and quality control testing shall be suitably trained and hold applicable and current
certification. Certification to Level II under the Institute of Corrosion Scheme or equivalent is
required.
2 Inspection and quality control activities shall be adequate to ensure all surfaces are prepared and all
coatings applied to comply with this Specification and the Coating Manufacturer’s
recommendations.
3 Inspection and quality control activities shall include but not be limited to:
a) Surface preparation including surface profile amplitude measurement
b) Mixing of coatings
c) Application of coatings
d) Monitoring of ambient conditions
e) Appearance and DFT of applied cured coatings
f) Recording of batch numbers of materials used
g) Recording of results of inspections and monitoring
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h) Adhesion Test for Pull Off Strength of Coatings using portable Adhesion Testers on sample
panels.
4 All site records will be kept in legible hard copy format and shall be computerised daily and available
for review by the Engineer.
5 The Contractor shall permit coating manufacturers to inspect the work in progress, including surface
preparation, and to take samples of their products if required. The Contractor shall not comply with
any directions or requests given by the coating manufacturer's representative unless and until
confirmed in writing by the Engineer.
6 The Contractor shall notify the Engineer of projected dates for start of surface preparation and
coating.
11.6 Protection
1 The Contractor shall protect freshly applied surface coatings from damage. Protect surfaces adjacent
to those being prepared and coated.
2 Stack coated components clear of the ground, separated by timber chocks, and so that ponding does
not occur.
11.7 Remedial Work

1 Early degradation of coatings (that is prior to the defects date) by blistering, peeling, flaking, cracking
and lack of adhesion must be made good by complete removal, preparation, and reapplication of all
coats.
2 Inadequate dry film thickness or surface defects shall be remedied by rubbing down and applying
further coat(s), as recommended by the coating manufacturer.
3 Mechanical damage to new coatings must be made good by local cutting back of coatings,
preparation, and re-application of all coats to leave a neat, continuous, and smooth finish.
4 Where damage to coatings or subsequent surface preparation has exposed bare metal, it must be
thoroughly cleaned, prepared, and primed within two hours.
11.8 Coating Application on Trial Panels

1 Prior to applying the system in the works, trial applications shall be carried out by the Contractor.
The trials will demonstrate the method proposed for applying the system, coverage, coating
thickness, colour and final appearance of the coating.
2 The coating application procedure trials applicable to the steelwork are to be the initial element of
works on the Site and the Contractor must allow adequate time for these procedure trials.
3 Representatives of the coating manufacturer shall attend the trials and the surface preparation and
application of the coating shall be carried out under their direction.
4 The coated element(s), when accepted will form the standard against which the corresponding
coating in the works will be judged.
5 No changes to the materials and/ or methods of application used in the painting trials shall be
permitted during the main works unless agreed by the Engineer.
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12 Waterproofing of Concrete Structures

12.1 General
1 The Works under this section will be done according to the provisions of the Contract and of these
2 The waterproofing system will comply with the requirements set out in the durability study report
prepared by the Contractor and will be constructed in accordance with the specialist suppliers detailed
requirements. Durability Report C0306-S02-ECB-RP-30018
12.2 Performance requirements

1 Waterproofing shall be resistant to hydrocarbons, sulphates, chlorides and other chemicals existing in
soil and ground water.
2 It shall be suitable for use in hot climates
3 Allow for structure deformations under acting loads as well as relative displacement of different
elements.
4 Compatibility with filling materials, curing compounds and with other water resisting membranes where
jointing is required.
5 Resistance to ultraviolet ranges during storage and installation period in additions to a margin period.
6 Compatibility with ventilation means (for parts with moisture vapor tolerable).
7 Durability for the project life.
8 Contractor can propose the use of waterproofing crystallization additive as long as it achieves all of the
above performance requirements.
12.3 Water-stops
1 Proprietary water-stops/ water bars used at construction joints and for compartments (except
movement joints) shall be compatible with the waterproofing membrane and with the sizes of the
structural elements.
2 Proprietary water-stop for movement joints shall be extruded from high grade PVC compound and shall
be having pre-punched holes for fixing with a torturous water path design.
3 The water stop shall be chemically resistant against water, sea water, alkalis, mineral oil and sewage
conditions
4 Flat Dumbbell plain web water stop shall be used for a Construction joint while for an Expansion joint or
a Contraction joint, a centre bulb water stop shall be used. The width of the water stop shall depend
upon the concrete thickness, the aggregate size, and the position of the reinforcement. In general, the
following shall be taken as a guide to select the width, w of a water stops.
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w<t but w>(6a+j)

Where t= concrete thickness
a= Largest Aggregate size
j= Width of Expansion Joints
The following Technical Data shall apply
Hardness :42-52 BS Softness degrees at 25°C
Tensile Strength :13.8 N/mm² minimum at 25°C
Elongation at Break :285% minimum at 25°C
1. The water bars shall withstand the water head indicated in the construction documents or permanent
site conditions. Unless noted otherwise, the water bar shall be able to accommodate 20mm expansion
and 10mm shear movement.
2. Water stops shall be placed centrally as a water barrier across the designated joint in in-situ concrete
structures and cast centrally into the edges of adjacent concrete components.
3. The requirement of a water stop shall be indicated in the drawing
12.4 Waterproofing for Substructures

12.4.1 Materials for waterproofing membranes
1 Waterproofing membranes to sub-structures will consist of a preformed, self-adhesive, multi- layer
polymer modified bitumen membrane with an internal high-density polyethylene film with integral
fabric reinforcement.
2 All foundations, manholes, water tanks and ancillary buildings in contact with ground shall be protected
by sheet waterproofing membrane
3 The membrane will provide long-term protection to reinforced concrete in the Middle East.
4 The water proofing membrane will be supplied by a manufacturer with a minimum of ten years’
experience in the Middle East.
5 All waterproofing materials, including membranes, protection boards, rubberised mastics, primers,
adhesive, fillets, armour tape and flashings etc. will be compatible with each other, will have a valid
Agreement Certificate for Roads and Bridge Structures issued by a member of the UEATC (The European
Union of Agreement) and will satisfy additional requirements in Table 16.
Property Test Method Requirement
Tensile Strength ASTM D638 5 N/mm2 minimum

Elongation ASTM D638 135% minimum
Tensile Adhesion 0.7 N/mm2 minimum

Tear Strength ASTM D1004 135 N/mm2 minimum
Water Resistance ASTM D2939 i &ii Excellent
Crack Bridging Capability United Kingdom Department of Transport (DoT) Up to 0.6 mm

test for the review of Waterproofing Systems for
Concrete Decks Method C IV
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Chemical Resistance to dilute acids, to To the levels expected in the most Resistant
dilute alkalis, to sulphates, to chlorides aggressive areas of the Middle East
6 The properties of the waterproofing membrane will not significantly diminish with age.
7 The provision of test data and/or evidence of successful performance of the membrane in climatic
conditions similar to the UAE will be a condition of approval of any waterproofing system.
8 The foundation types in the structures generally consist of pile caps, piles, retaining walls and bridge
abutment. Preparation of concrete surfaces to receive the membrane and method of application of
waterproofing membrane shall be in accordance with the membrane manufacturer's instructions and
requirements.
9 The waterproofing membrane will start 2m below the ground covering part of the pile up to 0.15m
above the ground level. Exposed part of the pier 3m above the finished ground shall be protected with a
liquid waterproofing membrane.
10 The waterproofing system for pile caps and piers can be either loose laid or fully bonded system. Pre-
applied integrally bonded sheet waterproofing membrane, when applied, will be installed above the
blinding concrete which will bond to the underside the pile cap once the concrete is poured, creating an
integral waterproofing system that will prevent water migration. When using loosely laid PVC/HDPE
membrane, the horizontal surface of membrane shall be covered with minimum 50 mm thick concrete
screed. The pile head shall be sealed with solvent free non-shrink epoxy grout
11 Waterproofing for abutment and retaining wall structures is similar to the pile cap, either loose laid or
fully bonded systems. Pre-applied integrally bonded sheet waterproofing membrane, when applied, will
be installed above the blinding concrete which will bond to the bottom of the foundation or base slab.
Post-applied self-adhesive sheet membrane will be applied on the sides and top of the foundation and
wall up to 0.15m above the ground level. Part of the wall 3m above the finished ground will be applied
with liquid waterproofing membrane on all the exposed sides.
12.5 Waterproofing for Superstructures

1 Rail bridge deck shall be protected with a liquid waterproofing membrane.
2 Liquid waterproofing membrane shall be applied to the exposed part of the foundation near the ground,
bridge deck, and similar applications.
3 Spray applied waterproofing membrane shall be provided to the bridge deck, pier-cap top, and similar
exposure areas. It shall be continuous and cover the entire deck/top surface between upstands, if any.
The membrane shall be resistant to exposure to sunlight, temperature variation, oil spillage, and
protected from damage during construction and suitable for in service conditions considering the effect
of the passage of plants and personnel.
4 The membrane system shall be capable of sealing across the expansion joints using bridge preservation
expansion joint system without the need to use a separate gland and bonding agents on the membrane.
This will assure a continuous waterproofing membrane system across the entire deck. Modification of
deck drains / up stand shall be as specified in the design documents / drawings where needed. The
modifications shall be made prior to waterproofing the deck.
12.5.1 Materials for waterproofing membranes

1 Waterproofing of bridge decks, approach slabs and other areas will provide long term protection to the
concrete from the ingress of water-borne chlorides or other deleterious substance.
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2 All materials will have a valid Agreement Certificate for Road and Bridge Structures approved by a
member of the UEATC.
3 Waterproofing for bridge decks will be one or two coat, rapid curing and liquid spray applied.
4 Sufficient time will be allowed for the first part to adequately cure prior to the application of the second
coat.
5 The finished membrane will be free of pinholes.
6 Adhesion between the membrane and the concrete will be at least 1.5 MPa average.
7 The membrane will have good flexibility and be able to bridge live cracks of up to 3mm.
8 The membrane will be resistant to water and chloride ion penetration, embrittlement, abrasion, UV
degradations, pedestrian traffic, indentation by hot or cold aggregates and the effect of placing asphalt.
9 It will be protected by a durable board of other protective layer if otherwise it would be in direct contact
with ballast or other unbound aggregate or rock.
10 The membrane will easily accommodate the need for day joints and patch repairs as result of testing for
adhesion or coating thickness.
11 The membrane will comply with the requirements in Table 17.
Minimum Thickness (for each layer) 2mm at concrete peaks

3mm on flat surface
Tensile Strength BS 903 Part A2 1989 5 MPa
Density DIN 53479 0.85 – 0.95 MG/m3
Elongation BS 903 Part A2 1989 300% minimum
Tear Strength BS 903 Part A3 10 MPa
Adhesion to Concrete Elcometer Test (minimum 3 per 500 m2) 1.5 MPa average
Adhesion to asphalt Japanese Industrial Standard 0.15 MPa in shear
Moisture Vapour Transmission rate DC 3177.1050 8.1 g/m2/day
Water penetration United Kingdom Department of Transport Zero

Tech Memo BD 47
Crack bridging ability Certified by supplier 3.0mm
Chemical resistance/Chemical transmission
Dilute acids Certified by supplier Resistant
Dilute alkalis Certified by supplier Resistant
Sulphates Certified by supplier Resistant
Hydraulic oil Certified by supplier Resistant
Chlorides TRL Research Report 248 0.02%
Microbial Attack Certified by supplier Resistant
Indentation by hot or cold aggregate during Negligible

asphalt placing or pedestrian traffic prior to any
protection
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Resistance to high temperature from concrete Yes

surface (80°C) Or due to asphalt placing (150°C)
Holidays (pin holes) None
Blisters None
Resistance to abrasion SNCF Taber Method
Resistance to embrittlement United Kingdom Department Transport Tech. No cracking

Memo BE27 90° Mandrel Test at 0°C
Resistance to hot asphalt BAM ZTV BEL-B @ 160° or more No change
Resistance to chisel impact United Kingdom Department Of Transport No indention

Test checks Appendix B Memo BE 17
Note: The above properties will also apply for small areas of patch repair that may be required.
12.5.2 Additional Bituminous Protection

Bituminous protection, where required on bridge decks as an additional protective layer, will be 20mm sand
asphalt having a Marshall Stability of 5.5 kN ± 2 kN when tested in accordance with BS 598: Part 107 and
comply with BS 3690: Part 1 and BS 594: Part 1 recipe Type F wearing course mixture Designation 0/3 except
that 5% ± 0.5% of the total mix will be inorganic red oxide and regarded as part of the filler content.
12.5.3 Integrity Testing of Waterproofing

1 The Contractor will undertake compatible tests to check the integrity of the waterproofing system in
order to substantiate fitness of purpose.
2 The test methods will be those which have been assessed by the British Board of Agreement (BBA) for
use with waterproofing system.
3 Testing procedure, Test results, Quality Assurance , delivery , storage , handling, field quality control and
warranties will be submitted to Engineer for acceptance.
12.6 Failure to Meet Requirements

1 Where the testing of any membrane identifies failures to meet requirements, the Contractor will verify
with the supplier the possibility of patch repair to the system, which repair method, if feasible and at the
sole discretion of the Engineer may be accepted.
2 If patch repair is not feasible, the membrane will be removed by suitable methods not detrimental to the
concrete to expose unblemished concrete surface prior to re-application of the protection system.
3 The Contractor will bear cost of all repairs.
12.7 Method Statement

1. Contractor shall submit a fully detailed individual method statements for approval (separate for
retaining/non-retaining structures) which shall include the following in addition to standard
requirements stated elsewhere in the Contract document:
i. Sequence of works in a logical order which will ensure that all the membranes are protected
immediately after they are laid and before next activity is started
ii. The testing regime, inspection, and test plan. All the joints must be tested.
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iii. Quality risks before and after laying the membrane, risk response and risk prevention plans.
iv. Maintaining a register of daily checks for the newly laid membrane from membrane laying stage
until it is covered permanently with concrete/ backfill.
v. Procedure for tests at completion and at switching off dewatering where applicable.
vi. Procedure for maintaining as-built markups for all the works before they are covered or buried.
2. The Contractor shall be responsible for preparing the Method Statement with input from waterproofing
applicator/ sub-contractor. The Method Statement shall be validated by the waterproofing system
manufacturer and applicator before submission.
3. List of QA/QC forms and documents including risk analysis, checklists, and inspection and testing plans
(ITP’s).
4. Shop Drawings
1. Contractor shall be responsible for preparing detailed coordinated general arrangement plans, sections,
and elevations for all construction elements.
2. Waterproofing sub-contractor shall be responsible for marking up all the waterproofing elements in the
project drawings and also preparing as-build drawings.
3. All shop drawings shall be stamped and signed by the waterproofing system manufacturer to confirm
that the details shown on the shop drawings are correct and appropriate to provide a watertight barrier
for the duration of the warranty period as a minimum.
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13 Bridge Bearings
13.1 General
1 Bearings for Bridge Works will be in accordance with the requirements of AREMA for Rail Structures or
AASHTO for Over-Bridges.
2 The design of the bearing will be carried out by the specialist manufacturer of the bearings.
3 The Contractor will submit at least 4 weeks prior to work commencement detailed design calculations,
shop drawings, method of statement for the work, maintenance, replacement schemes etc. Materials
Test Reports (MTR) will be included in the submittals item.
4 Refer to C0306-S02-ECB-FS-30001-Bearing Specification Rail Bridges and C0306-S02-ECB-FS-30002-
Bearing Specification Road Bridges
5 For overbridges PTFE or equivalent material shall be used wherever is required, as per RTA requirements
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14 Finishes to Structures
14.1 General
SECTION INCLUDES
A. Flush Aluminum Access Doors.
B. Aluminum panels.
14.2 Compliance
A. Local Code: Applicable Dubai laws, ordinances, codes, rules and regulations
B. Comply with the applicable requirements of NFPA 101, 130 and 255 relating to this section
14.3 References
A. AAMA 611 - Anodized Architectural Standards.
B. ASTM B 209 - Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate.
14.4 Materials
1. Stainless steel grade 316
2. Structural steel BS 4
3. Galvanized steel BS EN 10142
4. Aluminum: ASTM B 308
5. Glass: floated toughened glass
6. Brass
7. Bolts: ASTM A 307, A 325, A 345.
8. Grout: non shrink cementatious grouts premixed ready for use requiring addition of water
only, setting time 15 to 30 minutes, developing not less than 25 N/mm². Compressive
strength after one day and expansion of up to 1% to overcome plastic settlement in the unset
material.
9. Paint: epoxy polyurethane or powder organic coating to BS 6496.
10. Primer: Zinc epoxy, suitable for application to items embedded in concrete.
11. Gaskets, weather resistant neoprene.
14.5 Submittals
A. Product Data: Manufacturer's data sheets on each product to be used, including:
1. Fabrication methods, finish and accessories.
2. Preparation instructions and recommendations.
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3. Storage and handling requirements and recommendations.

4. Installation instructions.
5. Operation and maintenance data.
C. Shop Drawings: Indicate the following:
1. Elevations and details of each door and frame type.
2. Schedule of doors and frames.
3. Conditions at openings with various wall thickness and materials.
4. Hardware templates with location and installation requirements for hardware.
5. Thicknesses of materials, joints.
6. Connections and trim.
D. Selection Samples: For each finish product specified, two complete sets of colour chips representing
manufacturer's full range of available colours and patterns.
E. Verification Samples: For each finish product specified, two samples, minimum one full sample,
representing actual product, colour, and finish. Where colour or texture variations are anticipated for
anodized or powder coated finishes, include two or more units in each set of samples indicating
extreme limits of variations.
F. Manufacturer's Certificates: Certify products meet or exceed specified requirements.
G. Closeout Submittals: Provide manufacturer's maintenance instructions that include recommendations
for periodic checking and adjustment and periodic cleaning and maintenance of all components.
14.6 Quality Assurance

A. Manufacturer Qualifications: Company specializing in manufacturing aluminium door and frame
systems of the type required for this project, with minimum ten continuous years documented
experience. Manufacturer's representative shall be available for consultation including instruction to
installation personnel.
B. Installer Qualifications: Company specializing in installation aluminium door and frame systems of the
type required for this project, with minimum five continuous years documented experience.
C. Provide materials that have a minimum service life expectancy of 25 years.
14.7 Delivery, Storage, and Handling

A. Deliver doors and frames palleted, wrapped or individually crated. Doors shall be side protected with
surrounding grooved 2-inch (50.8 mm) by 4-inch (101.6 mm) wood frame and covered with 275-pound (124.74
kg) test corrugated cardboard.
B. Inspect delivered doors and frames for damage, unload and store with minimum handling.
C. Store products under cover in manufacturer's unopened packaging with labels intact until installation.
1. Place units on minimum 50 mm wood blocking.
2. Do not use non-vented plastic or canvas covers.
3. Remove packaging immediately if packaging becomes wet.
4. Provide minimum 10 mm air spaces between stacked doors.
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D. Protect materials and finish from damage during handling and installation.
14.8 Sequencing
Ensure that templates and other information required for installation of products of this section are
furnished to affected trades in time to prevent interruption of construction progress.
14.9 Project Conditions

A. Maintain environmental conditions (temperature, humidity, and ventilation) within limits
recommended by manufacturer for optimum results. Do not install products under environmental
conditions outside manufacturer's absolute limits.
B. Verify actual openings by field measurements before fabrication; show recorded measurements on
shop drawings.
C. Coordinate field measurements and fabrication schedule with construction progress to avoid
construction delays.
14.10 Warranty
A. Manufacturer: Provide manufacturer's 5-year warranty against defects in workmanship and materials,
including warping, rotting, paint chipping, decaying or bowing.
B. Installer: Warrant installation procedures and performance for five years against defects due to
workmanship and materials handling.
14.11 Manufacturers
A. Acceptable Manufacturer: Aluminum Doors in the Emirates of the construction phase.
B. Substitutions: Not permitted.
14.12 Aluminum Flush Doors, Frames and Sub-Frames

A. Aluminum Flush Doors: Provide Aluminum Flush Door, size and design indicated on the Drawings.
1. Welded G.I. sub-frame for opening control.
2. Minimum Thickness: 44 mm
3. Construction: 4MM TH. Of aluminium sheet fixed to aluminium frame of minimum 20x40mm
frame. Powder coted after assembly – color for engineer approval.
4. Door Size: see design drawings
B. Aluminum Frame:
1. Frame Components: Extruded channel (tubular) 6063-T5 aluminum alloy conforming to ASTM B
221, minimum wall thickness 3.18 mm; cut corners square and joinery shall be mechanical with no
exposed fasteners.
C. Finish
1. Finish: Equivalent (or better) high performance powder Fluoropolymer systems for aluminum
meet and exceed AAMA 2605
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2. Finish: High Performance Organic Coating: Kynar/Polyvinylidene Fluoride (PVDF) (AAMA

605.2).
3. Color: Selected by Architect/Engineer from manufacturer's full range of available colors.
4. Color: Custom color matching bridge's surface sample.
D. Accessories
1. Fasteners: Aluminum, nonmagnetic stainless steel, or other material warranted by manufacturer as
non-corrosive and compatible with aluminum components. Do not use exposed fasteners.
2. Brackets and Reinforcements: Manufacturer's high-strength aluminum units where feasible,
otherwise, nonferrous stainless steel.
3. Screwdriver operated cam latch, color to match powder coating or matt silver metallic finish.
14.13 Execution
1 EXAMINATION
A. Do not begin installation until substrates have been properly prepared.
B. Verify that wall surfaces and openings sub-frames are ready to receive frames and are within
tolerances specified.
2 PREPARATION
A. Clean surfaces thoroughly prior to installation.
B. Prepare surfaces using the methods recommended by the manufacturer for achieving
the best result for the substrate under the project conditions.
3 CLEANING
A. Upon completion of installation, thoroughly clean door and frame surfaces in accordance with
AAMA 609.
B. Do not use abrasive, caustic, or acid cleaning agents.
4 PROTECTION
A. Protect products of this section from damage caused by subsequent construction until substantial
completion.
B. Repair damaged or defective products to original specified condition in accordance with
manufacturer's recommendations.
C. Replace damaged or defective products that cannot be repaired to Engineer's acceptance.
5 SCHEDULES
A. Submit program aligned with the main project program
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15 Bridge Expansion Joints and Sealing of Gaps

15.1 General
The Works under this section will be done according to the provisions of the Contract and of these
15.2 Joints
15.2.1 Joint Filler and Dowel Bars
1 Joint filler will consist of a compressive non-extruding resin-bonded cork or bitumen impregnated
corkboards.
2 The physical properties of the materials will conform to the requirements of ASTM D-1751.
3 The joint filler will be fully compatible with the surface sealants.
4 The provision of dowel bars through expansion joints will be approved by the
Engineer/Engineer.
5 Dowel bars at movement joints, approach slabs and bearing shelves will be galvanized steel or stainless
steel as shown on the detailed design drawings.
6 Surround to dowels include compressible material sleeves and aluminium slots will be as shown on the
detailed design drawings.
7 Dowel bars will be protected by plastic sleeve at the movement joints and approach slab connection.
8 Dowel bars shall be Grade Stainless steel Alloy 316 austenitic stainless-steel Designation 1.4436 and
strength grade 500 complying with the requirements of BS6744:2001.
15.2.2Joint Sealant and Waterstops

1 Joint sealants will be high performance two part polysulphide based rubber sealants.
2 The sealant will be a gun-grade sealant with solids content in excess of 99% and will conform to the
requirements of BS 4254and U.S. Federal Specification TT-S-0227 E. Shore “A” hardness will be 25% with
a Movement Accommodation Factor of 25%.
3 The joint sealant will have properties suitable for its required use including the ability to retain its
elasticity at low temperatures; maintain its ability to form a watertight seal; not to bleed or flow at sun
temperatures up to 90°C and have no slump.
4 Colour of joint sealant will match the concrete or the colour selected to paint the structure in case
instruction is given to paint the structure.
5 The practice of flooding the joint with primer is forbidden.
6 All jointing and sealing will be carried out under the recommendations of BS 6093: 1993.
7 Construction sealants will comply with the performance characteristic requirements of BS 6213.
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15.3 Elastomeric Expansion Joints

15.3.1 General
1 The Contractor will design, furnish and install the expansion joint systems in bridge decks of the types
used where significant movements are expected across the joint.
2 The expansion joint for the bridges will consist of an assembly of metal and elastomeric materials
installed in recesses in the deck surface.
3 All expansion joints will prevent the intrusion of material and water through the joint system.
4 Before a subcontract is awarded for the expansion joints, the Contractor will submit to the Engineer for
acceptance the name and address of the organization proposed for the manufacture of the expansion
joints under these Specifications.
5 The named proposed manufacturer will submit evidence that it has, for a period of at least the last five
years, manufactured joints comparable to the expansion joint work under these Specifications, and will
verify this experience by citing at least two projects comparable to this project which has been
successfully accomplished.
15.3.2 Materials
1 Proprietary bridge deck Expansion joints will be of an accepted type for each size required and will be
from an manufacture whose products have been proved to be highly satisfactory in similar works and
environmental conditions.
2 Elastomeric bridge deck joints will be provided with a minimum guaranteed service life of 15 years in the
prevailing climatic and loading conditions of the UAE and Gulf Countries.
3 Expansion joint fixings (anchor bolt, nut, washers etc.) should be stainless steel type-316 with a mill
finish confirming to ASTM A276
4 Materials to be used for the installation of expansion joint for bedding and transition strips shall be
recommended by expansion joint manufacturer
5 The joint will be designed to withstand an axle load of up to approximately 35t for Rail Structures and
10t for Over-Bridges.
6 Elastomeric bridge deck joints for Over-Bridges will be skid resistant.
7 The elastomer compound will have the following minimum physical properties as determined by the
following ASTM requirements shown in Table 18:
Table 18: Elastomer physical properties
Property ASTM Value (min)
Hardness D2240 55 5
Tensile Strength Min 10 MPa
Ultimate Elongation D 412 min 350 %
Compression set ( 24 hrs @ 70oC) D 395 max 25 %
Ageing resistance (72 hrs @ 100oC) Change in hardness D 573 max  15
Change in tensile strength max  15 %
Change in ultimate elongation max – 40%
Oil resistance ( 72 hrs @ 100o C) D 471 max 10 %
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Property ASTM Value (min)
Ozone resistance ( 50 pphm/20 % strain 100 hrs @ 40o C) D 1149 No cracks
8 All structural steel for use in the elastomeric expansion joints will conform to the requirements of ASTM
A245 or A36. Structural steel angles and anchors will be fabricated and hot dip galvanised in accordance
with ASTM A153.
9 Anchor bolts for joint seals will be hot dip galvanised in accordance with ASTM A153.
10 Expansion joint system shall be comprised of: 1.) a heat-weldable, thermoplastic-rubber, double-celled
or multi-celled, extrusion with perforated flanges and, 2.) manufacturer’s cold applied elastomeric
nosing.
11 Elastomeric nosing shall be a two-part polyurethane material (epoxies not permitted) mixed with
aggregate with sand particles not to exceed 30-mesh. Nosing material shall be pourable grade material
capable of encapsulating the perforated flanges in a single pour without the laying of a setting-bed or
tack coat. The material shall flow so as to fill voids or irregularities in concrete blockouts and beneath the
perforated flanges of the gland. Material shall cure to flexible (non-rigid) state. So as to ensure proper
mixing, flow ability, and consolidation, mixed nosing material shall have an aggregate loading ratio by
weight of liquid resin to aggregate not exceed 1:2.
12 System to be installed into blockouts on each side of the joint-gap prepared to the dimensions 20mm
deep x 100mm wide.
Final selection of the seal size to be coordinated between manufacturer, designer, and contractor(s) in
consideration of expected movements as a product of structural design and expected temperature
variations, taking into account as-built joint-gap sizes and temperatures at expected installation time.
Width of joint-gaps at time of casting or cutting to be adjusted, if necessary, from baseline temperature
used and specified by designer in determining system suitability.
15.4 Manufacture and Fabrication

Expansion joint assemblies will be fabricated by the manufacturer and delivered to the bridge site completely
assembled.
15.5 Installation of Bridge Deck Expansion Joints

1 All expansion joint materials and assemblies, when stored at the job site will be protected from damage
and assemblies will be supported so as to maintain their true shape and alignment.
2 Expansion joints will be stored, constructed and installed in accordance with the manufacturer’s
recommendations and will provide a smooth ride.
3 Bridge deck joints will be covered over by protective material after installation until final cleanup of the
bridge deck.
4 After installation and prior to final acceptance, expansion joints will be tested for leakage of water
through the joint.
5 Any leakage of the joint seal will be cause for rejection.
6 Expansion joints will be constructed to provide absolute freedom of movement through a range
consistent with that prescribed on the detailed design drawings.
7 Final settings of the joint assembly at the time of casting in the anchorages of the unit depend on the
relationship of the current temperature of the superstructure to its expected mean temperature, and
will be as specified by the manufacturer or as shown on the detailed design drawings.
8 Anchors and exposed sections will be hot dip galvanized in accordance with ASTM A123.
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9 The contractor shall provide properly formed and prepared expansion joint openings constructed to the
exact dimensions and elevations shown on manufacturer’s standard system drawings or as shown on the
contract drawings.
10 The contractor shall clean the joint opening of all contaminants immediately prior to installation of
expansion joint system. Repair spalled, irregular or unsound joint surfaces using accepted industry
practices for repair of the substrates in question. Remove protruding roughness to ensure joint sides are
smooth. Refer to Manufacturers Installation Guide for detailed step-by-step instructions.
11 System to be installed by qualified sub-contractors only according to detailed published installation
procedures and/or in accordance with job-specific installation instructions of manufacturer’s field
technician
12 At locations in the bridge where deck drainage channel is to be continued from one deck to another and
not dropped, blockout-mounted, watertight, winged compression seal expansion joint systems to be
provided. The material to accommodate the movement and rotation of the deck and durable under the
live load and extreme weather conditions.
13 Protect the system and its components during construction. Subsequent damage to the expansion joint
system will be repaired. After work is complete, clean exposed surfaces with a suitable cleaner that will
not harm or attack the finish.
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16 Quality Control Arrangements

Quality control procedures will be implemented by the contractor and will follow the process below for
the intervention points
Legend: Definition of Intervention Points (Inspection Levels) on ITP’s are as follows: -
W = Witness point: i) A work operation that is watched observed or visually examined by the Employer;
ii) The Contractor and the Employer must agree to witness points prior to the start of the work; iii) The
Contractor will notify the Employer in advance of the operation to ensure the Employer can attend the
required witness point.
H = Hold Point: i) A critical operation in which, by prior agreement, the Contractor will notify the Employer
a reasonable time in advance of the operation so that the item may be visually examined, tested or
measured by the Employer to verify conformance with the Contract requirements; ii) The Contractor may
not proceed with work beyond such hold points except by written agreement of the Employer.
R = Review point: i) Review of the Contractor’s Inspection and Testing records by the Employer for
correctness and completeness.
I = Inspection: Responsible for carrying out inspection or test; includes sampling for testing.
S = Surveillance point: i) ‘In process’ monitoring of the Contractor’s activities to the degree necessary for
confidence that the work process/method is in compliance with the established criteria.
MIR: MIR's follow the same process as ITR's and are attached to ITR for processing. Types of Records
to be attached to the MIR's are listed on the MIR form. Employer signs-off the MIR once
Material satisfied, but not any of the Contractors QC Checklists.
Inspection
Request
Employer check that all activities [up to that point, or since last ITR] have been carried out by
ITR:
Inspection the Contractor and that includes checking that the Contractor has filled-in all his QC Checklists
and Test Forms (to be attached to ITR upon submittal). Employer sign-off the ITR once satisfied, but not
Request
any of the Contractors QC Checklists.
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17 Preparation of As Built Drawings

17.1 Detail and Contents of As Built Drawings
As built drawings are based on IFC drawings.
Some information that are represented (in general) at the level of shop drawings, has to be transferred from
shop drawings to As Built drawings.
Some information that are not part of any drawing, but that must be represented on the as built drawings are:
Modifications consequent to DCR/NCR/FCR/DAS
Name of incorporated materials used and their reference code (mix design, waterproofing, bearings, etc); NOT
to be included materials used for NCR repairs
DCR code and part that is interested
NCR code and part that is interested
FCR code and part that is interested
DAS code and part that is interested
RFI code and part that is interested
All the previous ones have to be represented in an adequate manner and included in a summary table that
has to be introduced on each drawing.
All the topographic data (N, E, elevation) already present on IFC have to be updated.
Every dimension already present on IFC has to be verified and, in case, updated
17.2 Planning and Preparation of the As Built Drawings List

A first list will be issued as “typical” including only the title of the typical deliverables that Contractor intends
to issue as “as built”. The list will be organized per WBS and per disciplines and will be submitted to the
Engineer for approval.
Upon approval of the typical list, a detailed schedule will be produced including the following information:
IFC doc number and title.
As built doc number and title corresponding to the previous one.
Planned date.
Detailed schedule will be provided reflecting the WBS construction progress.
17.3 Documents to Be Issued

17.3.1Red Marked Drawings
The Subcontractor, after that the completion of a system / WBS is reached, will transfer the Red-Marked
drawings to the Contractor’s Field Engineering Manager. The drawings will be transferred in the Site Archive
and kept by Contractor Site Document Control group.
Specific agreements will be taken between Subcontractor and Contractor to transfer the documentation in a
stepwise and structured manner.
C0306-S02-ECB-FS-30000-00 PAGE 115 OF 122
STRUCTURES
The Red-Marked drawings are sent by the Subcontractor to the Contractor’s Field Engineering Manager / Field
Engineer.
Construction supervisor, upon the verification of the compliance of the Red-Marked drawings with the site
conditions, will sign them as responsible for Contractor for the Red-Marked drawings correctness.
The numbers of copies of Red-Marked drawings to be transferred by the Subcontractor to the Contractor are
as per para 15.5.2.
17.3.2As-Built Drawings
Contractor will issue a number of copies of document of the As-built drawings to Engineer as defined at para
15.5.2.
The list of submittals of the As-built drawings will include all, Layouts, Plans, Sections, Alignment, Architectural
& Structural of below disciplines:
EAB Facilities & Building
ECB Structures-Bridges-Viaducts-stations
ECH Highways / Road
ELS Sand Mitigation
EQU Depot & Other Equipment
ERA Rail Alignment / Profile / Cross Section
ERT Track Work
ERS System (Comms / Sig / Radio / E&M / Etc.)
EUE Overhead Line/Traction Power
EUT Utilities
EWA Environmental Impact Assessment
17.4 Submission of Red-Marked Drawings

During progress of the Works, the Sub-Contractor will maintain a set of Record Documentation, with mark-up
of actual work which varies from the work as originally shown.
Before the Contractors request for final taking over inspection, the red marked copy of the As-built drawings
will be consolidated, organized, catalogued and submitted by the Contractor to the Engineer for review.
Marked up drawings will be officially submitted by Contractor to the Engineer as Rev AA of the As Built
drawings.
Subcontractor will maintain in his archive a complete and accurate field and manufacturing set of records of
all changes or deviations from the Issue for Construction drawings, the approved Shop Drawings, the Technical
Requirements, the Contractor’s subsystem and procurement specifications and the Contractor’s approved
equipment assembly drawings and similar documents indicating the work as actually fabricated and installed.
The Subcontractor will mark whatever document is most capable of showing the actual condition, fully and
accurately.
The changes in documentation may include:
DCR code and part that is interested
C0306-S02-ECB-FS-30000-00 PAGE 116 OF 122
STRUCTURES
FCR code and part that is interested

RFI code and part that is interested
DAS code and part that is interested
NCR code and part that is interested
The red marked drawings will be reported the name of incorporated materials used and their JV reference
code (mix design, waterproofing, bearings, etc); not to be included materials used for NCR repairs
All the above information will be summarized in a table included on each drawing accordingly to the following
format:
Table 19: Table of Actual Condition of Drawing
As built information Y/N Doc number Title / description
Design change request (DCR)
Field change request (FCR)
Design amendment sheet (DAS)
Non-Conformity (NCR)
Incorporated materials
A competent party of Subcontractor (typically the engineering office) will report in the Master Copy all the
above-mentioned information.
Each modification done on a document must be easily traceable.
After implementing modifications to the documents, its modified part will be marked on drawings with the
revision number in a triangle alongside the clouded revision, with all revisions identified and described in a
revision block.
The Red-Marked drawings will be issued to Contractor by the Subcontractor:
Their correctness in respect to site conditions will be reviewed by the Construction supervisor;
Their presentation and their verification in terms of original IFC and shop drawings will be verified by the FEM
/ FE;
Their verification against DCR and FCR will be verified by the FEM / FE;
Their consistency against the NCR will be verified by the QA/QC.
Once the approval life cycle is completed and upon the Contractor acceptance, Subcontractor will issue to
Contractor Red Marked drawings as Rev AA of the As-Built drawings.
Red marked drawings are submitted for review to Engineer as a scan copy in PDF format uploaded and sent
via EPFM. The review process will generate additional “red marks” on the drawings that, once agreed and
clarified with the Contractor, will be uploaded in EPFM.
C0306-S02-ECB-FS-30000-00 PAGE 117 OF 122
STRUCTURES
17.5 Submission of As-Built Drawings

The starting point of the As-Built drawings are the reviewed red marked drawings.
Once included all the comments agreed with Engineer, the As-Built drawings will be prepared by the
Subcontractor and will be submitted to Contractor for review and approval.
Upon Contractor final acceptance of the As-Built drawings, Contractor will submit As-Built drawings to
Engineer for review.
17.5.1As-Built Submission – Subcontractor to Contractor

Subcontractor will certify that each of the revised As-built drawings submitted to Contractor are complete and
accurate and are in full compliance with approved Red-Marked drawings.
All drawings will bear the official project name and number as described in the below numbering philosophy.
Subcontractor is responsible of the correctness of the As-built drawings; Contractor is responsible for the final
document.
The electronic copy of drawings will be submitted to Contractor in approved software Microstation DGN v8.
17.5.2As-Built Submission – Contractor to Engineer

Before submitting the as built to Engineer, all the document go through a QC check process that uses a
checklist similar to the one in Appendix B.
Once the final As-built record drawings are complete for any section of the works or the whole of the works,
the Contractor will transmit the As-built drawings in hard copy and electronic format. The Contractor will
submit them to the Engineer after taking over of any section of the works or whole of the works as applicable.
For all software unique to the Rail System and not "commercially available", the as-built documentation will
include, at a minimum, all of the information necessary to make revisions in the software programs
applications for the System for changes and/or expansions or extension of the system, such as functional,
performance and interface requirements; configuration control documentation; and programmer and user
manuals incorporating appropriate modification and control procedures, including the name of any
subcontractor if employed for preparation of this software.
For all "commercially available" software used in the Rail System, the as-built documentation will include all
of the documentation which is available from the supplier of such software. One reproducible master and two
copies of all programmer and user manuals and other similar material will be provided to the Employer with
the as-built drawings and documents along with a complete and fully documented listing of all software
programs.
17.6 Final Certificate of As-Built Drawings

The as built drawing final submission will be stamped and accompanied with a certificate signed by the
Contractor representative.
C0306-S02-ECB-FS-30000-00 PAGE 118 OF 122
STRUCTURES
18 Document Management
18.1 Numbering System
The As-built drawings will be uniquely numbered.
The document type will be changed from ‘DG - Drawing’ to ‘DB – As-built drawing’ retaining the same
document number.
Example: document number C0306-S02-ERA-DG-00001, after approval of As-built, will become C0306-S02-
ERA-DB-00001.
Revision number will be: (To be finalised)
AA for the red marked drawing
AB for the first issue of the as built
00 for the second and final issue of the as built
When required, As-Built drawing can be composed by different sheets.
Document different from drawings modified from the 00 revision will be delivered in the As Built final package
considering revision no 00 for record.
18.2 Number of Copies

Table 20: Number and Format of Copies to Be Submitted
From Subcontractor to JV From JV to Engineer
Document H S Format H S Format
Red marked (rev AA) 2 (A1) 2 CD DGN + pdf 2 (A1) 1 CD DGN + pdf
As built (rev AB) 2 (A1) 2 CD DGN + pdf 2 (A1) 1 CD DGN + pdf
As built (rev 00) To be agreed DGN + pdf To be agreed DGN + pdf
As built to be delivered to To be agreed DGN + pdf To be agreed DGN + pdf

Stakeholders
The number of copies is intended to include also the copies that Engineer/ER will deliver to other stakeholders
as part of the final handover process.
18.3 Associated Requirements for Originator

Below requirements will be considered during development of the As Built and are considered mandatory
minimum requirements for the final Take Over:
For each submission for approval (AA, AB etc.) at least one of the hard copies must be color copy.
For final As Built submission (00 etc.) all copies must be color copies.
Hard copies submission must be divided per WBS (when applicable) and well organized in folders; transmittal
is subject to acceptance.
Hard copies must be stored in Originator’s offices as well Contractor’s offices. Contractor is allowed for
inspection and Auditing.
In case of multi sheets drawings, Hard copies must be signed and stamped on all pages.
C0306-S02-ECB-FS-30000-00 PAGE 119 OF 122
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Hard copies and soft copies (H+S) must be stored for a minimum 10 years upon release of Final Take Over
certificates.
Once approved, full As Built hard copies must be delivered to the Head Office.
C0306-S02-ECB-FS-30000-00 PAGE 120 OF 122
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19 Inspection and Maintenance

19.1 Key Inspection Elements
The key elements inspected and maintained by the contractor are shown in the table below. These inspections
and maintenance schedule will be included in the contractors Operations and Maintenance manual for the
project .
Table 21: Key Elements of the Structure Requiring Regular Maintenance
Structure/Element Inspection Frequency
Concrete Surfaces Every 12 months
Steel Bridges and Connections Every 12 months
Bearings Every 10 years
Shear Keys Every 10 years
Expansion Joints Every 10 years
Noise Barriers Every 12 months
Drainage Systems Every 12 months
Water Proofing Every 12 months
Ballast Every 12 months
Sleepers Every 12 months
Coatings Every 4 months
Cladding Every 12 months
Railings Every 5 years
C0306-S02-ECB-FS-30000-00 PAGE 121 OF 122
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END OF DOCUMENT
C0306-S02-ECB-FS-30000-00 PAGE 122 OF 122

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Responsible Division Responsible Discipline Document Type Document Status

C0306 Structures-Bridges Specification Issued for Construction

ETIHAD RAIL STAGE 2 PROJECT

Name Signature Date

Document Number Issued Date 12-JAN-2021

Version Date Name Description of Review Changes

Revision Log – To Client

Revision Date Description of Changes

4 Structural Concrete – Rail and Civil Structures....................................................................... 38

7.4.8 Corrosion Protection............................................................................................ 76

10.10.7 As Built and Site Records ..................................................................................... 92

14.13 Execution ........................................................................................................................ 109

Acronyms and Abbreviations

1.2 Design Responsibilities

1.3 Construction Specifications

1.4 Reference Documents

1.6 Temporary Works

1.7 Shoring works

1.7.1 Required Submissions

• Detailed phasing of works and construction sequence and methodology showing

1.7.2 Design criteria

d) Shoring adjacent to bridge foundations: 10 mm

1.8 QA/QC and Records

2.2 Earthing and Bonding

2.3 Vehicle Parapets for Over-Bridges (Road over Rail)

2.4 Handrails for Under-Bridges (Rail over Road)

2.4.1.1 METAL FABRICATIONS

2.4.1.1.2 Quality Assurance

4. Provide materials that have a minimum service life expectancy of 25 years.

1. Stainless steel grade 316

1. Extruded Aluminum: ASTM B 221 (ASTM B 221M), 6063 alloy, T6 temper.

C. Materials – Ancillary Materials

4. Wood shims are not acceptable.

5. Shims to be designed to support the applied loads

a) Fasteners: Comply with the following

2.4.1.1.5 Grinding, Polishing and Finishing

2.4.1.1.6 Exposed Mechanical Fastening

f) Items found damaged at any time shall not be installed

2.4.1.1.7 Finishes – Aluminum

2.4.1.1.8 Structural Performance of Handrails and Railings:

2.4.1.2 Coating / Paint

A. ASTM International (ASTM):

A. Submit under provisions of Administrative Requirements.

1. Manufacturer's data sheets on each product to be used.

2. Preparation instructions and recommendations.

3. Storage and handling requirements and recommendations.

4. Typical installation methods.

2.4.1.2.4 QUALITY ASSURANCE

B. Installer Qualifications: Company specializing in performing Work of this section with

1. Intent of mock-up is to demonstrate quality of workmanship and visual

2. Retain mock-up during construction as a standard for comparison with completed

4. Do not alter or remove mock-up until work is completed or removal is authorized.

2.4.1.2.5 DELIVERY, STORAGE, AND HANDLING

B. Protect from damage due to weather, excessive temperature, and construction

2.4.1.2.6 PROJECT CONDITIONS

A. Maintain environmental conditions (temperature, humidity, and ventilation) within limits

A. Acceptable Manufacturer as per Engineer approval

B. Substitutions: Not permitted.

2.4.1.2.10 PAINT SYSTEMS